Note: Descriptions are shown in the official language in which they were submitted.
CA 02597736 2007-09-06
FOLDED WALL ANCHOR AND SURFACE-MOUNTED ANCHORING
This application is a division of commonly-owned and co-pending Canadian
Patent
Application No. 2,458,008 of February 17, 2004.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to folded wall anchors and to surface-mounted anchoring
systems
employing the same, both of which are used in cavity wall constructs. More
particularly, the
invention relates to sheetmetal wall anchors and wire formative veneer ties
that comprise
positive interlocking components of the anchoring system. The system has
application to
seismic-resistant structures and to cavity walls having special requirements.
The latter include
high-strength requirements for jumbo brick and stone block veneers and high-
span
requirements for larger cavities with thick insulation.
2. Description of the Prior Art
In the late 1980's, surface-mounted wall anchors were developed by Hohmann &
Barnard, Inc., patented under U.S. Patent No. 4,598,518 of the first-named
inventor hereof.
The invention was commercialized under trademarks DW-10, DW-10-X, and DW-10-
HS. These
widely accepted building specialty products were designed primarily for dry-
wall construction,
but were also used with masonry backup walls. For seismic applications, it was
common
practice to use these wall anchor as part of the DW-10 SeismiclipTM interlock
system which
added a Byna-Tie wire formative, a SeismiclipTMsnap-in device--described in
U.S. Patent No.
4,875,319 ('319), and a continuous wire reinforcement.
In the dry wall application, the surface-mounted wall anchor of the above-
described
system has pronged legs that pierce the insulation and the wall board and rest
against the
metal stud to provide mechanical stability in a four-point landing
arrangement. The vertical
slot of the wall anchor enables the mason to have the wire tie adjustably
positioned along a
pathway of up to 3.625-inch (max.)The interlock system served well and
received high scores
in testing and engineering evaluations which examined effects of various
forces, particularly
lateral forces, upon brick veneer masonry construction. However, under certain
conditions, the
system did not sufficiently maintain the integrity of the insulation.
The engineering evaluations further described the advantages of having a
continuous
wire embedded in the mortar joint of anchored veneer wythes. The seismic
aspects of these
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investigations were reported in the inventor's '319 patent. Besides earthquake
protection, the
failure of several high-rise buildings to withstand wind and other lateral
forces resulted in the
incorporation of a continuous wire reinforcement requirement in the Uniform
Building Code
provisions. The use of a continuous wire in masonry veneer walls has also been
found to
provide protection against problems arising from thermal expansion and
contraction and to
improve the uniformity of the distribution of lateral forces in the structure.
Shortly after the introduction of the pronged wall anchor, a seismic veneer
anchor, which
incorporated an L-shaped backplate, was introduced. This was formed from
either 12- or
14-gauge sheetmetal and provided horizontally disposed openings in the arms
thereof for pintle
legs of the veneer anchor. In general, the pintle-receiving sheetmetal version
of the
SeismiclipTM interlock system served well, but in addition to the insulation
integrity problem,
installations were hampered by mortar buildup interfering with pintle leg
insertion.
In the 1980's, an anchor for masonry veneer walls was developed and described
in U.S.
Patent No. 4,764,069 by Reinwall et al., which patent is an improvement of the
masonry veneer
anchor of Lopez, U.S. Patent No. 4,473,984. Here the anchors are keyed to
elements that are
installed using power-rotated drivers to deposit a mounting stud in a
cementitious or masonry
backup wall. Fittings are then attached to the stud which include an elongated
eye and a wire
tie therethrough for deposition in a bed joint of the outer wythe. It is
instructive to note that
pin-point loading--that is forces concentrated at substantially a single point-
-developed from
this design configuration. Upon experiencing lateral forces over time, this
resulted in the
loosening of the stud.
Exemplary of the public sector building specification is that of the Energy
Code
Requirement, Boston, Mass. (see Chapter 13 of 780 CMR, Seventh Edition). This
Code sets
forth insulation R-values well in excess of prior editions and evokes an
engineering response
opting for thicker insulation and correspondingly larger cavities. Here, the
emphasis is upon
creating a building envelope that is designed and constructed with a
continuous air barrier to
control air leakage into or out of conditioned space adjacent the inner wythe.
As insulation became thicker, the tearing of insulation during installation of
the pronged
DW-10X wall anchor, see supra, became more prevalent. This occurred as the
installer would
fully insert one side of the wall anchor before seating the other side. The
tearing would occur
during the arcuate path of the insertion of the second leg. The gapping caused
in the insulation
permitted air and moisture to infiltrate through the insulation along the
pathway formed by the
tear. While the gapping was largely resolved by placing a self-sealing, dual-
barrier polymeric
membrane at the site of the legs and the mounting hardware, with increasing
thickness in
insulation, this patchwork became less desirable. The improvements hereinbelow
in surface
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mounted wall anchors look toward greater retention of insulation integrity and
less reliance on
a patch.
