Truss and purlin support apparatus and a method of making and using same with building supports and floor and roof sheathing

Abstract

A support apparatus is for use with building supports and floor or roof sheathing. The apparatus includes purlins and Pratt-style trusses. Each truss is supported on the building supports. Each truss includes top and bottom chords, and web members extending therebetween. Each purlin extends transversely of the trusses and has notches spaced along an underside thereof. Each notch is saddled over a top chord of one of the trusses, so as to restrict sliding movement of the purlins. The purlins support the floor or roof sheathing thereon. The top chord, the bottom chord, the web members, and the purlin members are constructed from roll-formed light gauge steel material.

1 . A truss and purlin support apparatus for use with building support members and a substantially planar substrate sheathing member, said apparatus comprising: 
 a) a plurality of Pratt-style elongate truss members, each having at least two support portions longitudinally spaced from one another, with said support portions adapted to operatively engage and transfer loads to the building support members, with each of said truss members comprising an elongate top chord, an elongate bottom chord, and a plurality of web members securely extending between said top chord and said bottom chord; and    b) a plurality of purlin members, each extending in a substantially transverse direction relative to said elongate truss members, with each of said purlin members having an underside portion that is shaped to define a plurality of notched portions, with said notched portions being spaced from one another in said transverse direction along said underside portion, and with each of said notched portions saddled over a respective top chord of said truss members, so as to restrict sliding movement of said purlin members in said transverse direction; with said purlin members operatively supporting the substrate sheathing member thereon; and    wherein said top chord, said bottom chord, said web members, and said purlin members are constructed from roll-formed light gauge steel material.    
   
   
       2 . An apparatus according to  claim 1 , wherein each of said truss members has a center of gravity that is operatively located below said support portions.  
   
   
       3 . An apparatus according to  claim 1 , wherein neighboring ones of said truss members are spaced by a truss on-center distance in said substantially transverse direction that is selected from the group consisting of about 36 inches and about 48 inches.  
   
   
       4 . An apparatus according to  claim 3 , wherein neighboring ones of said purlin members are spaced by a purlin on-center distance in a substantially longitudinal direction that is selected from the group consisting of about 16 inches and about 24 inches.  
   
   
       5 . An apparatus according to  claim 1 , wherein each said top chord and each said bottom chord is shaped, in profile, so as to define: 
 a) a substantially “U”-shaped chord portion that includes two substantially planar chord side portions extending substantially at right angles from opposing ends of a substantially planar central chord base portion, with said chord side portions defining a web-receiving aperture therebetween; and    b) two substantially “L”-shaped chord portions, each of said “L”-shaped chord portions including a substantially planar first chord segment that extends in a substantially outward direction and substantially at right angles from a respective one of said chord side portions, and a substantially planar second chord segment that extends substantially at right angles from said first chord segment;    wherein, in each of said truss members, said web-receiving aperture of said bottom chord faces in a substantially upward direction and said web-receiving aperture of said top chord faces in a substantially downward direction, with each of said web members extending into each said web-receiving aperture, and securely engaging each said “U”-shaped chord portion, of said top chord and of said bottom chord.    
   
   
       6 . An apparatus according to  claim 5 , wherein one or more of said central chord base portion and said chord side portions of each said top chord and each said bottom chord is shaped so as to define a stiffening projection substantially along a longitudinal extent thereof, whereby each said top chord and each said bottom chord is provided with structural rigidity.  
   
   
       7 . An apparatus according to  claim 5 , wherein in each said top chord and in each said bottom chord, said chord side portions are shaped so as to define a plurality of longitudinally spaced locator apertures therein, and wherein each of said web members is provided with end portions that are each shaped to define a locator aperture mating portion, whereby each of said web members is located within each said web-receiving aperture, and securely engages each said “U”-shaped chord portion, of said top chord and of said bottom chord, with each said locator aperture mating portion being substantially securely aligned with one of said locator apertures.  
   
