Note: Descriptions are shown in the official language in which they were submitted.
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Title: TIE SYSTEM AND METHOD FOR CONNECTING A CEMENTITIOUS
BACKUP WALL MADE IN A PENETRABLE FORM AND A VENEER WALL
Inventor: Michael Hatzinikolas
FIELD OF THE INVENTION
This invention relates to a tie system and method for connecting a
veneer to a back-up wall. In a particularly embodiment, the invention relates
to a
tie system and method for connecting a veneer made from bricks or the like to
a
backup wall made from a cementitious material that is formed using a form made
from a penetrable material such a foam material.
BACKGROUND OF THE INVENTION
Certain types of building incorporate a backup wall that is made
from a cementitious material and a veneer that may be made from rows of bricks
or the like. The cementitious backup wall is sometimes poured on-site into a
form that may be made from slabs of foam material.
Connectors are typically used to secure the veneer to the backup
wall. However, these connectors sometimes move out of position during the
pouring of the cementitious material that makes up the backup wall, thereby
potentially impacting their ability to function as desired. For example, the
connector may not be properly positioned to secure the veneer in place once
the
cementitious material cures.
SUMMARY OF THE INVENTION
In accordance with the instant invention, a system and method are
provided to secure a veneer to a backup wall constructed from a pourable
material. The system includes a form connector that is securable, and
preferably
removably securable, to a wall form. In accordance with such an embodiment,
the form connector is secured in position and may accordingly be used to
secure
a backup wall connector in place while the pourable material is curing and,
more
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preferably, until the pourable material is cured, or is at least essentially
cured. In
a particularly preferred embodiment, the form connector secures the backup
wall
connector in place while the pourable material is placed, e.g., poured into,
the
wall form and during at least a sufficient portion of the during process such
that
the backup wall connector is secured in position by the pourable material.
In another embodiment, a wall tie, which is used to secure a veneer
to a backup wall, is connected to the backup wall connector with the form
connector in position. In such an embodiment, the form connector remains in
position when the veneer wall is installed.
In an alternate embodiment, the form connector is removed prior to
the veneer wall being installed, thus permitting the form connector to be
reused.
In an alternate embodiment, the engagement member that is used
to secure the form connector to the backup wall connector is also used to
secure
the wall tie to the form connector. Such an embodiment is particularly
preferred in
those embodiments wherein the form connector is removed prior to the veneer
wall being installed.
Accordingly, in accordance with one embodiment of the instant
invention, there is provided a tie system for use with a penetrable form for a
cementitious backup wall and for use with a wall tie to connect between the
cementitious backup wall and a veneer, the tie system comprising:
(a) a backup wall connector shaped to extend through an
aperture in the form and having:
(i) a forward-facing backup-wall-engagement surface and a
rearward-facing backup-wall-engagement surface that are positioned to engage
the cementitious material when the backup wall connector extends by a selected
amount through the aperture in the penetrable form; and,
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(ii) a forward-facing form-connector-engagement surface and a
rearward-facing form-connector-engagement surface that are positioned to
engage the form connector to substantially prevent forward and rearward
relative
movement between the backup wall connector and the form connector;
(b) a tie connector; and,
(c) a form connector connectable to the form.
In one embodiment, the tie system further comprises a forward-
facing wall-tie-engagement surface and a rearward-facing wall-tie-engagement
surface that are positioned to engage the wall tie to substantially prevent
forward
and rearward relative movement between the wall tie and the backup wall
connector.
In another embodiment, the forward-facing form-connector-
engagement surface is the same as the forward-facing wall-tie-engagement
surface, and wherein the rearward-facing form-connector-engagement surface is
the same as the rearward-facing wall-tie-engagement surface.
In another embodiment, the backup wall connector has a connector
aperture defined by a connector aperture wall, wherein the connector aperture
wall comprises the forward-facing and rearward-facing form-connector-
engagement surfaces.
In another embodiment, the backup wall connector has a connector
aperture defined by a connector aperture wall, wherein the connector aperture
wall comprises the forward-facing and rearward-facing wall-tie-engagement
surfaces.
In another embodiment, the backup wall connector is a
substantially planar plate.
In another embodiment, the backup wall connector has at least one
opening having a perimeter wall and the forward-facing backup-wall-engagement
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surface and the rearward-facing backup-wall-engagement surface comprise the
perimeter wall.