Another prior art development occurred shortly after that of Reinwall/Lopez
when
Hatzinikolas and Pacholok of Fero Holding Ltd. introduced their sheetmetal
masonry connector
for a cavity wall. This device is described in U.S. Patents Nos. 5,392,581 and
4,869,043. Here
a sheetmetal plate connects to the side of a dry wall column and protrudes
through the
insulation into the cavity. A wire tie is threaded through a slot in the
leading edge of the plate
capturing an insulative plate thereunder and extending into a bed joint of the
veneer. The
underlying sheetmetal plate is highly thermally conductive, and the '581
patent describes
lowering the thermal conductivity by foraminously structuring the plate.
However, as there is
no thermal break, a concomitant loss of the insulative integrity results.
In recent building codes for masonry structures a trend away from eye and
pintle
structures is seen in that newer codes require adjustable anchors be detailed
to prevent
disengagement. This has led to anchoring systems in which the open end of the
veneer tie is
embedded in the corresponding bed joint of the veneer and precludes
disengagement by
vertical displacement.
Another application for high-span anchoring systems is in the evolving
technology of
self-cooling buildings. Here, the cavity wall serves additionally as a plenum
for delivering air
from one area to another. While this technology has not seen wide application
in the United
States, the ability to size cavities to match air moving requirements for
naturally ventilated
buildings enable the architectural engineer to now consider cavity walls when
designing
structures in this environmentally favorable form.
In the past, the use of wire formatives have been limited by the mortar layer
thicknesses
which, in turn are dictated either by the new building specifications or by
pre-existing
conditions, e.g. matching during renovations or additions the existing mortar
layer thickness.
While arguments have been made for increasing the number of the fine-wire
anchors per unit
area of the facing layer, architects and architectural engineers have favored
wire formative
anchors of sturdier wire. On the other hand, contractors find that heavy wire
anchors, with
diameters approaching the mortar layer height specification, frequently result
in misalignment.
This led to the low-profile wall anchors of the inventors hereof as described
in U.S. Patent No.
6,279,283. However, the above-described technology did not address the
adaption thereof to
surface mounted devices.
In the course of prosecution of U.S. Patent No. 4,598,518 (Hohmann '518)
several
patents, indicated by an asterisk on the tabulation below, became known to the
inventors
hereof and are acknowledged hereby. Thereafter and in preparing for this
disclosure, the
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addit4onal patents which became known to the inventors are discussed further
as to the
significance thereof:
Patent Inventor 0. CI. Issue Date
2,058,148* Hard 52/714 October 1936
2,966,705* Massey 52/714 January 1961
3,377,764 Storch Apr. 16, 1968
4,021,990* Schwalberg 52/714 May 10, 1977
4,305,239* Geraghty 52/713 December 1981
4,373,314 Allan Feb. 15, 1983
4,438,611* Bryant 52/410 March 1984
4,473,984 Lopez Oct. 2, 1984
4,598,518 Hohmann Jul. 8, 1986
4,869,038 Catani Sep. 26, 1989
4,875,319 Hohmann Oct. 24, 1989
5,063,722 Hohmann Nov. 12, 1991
5,392,581 Hatzinikolas et al. Feb. 28, 1995
5,408,798 Hohmann Apr. 25, 1995
5,456,052 Anderson et al. Oct. 10, 1995
5,816,008 Hohmann Oct. 15, 1998
6,209,281 Rice Apr. 3, 2001
6,279,283 Hohmann et al. Aug. 28, 2001
Foreign Patent Documents
279209* CH 52/714 March 1952
2069024* GB 52/714 August 1981
Note: Original classification provided for asterisked items only.
It is noted that with some exceptions these devices are generally descriptive
of
wire-to-wire anchors and wall ties and have various cooperative functional
relationships with
straight wire runs embedded in the inner and/or outer wythe.
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U.S. Patent No. 3,377,764 - D. Storch - Issued Apr. 16, 1968
Discloses a bent wire, tie-type anchor for embedment in a facing exterior
wythe engaging with
a loop attached to a straight wire run in a backup interior wythe.
U.S. Patent No. 4,021,990 - B. J. Schwalberg - Issued May 10, 1977
Discloses a dry wall construction system for anchoring a facing veneer to
wallboard/metal stud
construction with a pronged sheet-metal anchor. Like Storch '764, the wall tie
is embedded in
the exterior wythe and is not attached to a straight wire run.
U.S. Patent No. 4,373,314 -.1. A. Allan - Issued Feb. 15, 1983
Discloses a vertical angle iron with one leg adapted for attachment to a stud;
and the other
having elongated slots to accommodate wall ties. Insulation is applied between
projecting
vertical legs of adjacent angle irons with slots being spaced away from the
stud to avoid the
insulation.
U.S. Patent No. 4,473,984 - Lopez - Issued Oct. 2, 1984
Discloses a curtain-wall masonry anchor system wherein a wall tie is attached
to the inner
wythe by a self-tapping screw to a metal stud and to the outer wythe by
embedment in a
corresponding bed joint. The stud is applied through a hole cut into the
insulation.
U.S. Patent No. 4,869,038 - M. J. Catani - Issued 09/26/89
Discloses a veneer wall anchor system having in the interior wythe a truss-
type anchor, similar
to Hala et al. '226, supra, but with horizontal sheetmetal extensions. The
extensions are
interlocked with bent wire pintle-type wall ties that are embedded within the
exterior wythe.
