Note: Descriptions are shown in the official language in which they were submitted.
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L-SHAPED SHEETMETAL ANCHOR WITH TUBULAR LEG AND
ANCHORING ASSEMBLY
BACKGROUND OF THE INVENTION
1. Field of the Invention
[0001] This invention provides an L-shaped sheet metal anchor and anchoring
assembly having a sealing, protective, and thermally-isolating tubular leg for
surface
mounting on the inner wythe of a cavity wall and an interengaging veneer tie
to
positively interconnect the inner and outer wythes. The assembly has
application to
seismic-resistant structures and to cavity walls having special requirements.
The latter
include high-strength requirements for both insulated and non-insulated
cavities,
namely, a structural performance characteristic capable of withstanding a 100
lbf, in
both tension and compression.
2. Description of the Prior Art
[0002] In the late 1980s, surface-mounted wall anchors were developed by
Hohmann & Barnard, Inc., now a unit of MiTEK-Berkshire Hathaway Corporation,
and
patented under U.S. Patent 4,598,518. 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 anchors as part of the DW-10 Seismiclip interlock system
which added
a Byna-Tie wire formative, a Seismiclip snap-in device - described in U.S.
Patent
4,875,319 (319), and a continuous wire reinforcement.
[0003] In an insulated dry wall application, the surface-mounted wall anchor
of the above-described system has pronged legs that pierce the insulation and
the
wallboard 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
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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. Also, upon the
promulgation of
more rigorous specifications by which tension and compression characteristics
were
raised, a different structure - such as one of those described in detail below
- was
required.
[0004] 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 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.
[0005] 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 Seismiclip interlock system served well,
but in
addition to the insulation integrity problem, installations were hampered by
mortar
buildup interfering with pintle leg insertion.
[0006] In the 1980's, an anchor for masonry veneer walls was developed and
described in U.S. Patent 4,764,069 by Reinwall et al., which patent is an
improvement of
the masonry veneer anchor of Lopez, U.S. Patent 4,473,984. Here the anchors
are keyed
to elements that are installed using power-rotated drivers to deposit a
mounting stud in
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a cementitious or masonry backup wall. Fittings are then attached to the stud
which
includes an elongated eye and a wire tie therethrough for disposition 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.
This resulted, upon experiencing lateral forces over time, in the loosening of
the stud.
[0007] Exemplary of the public sector building specification is that of the
Energy Code Requirement, Boston, Massachusetts (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.
[0008] 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 at two times, namely, during
the
arcuate path of the insertion of the second leg and separately upon
installation of the
attaching hardware. 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 mounted wall anchors look toward greater insulation integrity and less
reliance
on a patch.
[0009] 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
5,392,581 and 4,869,043. Here a sheetmetal plate connects to the side of a dry
wall
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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.
[0010] Focus on the thermal characteristics of cavity wall construction is
important to ensuring minimized heat transfer through the walls, both for
comfort and
for energy efficiency of heating and air conditioning. When the exterior is
cold relative
to the interior of a heated structure, heat from the interior should be
prevented from
passing through to the outside. Similarly, when the exterior is hot relative
to the
interior of an air conditioned structure, heat from the exterior should be
prevented
from passing through to the interior. Providing thermally-isolating seals at
the
insertion points of the different layers of the inner wythe assists in
controlling heat
transfer.
[0011] 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.
[0012] 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
in 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
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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 as described in U.S. Patent 6,279,283.
However, the
above-described technology did not address the adaption thereof to surface
mounted
devices or stud-type devices. Nor does it address the need to thermally-
isolate the wall
anchor.
[0013] In the course of preparing this Application, several patents, became
known to the inventors hereof and are acknowledged hereby:
Patent Inventor Issue Date
2,058,148 Hard 10/20/1936
2,966,705 Massey 01/3/1961
3,377,764 Storch 04/16/1968
4,021,990 Schwalberg 05/10/1977
4,305,239 Geraghty 12/15/1981
4,373,314 Allan 02/15/1983
4,438,611 Bryant 03/27/1984
4,473,984 Lopez 10/02/1984
4,598,518 Hohmann 07/08/1986
4,869,038 Catani 09/26/1989
4,875,319 Hohmann 10/24/1989
5,063,722 Hohmann 11/12/1991
5,392,581 Hatzinikolas et al 02/28/1995
5,408,798 Hohmann 04/25/1995
5,456,052 Anderson et al. 10/10/1995
5,816,008 Hohmann 10/15/1998
6,209,281 Rice 04/03/2001
6,279,283 Hohmann et al. 08/28/2001
7,415,803 Bronner 08/26/2008
7,562,506 Hohmann, Jr. 07/21/2009
7,845,137 Hohmann, Jr. 12/07/2010
Patent App. Inventor Publication Date
2008/0141605 Hohmann 6/19/2008
2010/0037552 Bronner 2/18/2010
2011/0047919 Hohmann, Jr. 03/03/2011
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Foreign Patent Documents
279209 CH 52/714 03/1952
2069024 GB 52/714 08/1981
[0014] 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.