   
       8 . An apparatus according to  claim 5 , wherein each of said truss members further comprises two support stiffening members, each securely engaging said top chord substantially adjacent to a respective one of said support portions, with each of said support stiffening members being positioned within said web-receiving aperture of said top chord, whereby said support stiffening members substantially maintain local structural integrity of said support portions whilst said support portions operatively transfer said loads to the building support members.  
   
   
       9 . An apparatus according to  claim 8 , wherein each of said support stiffening members is shaped, in profile, so as to define a substantially “C”-shaped support stiffening portion that includes two substantially planar support side portions extending substantially at right angles from opposing ends of a substantially planar central support base portion, with said central support base portion being positioned substantially vertically within said web-receiving aperture of said top chord.  
   
   
       10 . An apparatus according to  claim 5 , wherein each of said purlin members is shaped so as to define, remotely of said notched portions, a substantially “C”-shaped purlin profile that faces in said substantially downward direction.  
   
   
       11 . An apparatus according to  claim 10 , wherein said “C”-shaped purlin profile is defined by a substantially planar central purlin base portion and two substantially “L”-shaped purlin portions, with each of said “L”-shaped purlin portions including a substantially planar first purlin segment that extends substantially at right angles from one respective end of said purlin base portion, and a substantially planar second purlin segment that extends in a substantially inward direction and substantially at right angles from said first purlin segment.  
   
   
       12 . An apparatus according to  claim 11 , wherein said chord base portion of said top chord securely engages said purlin base portion adjacent to one of said notched portions, with said chord base portion being substantially flush with said purlin base portion, whereby said chord base portion operatively substantially supports the substrate sheathing member.  
   
   
       13 . An apparatus according to  claim 12 , wherein said opposing ends of said central chord base portion of said top chord define a concave portion therebetween, with said concave portion facing in said upward direction, with said apparatus further comprising a predetermined amount of an adhesive operatively interposed in adhering relation substantially between said concave portion and the substrate sheathing member.  
   
   
       14 . An apparatus according to  claim 11 , wherein each of said purlin members is shaped so as to define, substantially adjacent to said notched portions, a substantially “U”-shaped purlin profile that faces in said substantially downward direction and includes two purlin side portions extending substantially at right angles from opposing ends of said purlin base portion, with said first purlin segment extending beyond said purlin side portions in said downward direction, wherein said purlin side portions securely engage said chord base portion of said top chord, with said purlin side portions defining an up-set portion that extends between each of said notched portions and said purlin base portion, whereby said chord base portion of said top chord is operatively vertically spaced from the substrate sheathing member.  
   
   
       15 . An apparatus according to  claim 1 , wherein each of said web members is shaped, in profile, so as to define a substantially “C”-shaped web portion.  
   
   
       16 . An apparatus according to  claim 15 , wherein said “C”-shaped web portion includes a substantially planar central web base portion and two substantially “L”-shaped web side portions, with each of said web side portions including a substantially planar first web segment that extends substantially at right angles from one respective end of said web base portion, and a substantially planar second web segment that extends in a substantially inward direction and substantially at right angles from said first web segment.  
   
   
       17 . An apparatus according to  claim 1 , wherein each of said truss members further comprises two load distribution plates, each securely engaging said top chord, with each of said load distribution plates being operatively substantially interposed between a respective one of said support portions and one of the building support members, whereby said load distribution plates operatively transfer said loads to the building support members whilst substantially maintaining local structural integrity of the building support members.  
   
   
       18 . An apparatus according to  claim 17 , wherein each of said load distribution plates is operatively securely fastened to one of the building support members.  
   