U.S. Patent No. 4,879,319 - R. Hohmann - Issued Oct. 24, 1989
Discloses a seismic construction system for anchoring a facing veneer to
wallboard/metal stud
construction with a pronged sheet-metal anchor. Wall tie is distinguished over
that of
Schwalberg '990 and is clipped onto a straight wire run.
U.S. Patent No. 5,392,581 - Hatzinikolas et al. - Issued Feb. 28, 1995
Discloses a cavity-wall anchor having a conventional tie wire for mounting in
the brick veneer
and an L-shaped sheetmetal bracket for mounting vertically between side-by-
side blocks and
horizontally on atop a course of blocks. The bracket has a slit which is
vertically disposed and
protrudes into the cavity. The slit provides for a vertically adjustable
anchor.
U.S. Patent No. 5,408,798 - Hohmann - Issued Apr. 25, 1995
Discloses a seismic construction system for a cavity wall having a masonry
anchor, a wall tie,
and a facing anchor. Sealed eye wires extend into the cavity and wire wall
ties are threaded
therethrough with the open ends thereof embedded with a Hohmann '319 (see
supra) clip in
the mortar layer of the brick veneer.
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U.S. Patent No. 5,456,052 - Anderson et al. - Issued Oct. 10, 1995
Discloses a two-part masonry brick tie, the first part being designed to be
installed in the inner
wythe and then, later when the brick veneer is erected to be interconnected by
the second part.
Both parts are constructed from sheetmetal and are arranged on substantially
the same
horizontal plane.
U.S. Patent No. 5,816,008 - Hohmann - Issued Oct. 15, 1998
Discloses a brick veneer anchor primarily for use with a cavity wall with a
drywall inner wythe.
The device combines an L-shaped plate for mounting on the metal stud of the
drywall and
extending into the cavity with a T-head bent stay. After interengagement with
the L-shaped
plate the free end of the bent stay is embedded in the corresponding bed joint
of the veneer.
U.S. Patent No. 6,209,281 - Rice - Issued Apr. 3, 2001
Discloses a masonry anchor having a conventional tie wire for mounting in the
brick veneer and
sheetmetal bracket for mounting on the metal-stud-supported drywall. The
bracket has a slit
which is vertically disposed when the bracket is mounted on the metal stud
and, in application,
protrudes through the drywall into the cavity. The slit provides for a
vertically adjustable
anchor.
U.S. Patent No. 6,279,283 - Hohmann et al. - Issued Aug. 28, 2001
Discloses a low-profile wall tie primarily for use in renovation construction
where in order to
match existing mortar height in the facing wythe a compressed wall tie is
embedded in the bed
joint of the brick veneer.
None of the above provide the high-strength, surface-mounted wall anchor or
anchoring
systems utilizing these devices of this invention. As will become clear in
reviewing the
disclosure which follows, the cavity wall structures benefit from the recent
developments
described herein that lead to solving the problems of insulation integrity, of
interference from
excess mortar, and of high-span applications. In the related Application, wire
formatives are
compressively reduced in height at the junctures between the wall
reinforcements and the wall
anchors and various techniques of forming junctures between embedded wire
formatives are
introduced.
SUMMARY
In general terms, the invention disclosed hereby is a surface mounted wall
anchor and
an anchoring system employing the same. The wall anchor is a folded sheetmetal
device which
is described herein as functioning with various wire formative veneer ties.
The folded
construction of the wall tie enables the junctures of the legs and the base of
the wall anchor to
be located inboard from the periphery of the wall anchor. During formation of
the wall anchor,
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the outer surface of the enfolded leg and the underside of the base are caused
to be coplanar.
Upon installation, the coplanar elements act to seal the insertion point where
the legs enter into
the exterior layer of building materials on the inner wythe. This sealing
effect precludes the
penetration of air, moisture, and water vapor into the inner wythe structure.
In the first embodiment, the folded wall anchor is adapted from the earlier
inventions
of Schwalberg, U.S. Patent No. 4,021,990 and of Hohmann, U.S. Patent No.
4,875,319, see
supra. Here it is seen that the double folded wall anchor (with legs moved
inboard) together
with a swaged veneer tie and wire reinforcement in the outer wythe creates a
seismic construct
of superior strength. This construct is applied to a dry wall inner wythe
having thick insulation
over wallboard, a larger-than-normal cavity, and a facing of jumbo brick.
In the second and third embodiments, the folded wall anchors are of the winged
variety.
The wings in the second embodiment are perforated and permit selectively
adjustable
positioning of the veneer tie. Here it is seen that a double folded wall
anchor together with a
standard box veneer tie is applied to a dry wall inner wythe having interior
insulation and, thus,
the wall anchor legs have only to penetrate the wallboard layer. In the third
embodiment, the
wings are slotted with a centrally disposed reinforcement bar. The folded wall
anchor is paired
with a canted, low-profile veneer anchor. The folded wall anchor is surface-
mounted to a
masonry block inner wythe having insulation on the exterior surface and a
brick facing. The
use of this innovative surface-mounted wall anchor in various applications
addresses the
problems of insulation integrity, thermal conductivity, and pin-point loading
encountered in the
previously discussed inventions.