[0015] U.S. 3,377,764 - D. Storch - Issued 04/16/68 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.
[0016] U.S. 4,021,990 - B. J. Schwalberg - Issued 05/10/77 Discloses a dry
wall
construction system for anchoring a facing veneer to wallboard/metal stud
construction
with a pronged sheetmetal anchor. Like Storch '764, the wall tie is embedded
in the
exterior wythe and is not attached to a straight wire run.
[0017] U.S. 4,373,314 - J.A. Allan - Issued 02/15/83 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.
[0018] U.S. 4,473,984 - Lopez - Issued 10/02/84 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.
[0019] U.S. 4,869,038 - M. I. Catani - Issued 091/26/89 Discloses a veneer
wall
anchor system having in the interior wythe a truss-type anchor, similar to
Hata 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.
[0020] U.S. 4,875,319 - R. Hohmann - Issued 10/24/89 Discloses a seismic
construction system for anchoring a facing veneer to wallboard/metal stud
construction
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with a pronged sheetmetal anchor. The wall tie is distinguished over that of
Schitvalberg '990 and is clipped onto a straight wire run.
[0021] U.S. 5,392,581 - Hatzinikolas et al. - Issued 02/28/1995 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 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.
[0022] U.S. 5,408,798 - Hohmann - Issued 04/25/1995 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.
[0023] U.S. 5,456,052 - Anderson et al. - Issued 10/10/1995 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.
[0024] U.S. 5,816,008 - Hohmann - Issued 10/15/1998 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.
[0025] U.S. 6,209281 - Rice - Issued 04/03/2001 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,
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protrudes through the drywall into the cavity. The slit provides for a
vertically
adjustable anchor.
[00261 U.S. 6279,283 - Hohmann et al. - Issued 08/28/2001 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.
100271 U.S. 7415,803 ¨ Bronner ¨ Issued 08/26/2008 Discloses a wing nut wall
anchoring system for use with a two legged wire tie. The wing nut is rotatable
in all
directions to allow angular adjustment of the wire tie.
[0028] U.S. 7,562,506 ¨ Hohmann Jr. ¨ Issued 07/21/2009 Discloses a notched
surface-mounted wall anchor and anchoring system for use with various wire
formative veneer ties. The notches, upon surface mounting of the anchor, form
small
wells which entrain fluids and inhibit entry of same into the wallboard.
[0029] U.S. 7,845,137 ¨ Hohmann, Jr. ¨ Issued 12/07/2010 Disdoses a folded
wall anchor and anchoring system for use with various wire formative veneer
ties. The
folded wall anchor enables sheathing of the hardware and sealing of the
insertion
points.
[0030] U.S. Pub. No. 2008/0141605 ¨ Hohmann ¨ Filed 12/14/2006 Discloses a
dual seal anchoring system for use with insulated cavity walls. The stud-type
wall
anchor seals the insertion points and stabilizes the wall anchor.
[0031] U.S. Pub. No. 2010/0037552 ¨ Branner - Filed June 1, 2009 Discloses a
side-mounted anchoring system for veneer wall tie connection. The system
transfers
horizontal loads between a backup wall and a veneer wall.
[0032] U.S. Pub. No. 2011/0047919 ¨ Hohmann, Jr. ¨ Filed, 03/03/2011 Discloses
a thermally isolated anchoring system for cavity walls. The stud-type wall
anchor
operates with various veneer ties.
[0033]
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[0034]
SUMMARY
[0035] In general terms, the invention disclosed hereby is a tubule-type
anchoring system for surface mounting in a cavity wall 'structure. The
anchoring
system includes a tubule and bracket assembly for mounting on the inner wythe.
