BACKER ROD MATERIAL AND JOINT CONSTRUCTION FOR BUILDING COMPONENTS

MATERIAU DE TIGE D'APPUI ET CONSTRUCTION DE JOINTS POUR PIECES COMPOSANTES DE CONSTRUCTION

English Abstract

An efficient and reliable installation for a water tight and an aesthetically pleasing transition between adjacent building or construction components is provided with use of a backer rod material for placement between adjacent building or construction components for subsequent caulking. A closed cell foam backer rod material includes a terminal end portion of the backer rod joined to a remainder thereof by a frangible connection or perforated joint. The frangible connection or joint in the backer rod is nonlinear or arcuate-shaped to provide a crown- shaped or convex-shaped backer rod surface to receive the caulking compound to finish the joint. After the backer rod material is installed into the joint, the terminal end portion of the backer rod is removed by being torn along the frangible joint. A bead of caulk or similar finishing material is applied in the recess to provide a smooth and aesthetically pleasing transition from the frame to the wall. The convex or crown shape of the exposed surface of the backer rod material allows for and promotes integrity of the caulking compound during shifting, expansion and/or contraction of the adjacent building components relative to each other.

French Abstract

Une installation efficace et fiable pour une transition étanche et esthétiquement agréable entre des composantes de construction adjacentes est présentée pour être utilisée comme matériau de tige d'appui pour le positionnement entre les composantes de construction adjacentes en vue d'un calfeutrage subséquent. Un matériau de tige d'appui en mousse cellulaire fermée comprend une portion d'extrémité terminale de la tige d'appui jointe à un reste par une connexion frangible ou un joint perforé. La connexion frangible ou le joint dans la tige d'appui est non linéaire ou courbe pour offrir une surface de tige d'appui en forme de couronne ou convexe pour recevoir le composé de calfeutrage pour finir le joint. Après l'installation du matériau de tige d'appui dans le joint, la portion d'extrémité terminale de la tige d'appui est retirée en étant tordue le long du joint frangible. Une perle de calfeutrant ou un matériau de finition similaire est appliquée dans le creux pour fournir une transition lisse et esthétiquement agréable du cadre au mur. La forme convexe ou en couronne de la surface exposée du matériau de tige d'appui permet et favorise l'intégrité du composé de calfeutrage pendant le déplacement, la dilatation ou la contraction des composantes de construction adjacentes entre elles.

Claims

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WHAT IS CLAIMED IS:
1. A backer rod adapted to be placed between a pair of adjacent
components and have caulk applied thereto for forming a joint between
the components, the backer rod comprising:
a main body portion with a longitudinal axis;
a terminal portion; and
a primary frangible connection joining the main body portion and
the terminal portion together, the primary frangible connection being a
primary perforated joint and adapted to be severed to remove the
terminal portion from the main body portion and the main body portion
being adapted to receive the caulk thereon to form the joint between the
adjacent components.
2. The backer rod of claim 1 further comprising a plurality of the
terminal portions and at least one secondary frangible connection each
of which is a secondary perforated joint and joins one of the terminal
portions to an adjacent terminal portion.
3. The backer rod of claim 2 wherein each of the terminal portions
is serially connected to the adjacent terminal portion via one of the
secondary frangible connections.

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4. The backer rod of claim 1 wherein the primary frangible
connection is generally parallel to the longitudinal axis of the main body
portion.
5. The backer rod of claim 1 wherein a cross-sectional configuration
of the primary frangible connection is non-linear.
6. The backer rod of claim 5 wherein the cross-sectional
configuration is generally arcuate.
7. The backer rod of claim 6 wherein a surface of the main body
portion adjacent to the frangible connection and which is exposed once
the terminal portion is severed from the main body portion via the
primary frangible connection is convex shaped.
8. The backer rod of claim 5 wherein the cross-sectional
configuration of the frangible connection is symmetric.
9. The backer rod of claim 1 wherein the main body portion
includes at least one generally planar surface.
10. The backer rod of claim 9 further comprising:
a plurality of the generally planar surfaces on the main body
portion, two of the generally planar surfaces are generally parallel and
spaced from one another and adjacent to the frangible connection and