In summary of the foregoing, the invention according to the parent application
generally
provides a surface-mounted anchoring system for use in the construction of a
wall having an
inner wythe and an outer wythe, the outer wythe being formed from a plurality
of successive
courses with a bed joint between each two adjacent courses, the inner wythe
and the outer
wythe being in a spaced apart relationship one with the other forming a cavity
therebetween,
the inner wythe having an exterior layer selected from a group consisting of
insulation,
wallboard, and insulation and wallboard. A folded anchor constructed from a
plate-like body
having two major faces comprises: a pair of legs, each twice folded to extend
from one face of
the plate-like body from an inboard location of the plate-like body with the
longitudinal axis of
each leg being substantially normal to the face, the legs being adapted for
insertion at a
predetermined insertion point into the exterior layer of the inner wythe; a
cover portion formed
from the face of the plate-like body and an enfolded portion of the legs, the
cover portion
adapted to preclude penetration of air, moisture and water vapor into the
exterior layer; and
an apertured receptor portion adjacent a second face of the plate-like body,
the apertured
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receptor portion adapted to limit displacement of the outer wythe toward and
away from the
inner wythe. A veneer tie threadedly disposed through the apertured receptor
portion of the
folded wall anchor is adapted for embedment in the bed joint of the outer
wythe so as to
prevent disengagement from the anchoring system.
The invention of the present application also provides a surface-mounted
anchoring
system for use in the construction of a wall having an inner wythe and an
outer wythe, the
outer wythe being formed from a plurality of successive courses with a bed
joint between each
two adjacent courses, the inner wythe and the outer wythe being in a spaced
apart relationship
one with the other forming a cavity therebetween, the inner wythe having an
exterior layer
selected from a group consisting of insulation, wallboard, and insulation and
wallboard. With
this invention a body forming a base and having two major surfaces is
patterned to form leg
portions and wing portions. The body in turn comprises: at least two leg
portions bent
downwardly at 90 to the base; at least two wing portions bent upwardly at 900
to the base,
with one opposing the other; a plurality of apertures through the wing
portions arrayed to be
in horizontal alignment when the wall anchor is installed on a vertical
surface, the apertures
adapted to adjustably receive a veneer tie to align with a corresponding bed
joint in the outer
wythe.
OBJECTS AND FEATURES OF THE INVENTION
Accordingly, it is the primary object of the present invention to provide a
new and novel
anchoring systems for cavity walls, which systems are surface mountable to the
backup wythe
thereof.
It is another object of the present invention to provide a new and novel wall
anchor
mounted on the exterior surface of the wall board or the insulation layer and
secured to the
metal stud or standard framing member of a dry wall construction.
It is yet another object of the present invention to provide an anchoring
system which
is detailed to prevent disengagement under seismic or other severe
environmental conditions.
It is still yet another object of the present invention to provide an
anchoring system
which is constructed to maintain insulation integrity by preventing air and
water penetration.
It is a feature of the present invention that the folded wall anchor thereof
has a coplanar
baseplate for sealing against the leg insertion points.
It is another feature of the present invention that the legs of the folded
wall anchor
hereof have only point contact with the metal studs with substantially no
resultant thermal
conductivity.
It is yet another feature of the present invention that the bearing area
between the wall
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anchor and the veneer tie spreads the forces thereacross and avoids pin-point
loading.
Other objects and features of the invention will become apparent upon review
of the
drawing and the detailed description which follows.
BRIEF DESCRIPTION OF THE DRAWINGS
In the following drawing, the same parts in the various views are afforded the
same
reference designators.
FIG. 1 shows a first embodiment of this invention and is a perspective view of
a
surface-mounted anchoring system as applied to a cavity wall having a larger-
than-normal
cavity with an inner wythe of dry wall construction having thick insulation in
the cavity and an
outer wythe of brick;
FIG. 2 is a rear perspective view showing the folded wall anchor of the
surface-mounted
anchoring system of FIG. 1;
FIG. 3 is a perspective view of the surface-mounted anchoring system of FIG. 1
shown
with a folded wall anchor, a swaged veneer tie threaded therethrough, and a
reinforcing wire
for seismic protection;
FIG. 4 is a cross sectional view of FIG. 1 which shows the relationship of the
surface-mounted anchoring system of this invention to the dry wall
construction and to the
brick outer wythe;
FIG. 5 is a perspective view of a second embodiment of this invention showing
a
surface-mounted anchoring system for a cavity wall and is similar to FIG. 1,
but shows a dry
wall construction with interior insulation and a wall anchor with perforated
wings with a box
veneer tie for insertion into the bed joints of the brick veneer facing wall;
FIG. 6 is a rear perspective view showing the folded wall anchor with
perforated wings
of FIG. 5;
FIG. 7 is a partial perspective view of FIG. 5 showing the relationship of the
folded wall
anchor with perforated wings and the corresponding veneer tie;
FIG. 8 is a perspective view of a third embodiment of this invention showing a
surface-mounted anchoring system for a cavity wall and is similar to FIG. 1,
but shows a
masonry block backup wall with a folded wall anchor with slotted wings and a
low-profile,
canted veneer tie;
FIG. 9 is a rear perspective view showing the wall anchor with slotted wings
of FIG. 8;
and,
FIG. 10 is a partial perspective view of FIG. 8 showing the relationship of
the wall anchor
and the corresponding veneer tie.