The
tubule and bracket assembly is horizontally or vertically oriented and
contains a
stepped cylinder portion with a first and second external diameter and a
shaftway to
sheath a fastener. The stepped cylinder portion is attached to an L-shaped
plate that is
surface mounted on the inner wythe and extends into the cavity. The L-shaped
plate
includes a receptor aperture for interengagement with a veneer tie. The veneer
tie is
partially disposed in the outer wythe to limit movement and takes various
forms
including a wire formative V-shaped body and pintles. The tubule and bracket
assembly is affixed to the inner wythe by a fastener and seal assembly that is
sheathed
by the shaftway and sealed upon installation. The assembly is mounted either
vertically or horizontally.
[0036] The invention further provides for a tubule-type anchoring system with
similar attributes and includes a tubule and bracket assembly, veneer tie,
fastener and
seal assembly and an insulation seal. The anchoring system is thermally-
isolating and
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includes a specialized wallboard seal and insulation seal at the insulation
and wallboard
insertion points. The anchoring system also includes an adjustable veneer tie.
[0037] Another embodiment of the anchoring system includes a tubule and
bracket assembly with a stepped cylinder portion containing a shaftway for
sheathing a
fastener, an L-shaped plate for surface mounting, and a receptor aperture. The
tubule and
bracket assembly is surface mounted with a fastener and seal assembly and
interengages with
a veneer tie. The veneer tie accommodates a reinforcement wire for insertion
in the outer
wythe. The anchoring system is thermally-isolated through the use of
insulating seals. The use
of this innovative surface-mounted wall anchor in various applications
addresses the problems
of insulation integrity, veneer tie adjustability and thermal conductivity.
[0037a] Some embodiments relate to a tubule-type anchoring system for
surface mounting in a cavity wall, said cavity wall having an inner wythe and
an outer wythe
spaced apart from said inner wythe forming a cavity therebetween, said
anchoring system
comprising: a tubule and bracket assembly for disposition on a surface of said
inner wythe in
said cavity, said tubule and bracket assembly further comprising: a stepped
cylinder portion
with the steps thereof arrayed about a common longitudinal axis and having at
least a first
external diameter and a second external diameter, said stepped cylinder having
a shaftway
therethrough with an open end for disposition in said cavity, said shaftway
dimensioned to
sheath a fastener; an L-shaped plate having a surface mounted portion and a
receptor portion
with a juncture therebetween, said receptor portion for extending into said
cavity, said surface
mounted portion haying said stepped cylinder portion fixedly attached thereto
with the
longitudinal axis normal to a face of said surface mounted portion; and a
receptor aperture in
said receptor portion of said L-shaped plate, said receptor aperture being an
elongated slot
with the longitudinal axis thereof parallel to said juncture of said surface
mounted portion and
said receptor portion; a veneer tie having an insertion end for disposition
into said outer wythe
and an interengaging end for disposition in said receptor aperture of said L-
shaped plate, said
interengaging end of said veneer tie dimensioned to limit movement of the
outer wythe; and, a
fastener and seal assembly for attaching said tubule and bracket assembly to
said inner wythe
and for sealing said surface mounted portion of said L-shaped plate, said
fastener and seal
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assembly for extending through said shaftway of said stepped cylinder and
sealing against
said open end of said shaftway.
10037b1 Some embodiments relate to a tubule-type anchoring system for
surface mounting in a cavity wall, said cavity wall having an inner wythe and
an outer wythe
spaced apart from said inner wythe forming a cavity therebetween and having
insulation
disposed in said cavity on said inner wythe, said anchoring system comprising:
a tubule and
bracket assembly for disposition on a surface of said inner wythe in said
cavity, said tubule
and bracket assembly further comprising: a stepped cylinder portion with the
steps thereof
arrayed about a common longitudinal axis and having at least a first external
diameter and a
second external diameter, said stepped cylinder having a shaftway therethrough
with an open
end for disposition in said cavity, said shaftway dimensioned to sheath a
fastener; an L-shaped
plate having a surface mounted portion and a receptor portion with a juncture
therebetween,
said receptor portion for extending into said cavity, said surface mounted
portion having said
stepped cylinder portion fixedly attached thereto with the longitudinal axis
normal to a face of
said surface mounted portion; and a receptor aperture in said receptor portion
of said L-shaped
plate, said receptor aperture being an elongated slot with the longitudinal
axis thereof parallel
to said juncture of said surface mounted portion and said receptor portion; a
veneer tie having
an insertion end for disposition into said outer wythe and an interengaging
end for disposition
in said receptor aperture of said L-shaped plate, said interengaging end of
said veneer tie
dimensioned to limit movement of the outer wythe; a fastener and seal assembly
for attaching
said tubule and bracket assembly to said inner wythe and for sealing said
surface mounted
portion of said L-shaped plate, said fastener and seal assembly for extending
through said
shaftway of said stepped cylinder and sealing against said open end of said
shaftway; and, an
insulation seal disposed on said surface mounted portion of said L-shaped
bracket and
surrounding said stepped cylinder portion of said tubule and bracket assembly.