   
       19 . A method of forming a truss and purlin support apparatus for use with building support members, said method comprising the steps of: 
 a chord forming step of roll-forming a plurality of top chords and bottom chords by passing first elongate sheets of light gauge steel material through a series of roll-forming chord tool sets, with passage of said first elongate sheets through each successive one of the chord tool sets progressively forming said top chords and said bottom chords;    a web forming step of roll-forming a plurality of web members by passing second elongate sheets of light gauge steel material through a series of roll-forming web tool sets, with passage of said second elongate sheets through each successive one of the web tool sets progressively forming said web members; and    a purlin forming step of roll-forming a plurality of purlin members by passing a plurality of third elongate sheets of light gauge steel material through a series of roll-forming purlin tool sets, with passage of said third elongate sheets through each successive one of the purlin tool sets progressively forming said purlin members, such that each of said purlin members has an underside portion that defines a plurality of notched portions that are longitudinally spaced from one another;    wherein each of said web members is adapted to be operatively secured between one of said top chords and one of said bottom chords to form elongate truss members, with said truss members securable on the building support members, wherein said truss members are adapted to be nested and secured within said notched portions of said purlin members, with said purlin members operatively extending in a transverse direction relative to said elongate truss members, and wherein each of said purlin members is adapted to operatively support a substantially planar substrate sheathing member thereon.    
   
   
       20 . A method according to  claim 19 , further comprising a purlin sheet forming step, before said purlin forming step, of forming said plurality of said third elongate sheets with a plurality of opposed notch pairs along longitudinal edges thereof.  
   
   
       21 . An apparatus according to  claim 20 , wherein in said purlin sheet forming step, neighboring ones of said opposed notch pairs are spaced by a truss on-center distance that is selected from the group consisting of about 36 inches and about 48 inches.  
   
   
       22 . A method according to  claim 19 , wherein in said chord forming step, each of said top chords and said bottom chords is roll-formed so that a chord profile of each of said top chords and said bottom chords defines: 
 a) a substantially “U”-shaped chord portion that includes two substantially planar chord side portions extending substantially at right angles from opposing ends of a substantially planar central chord base portion, with said chord side portions defining a web-receiving aperture therebetween; and    b) two substantially “L”-shaped chord portions, each of said “L”-shaped chord portions including a substantially planar first chord segment that extends in a substantially outward direction and substantially at right angles from a respective one of said chord side portions, and a substantially planar second chord segment that extends substantially at right angles from said first chord segment; and    wherein said web-receiving aperture of each of said bottom chords operatively faces in a substantially upward direction and said web-receiving aperture of each of said top chords operatively faces in a substantially downward direction, with each of said web members being operatively adapted to extend into each said web-receiving aperture, and to be secured to each said “U”-shaped chord portion, of each of said top chords and said bottom chords.    
   
   
       23 . A method according to  claim 22 , wherein in said chord forming step, one or more of said central chord base portion and said chord side portions of each of said top chords and said bottom chords is roll-formed so as to define a stiffening projection substantially along a longitudinal extent thereof.  
   
   
       24 . A method according to  claim 22 , wherein in said chord forming step, a plurality of longitudinally spaced locator apertures are punched in said chord side portions of each of said top chords and said bottom chords; and wherein in said web forming step, a locator aperture mating portion is punched in each end portion of each of said web members, with each said locator aperture mating portion being adapted to be operatively aligned with one of said locator apertures.  
   
   
       25 . A method according to  claim 22 , further comprising a support stiffener forming step of roll-forming a plurality of support stiffening members by passing said second elongate sheets through said series of roll-forming web tool sets, with passage of said second elongate sheets through each successive one of the web tool sets progressively forming said support stiffening members, such that a support profile of each of said support stiffening members defines a substantially “C”-shaped support stiffening portion that includes two substantially planar support side portions extending substantially at right angles from opposing ends of a substantially planar central support base portion; and 
 wherein said web-receiving aperture of each of said top chords is adapted to operatively receive two support stiffening members therewithin, with each of said support stiffening members being substantially adjacent to said support portions, and with said central support base portion being positioned substantially vertically.    
   
   
       26 . A method according to  claim 22 , wherein in said chord forming step, said opposing ends of said central chord base portion of each of said top chords are roll-formed to define a concave portion therebetween, with said concave portion operatively facing in said upward direction, and with said concave portion adapted to operatively receive a predetermined amount of an adhesive.  
   
   
       27 . A method according to  claim 22 , wherein in said purlin forming step, each of said purlin members is roll-formed so as to define, remotely of said notched portions, a substantially “C”-shaped purlin profile that faces in said substantially downward direction.  
   