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DESCRIPTION OF THE PREFERRED EMBODIMENTS
Before entering into the detailed Description of the Preferred Embodiments,
several
terms which will be revisited later are defined. These terms are relevant to
discussions of
innovations introduced by the improvements of this disclosure that overcome
the deficits of the
prior art devices.
In the embodiments described hereinbelow, the inner wythe is provided with
insulation.
In the dry wall construction, this takes the form, in one embodiment, of
exterior insulation
disposed on the outer surface of the inner wythe and, in another embodiment,
of interior
insulation disposed between the metal columns of the inner wythe. In the
masonry block
backup wall construction, insulation is applied to the outer surface of the
masonry block.
Recently, building codes have required that after the anchoring system is
installed and, prior
to the inner wythe being closed up, that an inspection be made for insulation
integrity to ensure
that the insulation prevents infiltration of air and moisture. Here the term
insulation integrity
is used in the same sense as the building code in that, after the installation
of the anchoring
system, there is no change or interference with the insulative properties and
concomitantly
substantially no change in the air and moisture infiltration characteristics.
In a related sense, prior art sheetmetal anchors have formed a conductive
bridge
between the wall cavity and the interior of the building. Here the terms
thermal conductivity
and thermal conductivity analysis are used to examine this phenomenon and the
metal-to-metal contacts across the inner wythe.
Anchoring systems for cavity walls are used to secure veneer facings to a
building and
overcome seismic and other forces, i.e. wind shear, etc. In the past, some
systems have
experienced failure because the forces have been concentrated at substantially
a single point.
Here, the term pin-point loading refers to an anchoring system wherein forces
are concentrated
at a single point.
In addition to that which occurs at the facing wythe, attention is further
drawn to the
construction at the exterior surface of the inner or backup wythe. Here there
are two concerns
namely, maximizing the strength of the securement of the surface-mounted wall
anchor to the
backup wall and, as previously discussed minimizing the interference of the
anchoring system
with the insulation. The first concern is addressed using appropriate
fasteners such as, for
mounting to masonry block, the properly sized concrete threaded anchors with
expansion
sleeves or concrete expansion bolts and, for mounting to metal, dry-wall
studs, self-tapping
screws. The latter concern is addressed by the flatness of the base of the
surface-mounted,
folded anchors covering the openings formed by the legs (the profile is seen
in the
cross-sectional drawing FIG. 3).
CA 02597736 2007-09-06
In the detailed description, the veneer reinforcements and the veneer anchors
are wire
formatives the wire used in the fabrication of veneer joint reinforcement
conforms to the
requirements of ASTM Standard Specification A-951-00, Table 1. For the purpose
fo this
application tensile strength tests and yield tests of veneer joint
reinforcements are, where
applicable, those denominated in ASTM A-951-00 Standard Specification for
Masonry Joint
Reinforcement.
Referring now to FIGS. 1 through 4, the first embodiment shows a surface-
mounted
anchoring system suitable for seismic zone applications. This anchoring
system, discussed in
detail hereinbelow, has a folded wall anchor, an interengaging veneer tie, and
a veneer (outer
wythe) reinforcement and is surface mounted on a an externally insulated dry
wall. For the first
embodiment, a cavity wall having an insulative layer of 2.5 inches (approx and
a total span of
3.5 inches (approx is chosen as exemplary. As the veneer being anchored is a
jumbo brick
veneer, the anchoring system includes extra vertical adjustment.
The surface-mounted anchoring system for cavity walls is referred to generally
by the
numeral 10. A cavity wall structure 12 is shown having an inner wythe or dry
wall backup 14
with sheetrock or wallboard 16 mounted on metal studs or columns 17 and an
outer wythe or
facing wall 18 of brick 20 construction. Between the inner wythe 14 and the
outer wythe 18,
a cavity 22 is formed. The cavity 22, which has a 3.5-inch span, has attached
to the exterior
surface 24 of the inner wythe 14 insulation in the form of insulating panels
26. The insulation
26 is disposed on wallboard 16. Seams 28 between adjacent panels of insulation
26 are
substantially vertical and each aligns with the center of a column 17.
Successive bed joints 30 and 32 are substantially planar and horizontally
disposed and
in accord with building standards are 0.375-inch (approx in height. Selective
ones of bed joints
30 and 32, which are formed between courses of bricks 20, are constructed to
receive
therewithin the insertion portion of the anchoring system hereof. Being
surface mounted onto
the inner wythe, the anchoring system 10 is constructed cooperatively
therewith, and as
described in greater detail below, is configured to minimize air and moisture
penetration around
the wall anchor/inner wythe juncture.