10037c1 Some embodiments relate to a tubule-type anchoring system for
surface mounting in a cavity wall, said cavity wall having an inner wythe and
an outer wythe
spaced apart from said inner wythe forming a cavity therebetween and having
insulation
disposed in said cavity on said inner wythe, said anchoring system comprising:
a tubule and
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bracket assembly for disposition on a surface of said inner wythe in said
cavity, said tubule
and bracket assembly further comprising: a stepped cylinder portion with the
steps thereof
arrayed about a common longitudinal axis and having at least a first external
diameter and a
second external diameter, said stepped cylinder having a shaftway therethrough
with an open
end for disposition in said cavity, said shaftway dimensioned to sheath a
fastener; an L-shaped
plate having a surface mounted portion and a receptor portion with a juncture
therebetween,
said receptor portion for extending into said cavity, said surface mounted
portion having said
stepped cylinder portion fixedly attached thereto with the longitudinal axis
normal to a face
of said surface mounted portion; and a receptor aperture in said receptor
portion of said L-
shaped plate, said receptor aperture being an elongated slot with the
longitudinal axis thereof
parallel to said juncture of said surface mounted portion and said receptor
portion; a veneer tie
having an insertion end for disposition into said outer wythe and an
interengaging end for
disposition in said receptor aperture of said L-shaped plate, said
interengaging end of said
veneer tie dimensioned to limit movement of the outer wythe; a fastener and
seal assembly for
attaching said tubule and bracket assembly to said inner wythe and for sealing
said surface
mounted portion of said L-shaped plate, said fastener and seal assembly for
extending through
said shaftway of said stepped cylinder and sealing against said open end of
said shaftway; an
insulation seal disposed on said surface mounted portion of said L-shaped
bracket and
surrounding said stepped cylinder portion of said tubule and bracket assembly;
and, a
reinforcement wire disposed on said insertion end of said veneer tie in said
outer wythe.
[0037d] Some embodiments relate to a tubule-type anchoring system for
surface mounting in a cavity wall, said cavity wall having a wallboard inner
wythe and
insulation thereon, channels for wall anchors therethrough, and an outer wythe
spaced apart
from said inner wythe and said outer wythe in a spaced apart relationship the
one with the
other forming a cavity therebetween, said anchoring system comprising: a
tubule and bracket
assembly for disposition on a surface of said inner wythe in said cavity, said
tubule and
bracket assembly further comprising: a stepped cylinder portion with the steps
thereof arrayed
about a common longitudinal axis having at least a first external diameter and
a second
external diameter, said stepped cylinder having a shaftway therethrough with
an open end for
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disposition in said cavity, said shaftway dimensioned to sheath a fastener,
said stepped
cylinder further comprising: a wallboard step portion having said first
external diameter and
forming a shoulder at the juncture with said second external diameter; an L-
shaped plate
having a surface mounted portion and a receptor portion with a juncture
therebetween, said
receptor portion for extending into said cavity, said surface mounted portion
having said
stepped cylinder portion fixedly attached thereto with the longitudinal axis
normal to a face of
said surface mounted portion; a receptor aperture in said receptor portion of
said L-shaped
plate, said receptor aperture being an elongated slot with the longitudinal
axis thereof parallel
to said juncture of said surface mounted portion and said receptor portion; a
wallboard seal
disposed on said stepped cylinder at said shoulder; an insulation seal
disposed on said surface
mounted portion of said L-shaped plate and surrounding said stepped cylinder
portion of said
tubule and bracket assembly; and a fastener and seal assembly for attaching
said tubule and
bracket assembly to said inner wythe and for sealing said surface mounted
portion of said L-
shaped plate, said fastener and seal assembly for extending through said
shaftway of said
stepped cylinder and sealing against said open end of said shaftway.