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another of which is spaced from the frangible connection and generally
perpendicular to the other two planar surfaces.
11. A backer rod adapted to be placed between a pair of adjacent
components and have caulk applied thereto for forming a joint between
the components, the backer rod comprising:
a main body portion with a longitudinal axis and a plurality of
generally planar surfaces, two of which are generally parallel and spaced
from one another and another of which is generally perpendicular to the
other two planar surfaces;
a plurality of terminal portions; and
a plurality of arcuate frangible connections each being a
perforated joint which joins one of the terminal portions and the main
body portion or each adjacent terminal portion together, each frangible
connection being adapted to be severed to remove at least one of the
terminal portions from the main body portion and to receive the caulk
thereon to form the joint between the adjacent components;
wherein each of the terminal portions is serially connected to the
adjacent terminal portion via one of the frangible connections and each
frangible connection is generally parallel to the longitudinal axis of the
main body portion.
12. An arrangement comprising:
a pair of adjacent components;
a backer rod positioned between the adjacent components;

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a bead of caulk applied to the backer rod and contacting the
adjacent components to form a joint there between;
wherein the backer rod further comprises:
(a) a main body portion with a longitudinal axis;
(b) a terminal portion; and
(c) a primary frangible connection joining the main body
portion and the terminal portion together, the primary frangible
connection being a primary perforated joint and adapted to be severed
to remove the terminal portion from the main body portion and the main
body portion being adapted to receive the caulk thereon to form the joint
between the adjacent components.
13. The arrangement of claim 12 further comprising a plurality of the
terminal portions and at least one secondary frangible connection each
of which is a secondary perforated joint and joins one of the terminal
portions to an adjacent terminal portion.
14. The arrangement of claim 13 wherein each of the terminal
portions is serially connected to the adjacent terminal portion via one of
the secondary frangible connections.
15. The arrangement of claim 12 wherein the primary frangible
connection is generally parallel to the longitudinal axis of the main body
portion.

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16. The arrangement of claim 12 wherein a cross-sectional
configuration of the primary frangible connection is generally arcuate.
17. The arrangement of claim 16 wherein a surface of the main body
portion adjacent to the frangible connection and which is exposed once
the terminal portion is severed from the main body portion via the primary
frangible connection is convex shaped.
18. The arrangement of claim 16 wherein the cross-sectional
configuration of the frangible connection is symmetric.
19. The arrangement of claim 12 wherein the main body portion
includes at least one generally planar surface.
20. The arrangement of claim 12 wherein one of the components is a
wall and the other of the components is a frame bordering an opening in
the wall.
21. A method of constructing a joint between two adjacent
components, the method comprising the steps of:
inserting a backer rod between the two adjacent components;
removing a terminal portion of the backer rod along a frangible
connection which is a perforated joint joining the terminal portion with a
remainder of the backer rod; and

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applying a bead of caulk onto the remainder of the backer rod and
in contact with the two adjacent components.
22. The method of claim 21 wherein the removing step exposes a
convex shaped surface of the backer rod.
23. The method of claim 22 wherein applying the bead of caulk step
forms and hour glass-shaped caulk configuration in cross-section.

Description

CA 02504301 2012-09-17
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BACKER ROD MATERIAL AND JOINT CONSTRUCTION FOR
BUILDING COMPONENTS
Background of the Invention
This invention relates to backer rods used at joints
between building or construction components and, more particularly, to
backer rods used in association with window and door installations in a
veneer/cavity wall system for proper transition between the window or
door installation and the masonry veneer as well as other applications.
Wall systems having a masonry exterior are typically
constructed of at least one vertical layer of masonry components and at