In another embodiment, the backup wall connector extends other
than along a linear axis. For example, the backup wall connector may have an
end portion positioned within the cementitious material (when the form is
filled)
that is bent (e.g. about 90 ) of the backup wall connector may be distorted
(e.g.,
S shaped or corrugated) thereby increasing the surface area in contact with
the
cementitious material and creating a profile the resists the connector from
being
pulled outwardly from the cured cementitious material.
In another embodiment, the form connector is penetrable to permit
a nail to be driven therethrough into the form.
In another embodiment, the form connector is made from a material
selected from the group consisting of wood and polymeric material.
In another embodiment, the backup wall connector is shaped to at
least substantially prevent leakage of cementitious material out of the
aperture in
the form.
In another embodiment, the form connector is removable
connectable to the form.
In accordance with the instant invention, there is also provided a tie
system for use with a penetrable form for a cementitious backup wall
comprising
cementitious material and for connecting between the cementitious backup wall
and a veneer, comprising:
a backup wall connector shaped to extend through the form, the
backup wall connector having a length sufficient such that a portion of the
backup
wall connector is positioned in the cementitious material when the backup wall
connector extends by a selected amount through the form and the form is
filled,
the backup wall connector being configured to inhibit the backup wall
connector
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being pulled outwardly from the cementitious when the cementitious has cured,
the backup wall being configured to be engagable with a wall tie; and,
a form connector connectable to the form and the backup wall
connector.
In another embodiment, the tie system further comprises a wall tie.
In another embodiment, the backup wall connector has a connector
aperture positioned to engage the form connector to at least substantially
prevent
forward and rearward relative movement between the backup wall connector and
the form connector.
In another embodiment, the connector aperture is positioned to
engage the wall tie to at least substantially prevent forward and rearward
relative
movement between the wall tie and the backup wall connector.
In another embodiment, the backup wall connector is configured to
inhibit the backup wall connector being pulled outwardly from the cementitious
when the cementitious has cured by being a substantially planar plate that has
at least one aperture in the portion of the backup wall connector that is
positioned
in the cementitious material. Alternately, the backup wall connector may
extend
in other than along a linear axis
In another embodiment, the form connector is penetrable to permit
a nail to be driven therethrough into the form.
In another embodiment, the form connector is removable
connectable to the form.
In accordance with the instant invention, there is also provided a
method of securing a veneer to a backup wall comprising:
(a) positioning a backup wall connector to extend through a wall
form wherein a first portion of the backup wall connector is positioned within
the
wall form and a second portion of the backup wall connector is positioned
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exterior to the wall form, the second portion having a form connector
engagement member;
(b) securing a form connector to the wall form and the form
connector engagement member; and,
(c) attaching a wall tie to the second portion.
In one embodiment, the method further comprises filling the wall
form with cementitious material and removing the form connector from the wall
form and the form connector engagement member prior to attaching the wall tie
to backup wall connector.
In another embodiment, the method further comprises constructing
the wall form from foam.
In another embodiment, the method further comprises filling the
wall form with cementitious material and permitting the cementitious material
to
cure prior to removing the form connector from the wall form.
In another embodiment, the method further comprises filling the
wall form with cementitious material prior to attaching the wall tie to the
second
portion.
In another embodiment, the method further comprises selecting a
backup wall connector wherein the first portion has at least one form-
connector-
engagement surface.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the present invention and to show
clearly how it may be carried into effect, reference will now be made, by way
of
example only, to the accompanying drawings, in which:
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Figure 1 is a perspective view of the components that make up a tie
system in accordance with a first embodiment of the present invention;
Figure 2 is a side view of an initial tie assembly made from the
components shown in Figure 1, wherein the initial tie assembly is installed in
a
form for a cementitious backup wall;
Figure 3 is a perspective view of the initial tie assembly shown in
Figure 2, shown with the form shown in Figure 2 and a cementitious backup wall
made therein;
Figure 4 is a plan view of a final tie assembly made from the
components shown in Figure 1, wherein the final tie assembly connects between
the cementitious backup wall shown in Figure 3 and a veneer;
Figure 5 is a perspective view of the final tie assembly,
cementitious backup wall and veneer shown in Figure 4; and,
Figure 6 is a side view of an alternative backup wall connector to
that shown in Figure 1.