10037e] Some embodiments relate to a tubule-type anchoring system for
surface mounting in a cavity wall, said cavity wall having a wallboard inner
wythe and
insulation thereon, channels for wall anchors therethrough, and an outer wythe
spaced apart
from said inner wythe and said outer wythe in a spaced apart relationship the
one with the
other forming a cavity therebetween, said anchoring system comprising: a
tubule and bracket
assembly for disposition on a surface of said inner wythe in said cavity, said
tubule and
bracket assembly further comprising: a stepped cylinder portion with the steps
thereof arrayed
about a common longitudinal axis having at least a first external diameter and
a second
external diameter, said stepped cylinder having a shaftway therethrough with
an open end for
disposition in said cavity, said shaftway dimensioned to sheath a fastener,
said stepped
cylinder further comprising: a wallboard step portion having said first
external diameter and
forming a shoulder at the juncture with said second external diameter; an L-
shaped plate
having a surface mounted portion and a receptor portion with a juncture
therebetween, said
receptor portion for extending into said cavity, said surface mounted portion
having said
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stepped cylinder portion fixedly attached thereto with the longitudinal axis
normal to a face of
said surface mounted portion; a receptor aperture in said receptor portion of
said L-shaped
plate, said receptor aperture being an elongated slot with the longitudinal
axis thereof parallel
to said juncture of said surface mounted portion and said receptor portion; a
wallboard seal
disposed on said stepped cylinder at said shoulder; an insulation seal
disposed on said surface
mounted portion of said L-shaped plate and surrounding said stepped cylinder
portion of said
tubule and bracket assembly; a veneer tie having an insertion end for
disposition into said
outer wythe and an interengaging end for disposition in said receptor aperture
of said L-
shaped plate, said interengaging end of said veneer tie dimensioned to limit
movement of the
outer wythe; a fastener and seal assembly for attaching said tubule and
bracket assembly to
said inner wythe and for sealing said surface mounted portion of said L-shaped
plate, said
fastener and seal assembly for extending through said shaftway of said stepped
cylinder and
sealing against said open end of said shaftway; and, a reinforcement wire
disposed on said
insertion end of said veneer tie in said outer wythe.
[0038]
[0039]
[0040]
[0041]
[0042]
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[0043]
[0044]
[0045]
BRIEF DESCRIPTION OF THE DRAWINGS
[0046] In the following drawings, the same parts in the various views are
afforded the
same reference designators.
[0047] FIG. 1 shows a first embodiment of this invention and is a perspective
view of
an L-shaped sheetmetal anchor with tubular leg and anchoring assembly
horizontally surface-
mounted to a cavity wall with an inner wythe of dry wall construction having
insulation
disposed on the cavity-side thereof;
[0048] FIG. 2 is an exploded perspective view of the L-shaped sheetmetal
anchor with
tubular leg and the fastener and seal assembly of FIG. 1;
[0049] FIG. 3 is a perspective view showing the anchoring system of FIG. 1
with the
fastener and seal assembly and veneer tic with a pair of pintles interengaging
the tubule and
bracket assembly;
[0050] FIG. 4 is a perspective view of a second embodiment of this invention
showing
a horizontally surface-mounted L-shaped sheetmetal anchor with tubular leg and
anchoring
system with a veneer tie having a pair of pintles spring mounted within the
tubule and bracket
assembly and a reinforcement wire disposed within the veneer tie;
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[0051] FIG. 5 is a perspective of a third embodiment of this invention showing
a vertically surface-mounted L-shaped sheetmetal anchor with tubular leg and
anchoring system with the fastener and seal assembly;
[0052] FIG. 6 is a perspective view showing the anchoring system of FIG. 5
with the fastener and seal assembly and veneer tie interengaged with the
tubule and
bracket assembly and a reinforcement wire disposed within the veneer tie; and
[0053] FIG. 7 is a side view of the anchoring system of FIG. 5 with the
anchoring system surfaced mounted in the inner wythe and the veneer tie
disposed
within the bed joint of the outer wythe.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0054] 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 technical shortcomings of the prior art devices.
100551 In the embodiments described hereinbelow, the inner wythe is provided
with insulation. In the dry wall or wallboard construction, this takes the
form of
exterior insulation disposed on the outer surface of the inner wythe.
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 thermal transfer from the exterior to the
interior and from
the interior to the exterior. 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 and
substantially no loss of
heat or air conditioned air from the interior. The present invention is
designed to
minimize invasiveness into the insulative layer.
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[0056] In a related sense, prior art sheetmetal anchors have formed a
conductive bridge between the wall cavity and the metal studs of columns of
the
interior of the building. Here the terms thermal conductivity, thermally-
isolated and -
isolating, and thermal conductivity analysis are used to examine this
phenomenon
and the metal-to-metal contacts across the inner wythe.