CA 02504301 2005-04-15
least a second vertical layer of a material forming a back-up system. The -2-
back-up system may be constructed of lumber, light gauge steel studs or
of a concrete masonry unit. The masonry and back-up system are
typically bonded together by horizontal metallic ties spaced apart
vertically. A space is often provided in such wall systems (e.g., cavity
wall systems) between the masonry and back-up system for moisture
drainage.
Problems often arise during the construction of a building
or other structure, be it a cavity wall or other building system, in
maintaining a proper transition between adjacent building or construction
components. For example, the dimensioning of the window or door
frame installed in the wall is frequently different and incompatible with
the thickness, geometry and dimensions of the cavity wall construction.
Caulk is often used in many joints, for example, along the wall jamb and
header in an effort to provide a water tight seal and aesthetic transition
to the window or door frame.
Commercial buildings have numerous lengthy joints
between various components or surfaces. For example, slabs of marble
are spaced apart by joints to allow for expansion and contraction. The
joints must be sealed with caulking compound or other suitable material
placed adjacent the exterior surface of the slabs. Backer rods, typically
produced from polyethylene, are initially installed in the joint at a
specified depth with the remaining portion of the joint from the backer-
rod to the outside surface then being filled with caulking compound.

,
CA 02504301 2005-04-15
The typical practice in installing a backer-rod is to initially -3-
force the backer-rod into the joint and to then further force the backer-
rod to the predetermined depth by means of forcing a putty knife against
the rod. Use of such a tool does not provide accurate depth control of
the backer-rod since the putty knife does not provide any means for
measuring the depth of the slot or joint once the rod is installed. Further,
many commercial buildings have thousands and thousands of linear feet
of joints requiring an inordinate amount of time for the installation of the
backer-rod to the predetermined depth. If the joint is not properly
constructed, the caulk may fail or separate from the adjacent
components thereby jeopardizing the fluid impermeable joint when the
components expand or contract in response to changes in the weather.
Municipal building codes differ from locale to locale and
different window or door frame profiles from the variety of manufacturers
make predictable spacing for caulk application nearly impossible. As a
result, the detailing and finishing work required for proper transition
between building or construction components such as the installation of
a window or door into a masonry veneer or cavity wall construction is
typically very labor intensive, non-uniform and highly dependent upon
the skill and experience of the particular contractor or tradesman
performing the installation. Because of the importance and wide spread
popularity of concrete and masonry structures, a better method for
proper and consistent transition between adjacent building components
is needed.

CA 02504301 2005-04-15
Summary of the Invention -4-
This invention provides a solution to these and other
problems in the art and allows an efficient and reliable installation for a
water tight and an aesthetically pleasing transition between adjacent
building or construction components, including, but not limited to, the
transition from the window or door frame to the masonry veneer.
Generally, this invention includes a novel backer rod material for
placement between adjacent building or construction components for
subsequent caulking.
In one embodiment, this invention includes a surround
device installed adjacent the window frame or door frame and such
backer rod material to provide a proper transition from the frame to the
wall structure. In one embodiment, the surround device has a generally
L-shaped configuration with a first leg of the device being mounted to the
outer face of the inner wall of the cavity wall construction and in the
cavity between the spaced walls. The second leg of the surround device
projects generally perpendicularly from the first leg and from the inner
wall toward the outer wall adjacent the window or door frame.
Additionally, in one embodiment, a closed cell foam backer rod material
in which a terminal end portion of the backer rod is joined to a remainder
thereof by a frangible connection or perforated joint is included.
Advantageously, the frangible connection or joint in the backer rod is
non-linear or arcuate-shaped to provide a crown-shaped or convex-
shaped backer rod surface to receive the caulking compound to finish

CA 02504301 2005-04-15
the joint. After the surround device is installed adjacent to the frame and -5-
the inner and outer wall construction is complete, the terminal end
portion of the backer rod is removed by being torn along the frangible
joint. After the terminal end portion is removed, a recess is exposed at a
juncture of the building components. A bead of caulk or similar finishing
material is applied in the recess to provide a smooth and aesthetically
pleasing transition from the frame to the wall. Additionally, the juncture
between the frame and the wall is sealed by the caulk bead to inhibit
and/or prevent the entry of moisture or other foreign material. Additional
embodiments of the invention are also disclosed.
The convex or crown shape of the exposed surface of the
backer rod material allows for and promotes integrity of the caulking
compound during shifting, expansion and/or contraction of the adjacent
building components relative to each other. Advantageously, the backer
rod material is readily adaptable for use with a wide variety of building
anc construction applications, including window and door frame designs
and construction specifications without requiring highly skilled or
specialized installation and construction techniques.
Brief Description Of The Drawings
The objectives and features of the invention will become
more readily apparent from the following detailed description taken in
conjunction with the accompanying drawings in which:

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FIG.1 is an exemplary view of a window installation in a
masonry cavity wall showing in cross-sectional view a transition between
a wall jamb and a window frame, including backer rod material,
according to one embodiment of this invention;
FIG. 2 is an enlarged cross-sectional view of the encircled
area 2 of FIG. 1 showing the finished transition between the wall jamb
and window frame;
FIG. 2A is a view similar to that of FIG. 2 showing the joint
during movement of the adjacent building components; and
FIG. 3 is a view similar to FIG. 2A of a prior art backer rod
and the associated joint during movement of the adjacent building
components.
Detailed Description of the Invention
Referring to FIG. 1, an exemplary window installation 10 in
a masonry wall 12 is shown. The window installation 10 includes a
perimeter window frame 14, one or more window panes 16, and a
window opening 18 in the wall defined by a pair of jambs 20 and a
header (not shown) above and a sill (not shown) below the window
frame 14. Although one example of a window installation is shown in
FIG. 1, this invention is readily applicable for a variety of window
installations, frame designs, doors and other openings or interruptions in
the masonry wall. Moreover, this invention is not limited to window or

CA 02504301 2005-04-15
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door installations and is readily applicable for transitions, joints or
junctures between any adjacent building or construction components.
As the environment for one application of this invention,
the masonry wall 12 for the exterior of a building includes an outer wall
22 of masonry or brick veneer and an insulated interior wall 24. The
brick veneer outer wall 22 is constructed from bricks or blocks 26
arranged in a vertical pattern. The brick veneer 22 is built up by placing
one layer of bricks 26 over another layer. The spaces between
adjacent bricks 26 and between adjacent layers of bricks are filled with
mortar (not shown). Alternatively, the veneer 26 may be stone or other
masonry components.
The interior wall 24 includes wood framing studs 28, dry
wall 30, and outer sheathing material 32. Other materials may be used
as is well known in the art. In any event, the building wall 12 is
constructed so that there is a small cavity or airspace A between the
back side of the outer wall 22 and the outer surface of the interior wall
24. The airspace A between the back side of the outer wall 22 and the
surface of the interior wall 24 is usually at least about one to two inches
deep, although the exact dimension may vary depending upon the
nature of the construction.
Referring to FIGS. 1-2A, one embodiment of a
jamb/header surround device 34 is shown installed in the wall 12 to
provide a proper transition from the window frame 14 to the wall 12. The
jamb/header surround 34 is installed in the jambs 20 of

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02504301 2012-07-06
the window opening 18 adjacent to the corresponding portions of the-8-
window frame 14. In one embodiment, the surround device 34 is
generally L-shaped, in which a first leg 36 of the device 34 confronts an
outer face of the inner wall 24, and a second leg 38 of the device 34
projects generally perpendicular to the plane of the wall 12 and is
juxtaposed to the outer wall 22 at the window opening 18 to provide a
transition from the window frame 14 to the wall 12. As is readily
apparent, particularly from FIG. 1, the forward-most edge 40 of the
window frame 14 is recessed relative to the front face of the outer wall
22. Therefore, a proper transition from the window frame 14 to the wall
12 that is effectively sealed against wind, rain, and other elements as
well as aesthetically pleasing is often difficult. The wide variety, sizes
and configurations of window frames 14 available from various
manufacturers increases the complexity and difficulty with providing a
proper transition from the window frame 14 to the wall 12.
A recess 42 is formed between the adjacent components
12, 14. Backer rod material 44 which is open or closed cell foam or
similar material is inserted in the recess 42 and a bead of caulk 46 is
applied between the frame 14 and the adjacent portion of wall 12 to
provide a proper finished transition, and thereby substantially cover and
seal the recess 42.