   
       28 . A method according to  claim 27 , wherein in said purlin forming step, said “C”-shaped purlin profile is roll-formed to include a substantially planar central purlin base portion and two substantially “L”-shaped purlin portions, with each of said “L”-shaped purlin portions including a substantially planar first purlin segment that extends substantially at right angles from one respective end of said purlin base portion, and a substantially planar second purlin segment that extends in a substantially inward direction and substantially at right angles from said first purlin segment.  
   
   
       29 . A method according to  claim 28 , wherein in said purlin forming step, each of said purlin members is roll-formed so as to define, substantially adjacent to said notched portions, a substantially “U”-shaped purlin profile that faces in said substantially downward direction and includes two purlin side portions extending substantially at right angles from opposing ends of said purlin base portion, with said first purlin segment extending beyond said purlin side portions in said downward direction, with said purlin side portions defining an up-set portion that extends between each of said notched portions and said purlin base portion; and with said purlin side portions operatively engaging said chord base portion of each of said top chords, such that said chord base portion of said top chord is operatively vertically spaced from the substrate sheathing member.  
   
   
       30 . A method according to  claim 19 , wherein in said web forming step, each of said web members is roll-formed so that a web profile of each of said web members defines a substantially “C”-shaped web portion.  
   
   
       31 . A method according to  claim 30 , wherein in said web forming step, said “C”-shaped web portion is roll-formed to include a substantially planar central web base portion and two substantially “L”-shaped web side portions, with each of said web side portions including a substantially planar first web segment that extends substantially at right angles from one respective end of said web base portion, and a substantially planar second web segment that extends in a substantially inward direction and substantially at right angles from said first web segment.  
   
   
       32 . A method of forming a truss and purlin support apparatus on building support members, said method comprising the steps of: 
 a truss assembling step of assembling a plurality of elongate truss members, each having a plurality of support portions longitudinally spaced from one another, and each being assembled by locating and securing a plurality of roll-formed web members between a roll-formed top chord and a roll-formed bottom chord;    a truss supporting step, after said truss assembling step, of locating and securing said support portions of said truss members on the building support members;    an apparatus assembling step of nesting and securing said truss members within a plurality of notched portions of a plurality of roll-formed purlin members, with said purlin members extending in a transverse direction relative to said elongate truss members, so as to restrict sliding movement of said purlin members in said transverse direction; and    a sheathing step, after said apparatus assembling step, of supporting a substantially planar substrate sheathing member on said purlin members.    
   
   
       33 . A method according to  claim 32 , wherein in said truss supporting step, centers of gravity of said truss members are located below said support portions.  
   
   
       34 . A method according to  claim 32 , wherein in said apparatus assembling step, neighboring ones of said purlin members are spaced in a substantially longitudinal direction by a purlin on-center distance that is selected from the group consisting of about 16 inches and about 24 inches.  
   
   
       35 . A method according to  claim 32 , wherein in said truss supporting step, two load distribution plates, securely engaging said top chord, are substantially securely interposed between said support portions and the building support members.  
   
   
       36 . A method according to  claim 35 , wherein in said truss supporting step, said load distribution plates are securely fastened to the building support members.  
   
   
       37 . A method according to  claim 32 , wherein in said apparatus assembling step, each of said top chords is substantially flush with each of said purlin members; and wherein in said sheathing step, said top chord substantially supports the substrate sheathing member.  
   
   
       38 . A method according to  claim 37 , further comprising a gluing step, before said sheathing step, of applying a predetermined amount of an adhesive to one of said substrate sheathing member and a upward-facing concave portion of said top chord; whereby, in said sheathing step, said predetermined amount of said adhesive is operatively interposed in adhering relation substantially between said concave portion and the substrate sheathing member.  
   
   
       39 . A method according to  claim 32 , wherein in said apparatus assembling step, up-set portions of said purlin members substantially adjacent to said notched portions engage each said top chord; and wherein in said sheathing step, said top chord is vertically spaced from the substrate sheathing member.