For purposes of discussion, the cavity surface 24 of the inner wythe 14
contains a
horizontal line or x-axis 34 and an intersecting vertical line or y-axis 36. A
horizontal line or
z-axis 38, normal to the xy-plane, passes through the coordinate origin formed
by the
intersecting x- and y-axes. A folded wall anchor 40 is shown which has a Pair
of legs 42 which
penetrate the wallboard 16 and insulation 26. Folded wall anchor 40 is a
stamped metal
construct which is constructed for surface mounting on inner wythe 14 and for
interconnection
with veneer tie 44.
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The veneer tie 44 is adapted from one shown and described in Hohmann, U.S.
Patent
No. 4,875,319. The veneer tie 44 is shown in FIG. 1 as being emplaced on a
course of bricks
20 in preparation for embedment in the mortar of bed joint 30. In this
embodiment, the system
includes a veneer or outer wythe reinforcement 46, a wall anchor 40 and a
veneer tie 44. The
veneer reinforcement 46 is constructed of a wire formative conforming to the
joint
reinforcement requirements of ASTM Standard Specification A-951-00, Table 1,
see supra.
At intervals along a horizontal line surface 24, folded wall anchors 40 are
surface-mounted using mounting hardware 48. The folded wall anchors 40 are
positioned on
surface 24 so that the longitudinal axis of a column 17 lies within the yz-
plane formed by the
longitudinal axes 50 and 52 of upper leg 54 and lower leg 56, respectively.
The legs 54 and
56 are folded, as best shown in FIG. 2, so that the base surface 58 of the leg
portions and the
base surface 60 of the bail portion 62 are substantially coplanar and, when
installed, lie in an
xy-plane. Upon insertion in insulation 26, the base surfaces 58 and 60 rest
snugly against the
opening formed thereby and serves to cover the opening precluding the passage
of air and
moisture therethrough. This construct maintains the insulation integrity.
Optionally, a layer
of Textroseal . sealant 63, a thick multiply polyethylene/polymer-modified
asphalt distributed
by Hohmann & Barnard, Inc., Hauppauge, N.Y. 11788 may be applied under the
base surfaces
58 and 60 for additional protection.
The dimensional relationship between wall anchor 40 and veneer tie 44 limits
the axial
movement of the construct. Each veneer tie 44 has a rear leg 64 opposite the
bed-joint-deposited portion thereof which is formed continuous therewith. The
slot or bail
aperture 66 of bail 62 is constructed, in accordance with the building code
requirements, to be
within the predetermined dimensions to limit the z-axis 38 movement. The slot
66 is slightly
larger horizontally than the diameter of the tie. The bail-receiving slot 66
is elongated vertically
to accept a veneer tie threadedly therethrough and permit y-axis adjustment.
The dimensional
relationship of the rear leg 64 to the width of bail 62 limits the x-axis
movement of the
construct. For positive interengagement and to prevent disengagement under
seismic
conditions, the front legs 68 and 70 of veneer tie 44 and the reinforcement
wire 46 are sealed
in bed joint 30 forming a closed loop.
The folded wall anchor 40 is seen in more detail in FIGS. 2 through 4. The
legs 54 and
56 are folded 180° about end seams 72 and 74, respectively, and then
900 at the
inboard seams 76 and 78, respectively, so as to extend parallel the one to the
other. The legs
54 and 56 are dimensioned so that, upon installation, they extend through
insulation panels
26 and wallboard 16 and the endpoints 80 thereof abut the metal studs 17.
Although only
two-leg structures are shown, it is within the contemplation of this invention
that more folded
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CA 02597736 2007-09-06
legs could be constructed with each leg terminating at an inboard seam and
having the
insertion point 82 of the insulation 26 covered by the wall anchor body.
Because the legs 54
and 56 abut the studs 17 only at endpoints 80, the thermal conductivity across
the construct
is minimal as the cross sectional metal-to-metal contact area is minimized.
(There is virtually
no heat transfer across the mounting hardware 48 because of the nonconductive
washers
thereof.)
The description which follows is a second embodiment of the surface-mounted
anchoring
system for cavity walls of this invention. For ease of comprehension, wherever
possible similar
parts use reference designators 100 units higher than those above. Thus, the
veneer tie 144
of the second embodiment is analogous to the veneer tie 44 of the first
embodiment. Referring
now to FIGS. 5 through 7, the second embodiment of the surface-mounted
anchoring system
is shown and is referred to generally by the numeral 110. As in the first
embodiment, a wall
structure 112 is shown. The second embodiment has an inner wythe or backup
wall 114 of a
dry wall or a wallboard construct 116 on columns or studs 117 and an outer
wythe or veneer
118 of facing stone 120. The inner wythe 114 and the outer wythe 118 have a
cavity 122
therebetween. Here, the anchoring system has a surface-mounted wall anchor
with perforated
wing portions or receptors for receiving the veneer tie portion of the
anchoring system.
The anchoring system 110 is surface mounted to the exterior surface 124 of the
inner
wythe 114. In this embodiment batts of insulation 126 are disposed between
adjacent columns
117. Successive bed joints 130 and 132 are substantially planar and
horizontally disposed and
in accord with building standards are 0.375-inch (approx.) in height.