CA 02504301 2005-04-15
-.9-
The joint of this invention also allows for expansion and
contraction of one component, such as the window frame 14 relative to
another component, such as the wall 12 during a variety of climatic
conditions. The backer rod 44 and caulk 46 accommodate expansion
and contraction of the adjacent components 12, 24 relative to each
other.
Referring to FIGS. 1, 2 and 2A, the backer rod material 44
according to one embodiment of this invention includes a main body
portion 48 and one or more distal, terminal end portions 50 serially
connected to the body portion 48 by frangible joints or connections 52.
Advantageously, each frangible joint or connection 52 is shaped
arcuately or non-linearly relative to the planar, spaced, side edges 54 of
the backer rod 44. A planar end surface 56 is spaced from the terminal
portions 50.
As a result of the arcuate-shaped frangible connection 52
between the body portion 48 and the adjacent end portions 50 of the
backer rod 44, when the backer rod 44 is inserted into the recess 42
between adjacent building components, such as the window frame 14
and adjacent wall 12, one or more of the terminal end portions 50 is
severed or removed from the body portion 48 along the appropriate
arcuate-shaped frangible connection 52. As a result, the backer rod 44
remaining in the recess 42 includes a crown or convex-shaped surface
or edge 58. Depending upon the geometry of the joint, the back rod 44
may include any number of serially connected terminal end portions 50

CA 02504301 2005-04-15
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and the appropriate frangible connections 52 as shown in FIG. 1. The
appropriate number of the terminal end portions 50 are removed to
present the recessed convex or crown-shaped surface 58 as shown in
FIG. 2.
After the terminal end portion(s) 50 is/are removed from
the body portion 48 of the backer rod 44, the appropriate bead of caulk
46 is applied to the crown or convex-shaped surface 58 of the backer
rod 44 to provide a finished transition between the adjacent building or
construction components 12, 14. Advantageously, the crown or convex-
shaped surface 58 of the backer rod material 44 accommodates
expansion, contraction and/or general movement of the adjacent
building components as shown by arrows C in FIG 2A without separation
of the caulk 46 from the building components 12, 14 thereby avoiding
deterioration of the joint.
Specifically, as the adjacent components 12, 14 contract or
move away from each other as shown by arrows C, the crown or convex-
shaped surface 58 of the backer rod 44 promotes narrowing or necking
down of the thinnest portion 60 of the caulk material 46 adjacent an
apex 62 of the crown-shaped edge 58 as shown by comparing FIGS. 2
and 2A. This crowing or necking of the caulk material 46 along the apex
62 of the backer rod convex edge 58 advantageously avoids separation
of the caulk 46 from the adjacent building components 12, 14, which
occurs with the prior art arrangement of FIG.3 wherein the backer rod 45
has a generally linear or planar edge 59. In that the hour glass-shaped

CA 02504301 2005-04-15
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configuration of the caulk 46 in FIG. 2 provides for stretching of the caulk
in the narrow middle portion 60 of the bead 46, when the components
12, 14 adjacent the caulk 46 move as shown in FIG. 2A, the narrow
middle portion of the caulk 60 adjacent the apex 62 of the crown edge
58 further necks down avoiding separation of the caulk 46 at the
interface with the adjacent building components 12, 14. Moreover, the
back rod 44 having one or more frangible connections 52 each which
provide a crown or convex-shaped edge 58 allows for easy, convenient
and reliable installation of the backer rod 44 during construction. The
appropriate number of end portions 50 are removed from the body
portion 48 to provide the recess 42 of the proper depth for application of
the caulk 46.
The backer rod material 44 may be used generally at the
joint between two building/construction components 12, 14. The two
components may, for example, be produced from marble and provide
the exterior skin of a office building. Components are spaced apart to
provide a control joint for contraction and expansion of the materials.
Thus, a joint is provided between both components and opens outwardly
through the front exterior surfaces of components. The backer rod may
be polyethylene and positioned in the recess 42 and has a most forward
located surface 58 located a distance from the forward surfaces of
components 12, 14 to define the recess 42. Typically, the depth of the
recess 42 should be one-half the width of the spacing between
components 12, 14.

CA 02504301 2012-07-06
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From the above disclosure of the general principles of the
present invention and the preceding detailed description of at least one
preferred embodiment, those skilled in the art will readily comprehend
the various modifications to which this invention is susceptible for
example, the backer rod material of this invention can be used at the
joint between any adjacent building or construction components,
including window and door frames, with or without a surround device as
shown in one embodiment herein. Therefore, the scope of the claims
should not be limited by the preferred embodiments set forth in the
examples, but should be given the broadest interpretation consistent
with the description as a whole.

Representative Drawing