DETAILED DESCRIPTION OF THE INVENTION
Reference is made to Figure 1, which shows a tie system 10 in
accordance with a preferred embodiment of the present invention. The tie
system
10 exemplified in Figure 1 is used to make a final tie assembly 11,
exemplified in
Figure 4, for connecting between a backup wall 12 and a wall of veneer 14 in
certain types of structures. The backup wall 12 may be made from a
cementitious material 16 that is poured in situ into a form 18 made from slabs
of
a penetrable material 20 such as a polymeric foam material. It will be
appreciated
that cementitious material 16 may be any fluid cementitious material 16 known
in
the building industry to fill a wall form 18. It will also be appreciated that
form 18
may be made from any material known in the building industry to construct a
wall
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form 18. The veneer 14 may be made from rows of bricks 22 or the like, which
may also be referred to as veneer elements 22. It will be appreciated that
veneer
14 may be any veneer known in the building industry that is secured to a
support
by a wall tie.
Referring to Figure 1, the tie system 10 includes a backup wall
connector 24 for connecting to the backup wall 12 (Figure 4), a form connector
26 for connecting to the form 18 (Figure 4), one or more fasteners 28 for
attaching the form connector 26 to the form 18 (Figure 4), and a wall tie 30
(Figure 4).
Referring to Figure 2, the backup wall connector 24 extends
through (such as by being pushed inwardly through, slide downwardly through or
otherwise inserted) the form 18 into the space shown at 32 that will receive
the
cementitious material 16 (see Figure 3) that will make up the backup wall 12
(i.e.
the cavity defined by the wall form 18). The backup wall connector 24
preferably
has a shape that facilitates penetration of the form 18. For example, the
backup
wall connector 24 may be a generally planar plate (i.e. sides 40 and 42 may be
planar) having a length, a width and a thickness, such that the leading edge
face
(i.e., the edge face that penetrates the form 18 at forward end 36) is defined
by
the width and thickness of the plate. It will be appreciated that backup wall
connector 24 may alternately have sides 40 and 42 that are not planar, e.g.,
they
may be S shaped, corrugated or have a portion that extends laterally outwardly
(e.g. bent laterally). In such an embodiment, backup wall connector 24 may be
positioned by sliding backup wall connector 24 downwardly into a slot provided
in
a wall form.
The plate may be made from corrosion resistant steel, or from
some other suitable material having a suitable thickness. Preferably, the
backup
wall connector 24 does not have any flanges or the like extending outwardly
from
first and second sides 40, 42. As the backup wall connector 24 is inserted
through the form 18 (e.g., by hammering it on its rearward end 38), it creates
a
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form aperture 34 (see Figure 4). Preferably, the backup wall connector 24
seals
with the wall of the form aperture 34, shown at 35 in Figure 4, to at least
substantially prevent leakage of cementitious material 16 out of the aperture
34
in the form 18 prior to the curing of the cementitious material 16. It will
also be
appreciated that a preformed aperture may be provided in the wall form.
It will be understood that a sectional view of the backup wall 12 and
the form 18 are shown in Figure 3 to facilitate illustration of the structure
of the
backup wall connector 24.
Referring to the back up wall connector 24 exemplified in Figure 4,
the back up wall connector 24 has a forward end 36 (which has the leading
edge), a rearward end 38, a first side 40, a second side 42, a top 44 (Figure
2)
and a bottom 46 (Figure 2). Preferably, the backup wall connector 24 has
additional surfaces to abut against the cured cementitious material to assist
in
retaining backup wall connector 24 in position in the cured cementitious
material.
Referring to Figure 2, such additional surfaces are provided by
providing at least one aperture. As exemplified in Figure 2, proximate the
forward
end 36, the backup wall connector 24 has a first backup-wall-engagement
surface 48 and a second backup-wall-engagement surface 50, both of which are
positioned in the space 32 so that they are buried in the cementitious
material 16
of the back up wall 12. The first backup-wall-engagement surface 48 is forward-
facing in use, and engages the cementitious material 16 (Figure 3) preferably
to
prevent movement of the backup wall connector 24 in the forward direction
(i.e.,
into the cementitious material 16). The second surface backup-wall-engagement
50 is rearward-facing and engages the cementitious material 16 preferably to
prevent movement of the backup wall connector 24 in the rearward
direction(i.e.,
out of the cementitious material 16).
It is not necessary for the forward-facing surface 48 to face directly
forwardly. Thus, it is not necessary for the forward-facing surface 48 to be
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vertical or to have any portion that is vertical. The forward-facing surface
48 may
have any shape that faces forwardly at least somewhat. It may be curved,
linear,
or a combination of both. Similarly, it is not necessary for the rearward-
facing
surface 50 to face directly rearwardly and therefore it is not necessary for
the
rearward-facing surface 50 to be vertical. The rearward-facing surface 50 may
have any shape that faces rearwardly at least somewhat, and may be curved,
linear or a combination of both.