Selective ones of bed
joints 130 and 132, which are formed between courses of bricks 120, are
constructed to receive
therewithin the insertion portion of the anchoring system construct hereof.
Being surface
mounted onto the inner wythe, the anchoring system 110 is constructed
cooperatively
therewith, and as described in greater detail below, is configured to
penetrate through the
wallboard at a covered insertion point.
For purposes of discussion, the cavity surface 124 of the inner wythe 114
contains a
horizontal line or x-axis 134 and an intersecting vertical line or y-axis 136.
A horizontal line
or z-axis 138, normal to the xy-plane, passes through the coordinate origin
formed by the
intersecting x- and y-axes. A folded wall anchor 140 is shown which has a pair
of legs 142
which penetrate the wallboard 116. Folded wall anchor 140 is a stamped metal
construct which
is constructed for surface mounting on inner wythe 114 and for interconnection
with veneer tie
144.
The veneer tie 144 is a box Byna-Tie device manufactured by Hohmann &
Barnard,
Inc., Hauppauge, N.Y. 11788. The veneer tie 144 is shown in FIG. 5 as being
emplaced on a
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CA 02597736 2007-09-06
course of bricks 120 in preparation for embedment in the mortar of bed joint
130. In this
embodiment, the system includes a folded wall anchor 140 and a veneer tie 144.
At intervals along a horizontal line on surface 124, folded wall anchors 140
are
surface-mounted using mounting hardware 148 with neoprene sealing washers. The
folded wall
anchors 140 are positioned on surface 124 so that the longitudinal axis of a
column 117 lies
within the yz-plane formed by the longitudinal axes 150 and 152 of upper leg
154 and lower
leg 156, respectively. The legs 154 and 156 are folded, as best shown in FIG.
6, so that the
base surface 158 of the leg portions and the intermediate base surface 160 are
substantially
coplanar and, when installed, lie in an xy-plane. Upon insertion in the
wallboard 116, the base
surfaces 158 and 160 rest snugly against the opening formed thereby and serves
to cover the
opening precluding the passage of air and moisture therethrough, thereby
maintaining the
insulation integrity. It is within the contemplation of this invention that a
coating of sealant or
a layer of a polymeric compound--such as a closed-cell foam--be placed on base
surfaces 158
and 160 for additional sealing.
In the second embodiment, perforated wing portions 162 therealong are bent
upwardly
(when viewing legs 142 as being bent downwardly) from intermediate base 160
for receiving
veneer tie 144 therethrough. The dimensional relationship between wall anchor
140 and veneer
tie 144 limits the axial movement of the construct. Each veneer tie 144 has a
rear leg 164
opposite the bed-joint deposited portion thereof, which rear leg 164 is formed
continuous
therewith. The perforations 166 provide for selective adjustability and,
unlike the other
embodiments hereof, restrict the y-axis 136 movement of the anchored veneer.
The opening
of the perforation 166 of wing portions 162 is constructed to be within the
predetermined
dimensions to limit the z-axis 138 movement in accordance with the building
code
requirements. The perforation 166 is slightly larger horizontally than the
diameter of the tie
144. If y-axis 136 adjustability is desired, the perforations 166 may be
elongated vertically.
The dimensional relationship of the rear leg 164 to the width of spacing
between wing portions
162 limits the x-axis movement of the construct. For positive interengagement,
the front legs
168 and 170 of veneer tie 144 are sealed in bed joint 130 forming a closed
loop.
The folded wall anchor 140 is seen in more detail in FIGS. 6 and 7. The upper
legs 154
and lower leg 156 are folded 180° about end seams 172 and 174,
respectively, and
then 90° at the inboard seams 176 and 178, respectively, so as to
extend parallel the
one to the other. The legs 154 and 156 are dimensioned so that, upon
installation, they extend
through wallboard 116 and the endpoints 180 thereof abut the metal studs 117.
Although only
two leg structures are shown, it is within the contemplation of this invention
that more folded
legs could be constructed with each leg terminating at an inboard seam and
having the
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CA 02597736 2007-09-06
insertion point 182 of the wallboard 116 covered by the wall anchor body.
Because the legs
154 and 156 abut the studs 117 only at endpoints 180, the thermal conductivity
across the
construct is minimal as the cross sectional metal-to-metal contact area is
minimized. (There
is virtually no heat transfer across the mounting hardware 148 because of the
nonconductive
washers thereof.
The description which follows is a third embodiment of the surface-mounted
anchoring
system for cavity walls of this invention. For ease of comprehension, wherever
possible similar
parts use reference designators 100 units higher than those above. Thus, the
veneer tie 244
of the third embodiment is analogous to the veneer tie 144 of the second
embodiment.
Referring now to FIGS. 8 through 10, the third embodiment of the surface-
mounted anchoring
system is shown and is referred to generally by the numeral 210. As in the
previous
embodiments, a wall structure 212 is shown. Here, the third embodiment has an
inner wythe
or backup wall 214 of masonry block 216 and an outer wythe or veneer 218 of
facing brick 220.
The inner wythe 214 and the outer wythe 218 have a cavity 222 therebetween.
The anchoring
system has a surface-mounted wall anchor with slotted wing portions or
receptors for receiving
the veneer tie portion of the anchoring system and a low-profile box tie.