In the exemplary embodiment shown in Figure 2, the forward-facing
and rearward-facing surfaces 48 and 50 are halves of the wall or perimeter of
a
backup wall connection aperture 52 formed through the thickness of the
connector 24 from the first side 40 to the second side 42 (Figure 3) proximate
the
forward end 36 of the backup wall connector 24. In the embodiment shown in
Figure 2, the backup wall connection aperture 52 is closed and is generally
circular.
In another exemplary embodiment shown in Figure 6, the forward-
facing and rearward-facing surfaces 48 and 50 are halves of a backup wall
connection aperture 54 that is U-shaped and is an open-ended slot. The
aperture 54 passes through the thickness of the connector 24 from the first
side
40 to the second side (not shown in Figure 6), proximate the forward end 36.
The backup wall connector 24 may have a plurality of forward-
facing surfaces 48 instead of one. The backup wall connector 24 may have a
plurality of rearward-facing surfaces 50 instead of one. For example, the
backup
wall connector may have a plurality of apertures and the apertures may be
positioned on any portion of the backup wall connector 24 that will be
positioned
in the cementitious material 16 when the cementitious material 16 is cured.
In a further alternate embodiment, It will be appreciated that backup
wall connector 24 may alternately have sides 40 and 42 that are not planar,
e.g.,
they may be S shaped, corrugated or have a portion that extends laterally
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outwardly (e.g. bent laterally with respect to the longitudinal axis of backup
wall
connector 24, i.e. the axis defined by a line passing through forward end 36
and
rearward end 38).
Referring to Figure 1, the backup wall connector 24 has a
connecting aperture 56 extending therethrough between the first side 40 and
the
second side 42 (not shown in Figure 1) proximate the rearward end 38. The
connecting aperture 56 is preferably sized to snuggly receive the form
connector
26 (Figures 2 and 3) therethrough when initially connecting the back up wall
connector 24 to the form 18. Referring to Figure 2, the connecting aperture 56
has a forward-facing form connector engagement surface 58 and a rearward-
facing forrn connector engagement surface 60. The forward-facing and
rearward-facing form connector engagement surfaces 58 and 60 preferably
cooperate with the form connector 26 to at least substantially prevent the
forward
and rearward relative movement between the backup wall connector 24 and the
form connector 26, (and therefore between the backup wall connector 24 and the
form 18), when the cementitious material 16 is poured into the space 32. It
will
be appreciated that, in an alternate embodiment, the form connector 26 may be
secured to backup wall connector 24 by other means.
The connecting aperture 56 is preferably sized to concurrently or
subsequently (i.e., after form connector 26 is removed) receive the wall tie
30
(Figures 4 and 5) therethrough. The wall tie 30 is used to connect the backup
wall connector 24 to the veneer 14. In this way, the forward-facing and
rearward-
facing form connector engagement surfaces 58 and 60 may also be referred to
as forward-facing and rearward-facing wall tie engagement surfaces 58 and 60
(see Figure 4). It will be appreciated that, in an alternate embodiment, the
wall tie
may be secured to backup wall connector 24 by other means and may be of
any construction known in the building industry.
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It will be understood that a sectional view of the backup wall 12 and
the form 18 are shown in Figures 4 and 5 to facilitate illustration of the
structure
of the backup wall connector 24.
Instead of having a single connector aperture 56, as shown in
Figure 1, for receiving both the form connector 26 and the wall tie 30, it is
alternatively possible to provide a backup wall connector that is not shown in
the
Figures that includes a separate connector aperture for receiving the form
connector 26, and a separate connector aperture for receiving the wall tie 30.
In
such an alternative, the forward-facing and rearward-facing form connector
engagement surfaces of the connector aperture for the form connector would be
separate from the forward-facing and rearward-facing wall tie engagement
surfaces of the connector aperture for the wall tie. In such an embodiment,
the
form connector 26 may be left in position once the cementitious material cures
to
a sufficient degree with retain backup connector 24 in position.
The connector aperture 56 is shown in Figure 1 as being a closed
aperture. It is alternatively possible for the backup wall connector 24 to
have a
connector aperture as shown at 62 in Figure 6. The connector aperture 62 is
open at one end, which facilitates positioning the form connector 26 (Figure
2)
therein and which also facilitates positioning the wall tie 30 (Figure 4)
therein.
Referring to Figure 2, the form connector 26 connects the backup
wall connector 24 to the form 18 and thereby fixes the position of the backup
wall
connector 24 so that the backup wall connector 24 is not moved inadvertently,
or
more then a desired amount, during the pouring and curing of cementitious
material 16. The form connector 26 may have any suitable shape, but is
preferably planar and generally rectangular.
The form connector 26 may be connected to the form 18 in any
suitable way. For example, the form connector 26 may be secured to, and
preferably removably secured to, the form 18 by fasteners 28 which may be, for
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example, nails or screws. In this scenario, the form connector 26 may be made
from a relatively soft material that is relatively easily penetrated by a nail
being
hammered therethrough. For example, the form connector 26 may be made
from a polymeric material (e.g., plastic), or wood.
The assembly shown in Figures 2 and 3, which comprises the
backup wall connector 24, the form connector 26 and the fasteners 28, may be
referred to as an initial tie assembly 64.
Referring to Figure 3, after the cementitious material 16 has been
poured and has cured sufficiently, the fasteners 28 may be removed from the
form 18 and the form connector 26 may be removed from the connector aperture
56.
After removal of the form connector 26 (Figure 3) from the aperture
56 (Figure 4), the wall tie 30 may be positioned in the connector aperture 56.
Referring to Figure 4, the wall tie 30 may have any suitable configuration for
connecting between the backup wall connector 24 and the veneer 14. The wall
tie 30 may, for example, be a generally V-shaped wire or rod, which has a
first,
closed end 66 and a second, open end 68.
The first end 66 connects to the connector aperture 56. The
forward-facing and rearward-facing wall tie surfaces 58 and 60 preferably
cooperate with the first end 66 to substantially prevent forward and rearward
movement between the backup wall connector 24 and the wall tie 30, and
therefore between the backup wall connector 24 and the veneer 14.
The second end 68 of the wall tie 30 connects to the veneer 14 in
any suitable way known in the industry. For example, it may be buried in
mortar
between adjacent rows of veneer elements 22.
Referring to Figure 5, the connecting aperture 56 is preferably
sufficiently tall to provide some freedom of movement over a selected vertical
range for the wall tie 30. This permits the height of the wall tie to be
adjusted to
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account for variability in the exact height of, e.g., a row of bricks 22 upon
which
the second end 68 of the wall tie 30 will rest.
It is preferable for the connecting aperture 56 to be a closed
aperture, as shown in Figures 1, 2, 3 and 5 to eliminate the risk of the wall
tie 30
inadvertently disconnecting from the backup wall connector 24 in the event
that
one or both of the veneer 14 and the backup wall 12 move vertically relative
to
the other.
Referring to Figures 4 and 5, the assembly comprising the backup
wall connector 24 and the wall tie 30 is the final tie assembly 11.
The penetrable form 18 may be made from a polymeric foam
material, such as the foam material that it is used currently in slabs to make
a
form at certain construction sites. Such foam material is penetrable by means
such as a nail. Additionally, such foam material can be left in the erected
structure to act as an insulation material. It is alternatively possible,
however, to
make the form out of some other material that is penetrable by a fastener such
as a nail.
The structure of the backup wall connector 24 may be selected to
permit it to be manufactured inexpensively. For example, the backup wall
connector 24 shown in Figure 1 may be made simply from a rectangular piece of
plate material with two apertures therein (i.e., the aperture 52 and the
connector
aperture 56), such as by stamping.
The structure of the form connector 26 may be selected to permit it
to be manufactured inexpensively. For example, the form connector 24 shown in
Figure 1 is simply a rectangular piece of plate material with apertures for
fasteners to pass therethrough.
It is possible that the tie system 10 (Figure 1) may be provided
without some of the above described components, with the expectation that the
user of the tie system 10 will acquire those omitted components separately.
For
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example, the fasteners 28 may be omitted from the tie system 10 and the user
may be expected to provide their own fasteners. As another example, the wall
tie 30 may be omitted with the expectation that the customer (i.e., the user)
will
acquire them or will already have a supply of them. Further, form connector
may
be a reusable member, i.e., it may be removed prior to wall tie 30 being used.
It will be understood that various modifications and adaptations of
the embodiments shown herein can be made without departing from the present
invention, the scope of which is defined in the appended claims.