The anchoring system 210 is surface mounted to the exterior surface 224 of the
inner
wythe 214. In this embodiment panels of insulation 226 are disposed on the
masonry block
216. Successive bed joints 230 and 232 are substantially planar and
horizontally disposed and
in accord with building standards are 0.375-inch (approx.) in height.
Selective ones of bed
joints 230 and 232, which are formed between courses of bricks 220, are
constructed to receive
therewithin the insertion portion of the anchoring system construct hereof.
Being surface
mounted onto the inner wythe, the anchoring system 210 is constructed
cooperatively
therewith, and as described in greater detail below, is configured to
penetrate through the
insulation at a covered insertion point.
For purposes of discussion, the cavity surface 224 of the inner wythe 214
contains a
horizontal line or x-axis 234 and an intersecting vertical line or y-axis 236.
A horizontal line
or z-axis 238, normal to the xy-plane, passes through the coordinate origin
formed by the
intersecting x- and y-axes. A folded wall anchor 240 is shown which has a pair
of legs 242
which penetrate the insulation 226. Folded wall anchor 240 is a stamped metal
construct which
is constructed for surface mounting on inner wythe 214 and for interconnection
with veneer tie
244.
The veneer tie 244 is adapted from the low-profile box Byna-Tie device
manufactured
by Hohmann & Barnard, Inc., Hauppauge, N.Y. 11788 under U.S. Patent No.
6,279,283. The
veneer tie 244 is shown in FIG. 8 as being emplaced on a course of bricks 220
in preparation
CA 02597736 2007-09-06
for embedment in the mortar of bed joint 230. In this embodiment, the system
includes a
folded wall anchor 240 and a canted veneer tie 244.
At intervals along a horizontal line surface 224, folded wall anchors 240 are
surface-mounted using masonry mounting hardware 248. The folded wall anchors
240 are
positioned on surface 224 at the intervals required by the applicable building
codes. The upper
legs 254 and lower leg 256 are folded, as best shown in FIG. 9, so that the
base surface 258
of the leg portions and the intermediate base surface 260 are substantially
coplanar and, when
installed, lie in an xy-plane. Upon insertion in insulation 226, the base
surfaces 258 and 260
rest snugly against the opening formed thereby and serves to cover the opening
precluding the
passage of air and moisture therethrough, thereby maintaining the insulation
integrity. It is
within the contemplation of this invention that a coating of sealant or a
layer of a polymeric
compound--such as a closed-cell foam--be placed on base surfaces 258 and 260
for additional
sealing.
In the third embodiment, slotted wing portions 262 therealong are bent
upwardly (when
viewing legs 242 as being bent downwardly) from intermediate base 260 for
receiving veneer
tie 244 therethrough. The dimensional relationship between wall anchor 240 and
veneer tie
244 limits the axial movement of the construct. Each veneer tie 244 has a rear
leg 264
opposite the bed-joint deposited portion thereof, which rear leg 264 is formed
continuous
therewith. The slots 266 provide for adjustability and, unlike the second
embodiment hereof,
do not restrict the y-axis 236 movement of the anchored veneer. The opening of
the slot 266
of wing portions 262 is constructed to be within the predetermined dimensions
to limit the
z-axis 238 movement in accordance with the building code requirements. The
slots 266 are
slightly larger horizontally than the diameter of the tie 244. The dimensional
relationship of
the rear leg 264 to the width of spacing between wing portions 262 limits the
x-axis movement
of the construct. For positive interengagement, the front legs 268 and 270 of
veneer tie 244
are sealed in bed joint 230 forming a closed loop.
The folded wall anchor 240 is seen in more detail in FIGS. 9 and 10. The upper
legs 254
and lower leg 256 are folded 180° about end seams 272 and 274,
respectively, and
then 90° at the inboard seams 276 and 278 respectively, so as to extend
parallel the
one to the other. The legs 254 and 256 are dimensioned-so that, upon
installation, they extend
through insulation panels 226 and the endpoints 280 thereof abut the exterior
surface 124 of
masonry block 216. Because the insertion point 282 into insulation 226 of the
legs 254 and
256 is sealingly covered by the structure, the water and water vapor
penetration into the
backup wall is minimal. (There is virtually no heat transfer across the
mounting hardware 248
because of the nonconductive washers thereof.)
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CA 02597736 2007-09-06
In the veneer tie shown in FIGS. 8 and 10, a bend is made at a point of
inflection 284.
This configuring of the veneer tie 244, compensates for the additional
strengthening of wall
anchor 240 at crossbar 286. Thus, if the bed joint 230 is exactly coplanar
with the
strengthening crossbar 286 the bent veneer tie 244 facilitates the alignment
thereof.
In the above description of the folded wall anchors of this invention various
configurations are described and applications thereof in corresponding
anchoring systems are
provided. Because many varying and different embodiments may be made within
the scope
of the inventive concept herein taught, and because many modifications may be
made in the
embodiments herein detailed in accordance with the descriptive requirement of
the law, it is
to be understood that the details herein are to be interpreted as illustrative
and not in a limiting
sense.
17