[0057] The term stepped cylinder as used hereinafter refers to a cylinder
having
cylindrical portions with differing diameters about a common longitudinal axis
and
having shoulders between adjacent portions or steps. The term thermally-
isolated
tubule or tubule and bracket assembly for thermally isolating a surface-
mounted wall
anchor as used hereinafter refers to a stepped cylinder that is joined to a
metal base,
where the base is positioned substantially at right angles (normal) to the
longitudinal
axis of the stepped cylinder and where at the location that the stepped
cylinder joins to
the base, the base surrounds the latitudinal (cross-sectional) perimeter of
the stepped
cylinder with some area of cylinder material extending on all sides of this
joint forming
a press-fit relationship. The base has two major faces, identified by the
orientation
presented when the veneer anchor is installed. The face oriented towards the
inner
wythe is identified as the base surface, mounting surface, or the surface
mounted
portion and the face oriented towards the outer wythe is the outer surface.
The stepped
cylinder sheaths the mounting hardware or fastener and is thermally-isolated
through
the use of a series of neoprene or similar washers.
[0058] 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, self-
drilling
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screws. The latter concern is addressed by the thermally-isolating fittings
affixed to the
stepped cylinder. The fittings seal any openings made in the insulation during
installation and inhibit thermal transfer.
[0059] In the detailed description, the L-shaped sheetmetal anchor with
tubular
leg and anchoring assembly is oriented vertically or horizontally and paired
with a
variety of veneer ties. The anchor is secured to the inner wythe through the
use of a
fastener and seal assembly.
[0060] Referring now to Figures 1 through 3, the first embodiment shows an L-
shaped sheetmetal anchor with tubular leg and anchoring assembly for
horizontal
surface mounting in a cavity wall. This anchor and anchoring assembly are
suitable for
recently promulgated standards with more rigorous tension and compression
characteristics. The system discussed in detail hereinbelow, is a high-
strength wall
anchor for connection with an interengaging veneer tie. The wall anchor is
horizontally
surface mounted onto an externally insulated dry wall inner wythe. A cavity
wall
having dry wall and insulation mounted on metal studs or columns is chosen as
exemplary.
[0061] The L-shaped sheetmetal anchor with tubular leg and anchoring
assembly for surface mounting in a cavity wall is referred to generally by the
numeral
10. An inner wythe or dry wall backup 14 with sheetrock or wallboard 16 and
insulation 17 mounted on metal studs or columns 24 is shown. The outer wythe
or
veneer wall 18 is constructed of facing brick, block or stone 20. Between the
backup
wall 14 and the veneer wall 18, a cavity 22 extends outwardly from the surface
25 of the
backup wall 14.
[0062] In this embodiment, successive bed joints 26 and 28 are formed between
courses of blocks 20 and the joints are substantially planar and horizontally
disposed.
For each structure, the bed joints 26 and 28 are specified as to the height or
thickness of
the mortar layer and such thickness specification is rigorously adhered to so
as to
provide the uniformity inherent in quality construction.
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[0063] For purposes of discussion, the exterior surface 25 of the backup wall
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, also passes through the
coordinate
origin formed by the intersecting x- and y-axes. In the discussion which
follows, it will
be seen that the various anchor structures are constructed to restrict
movement
interfacially - wythe vs. wythe - along the z-axis and, in this embodiment,
along the x-
axis. The assembly 10 includes a tubule and bracket assembly or wall anchor 40
and
with a veneer tie 44 constructed for embedment in bed joint 26.
100641 The tubule-type anchoring system 12 is shown having a tubule and
bracket assembly or anchor 40 with a stepped cylinder portion 42 which
penetrates the
wallboard 16 and insulation 17. The stepped cylinder 42 has at least a first
external
diameter or wallboard step 52 and a second external diameter or insulation
step 55
arrayed about a common longitudinal axis 47 which is substantially normal to
the
surface mounted portion 53 of the anchor 40. The stepped cylinder 42 has a
shaftway
or aperture therethrough 50 to sheath a fastener 48 and is affixed to the
anchor 40,
which is an L-shaped plate with a surface mounted portion 53 and a receptor
portion 82
which form a juncture 84 therebetween. The receptor portion 82 extends into
the cavity
22 and contains a receptor aperture 83 which is substantially parallel to the
juncture 84.
[0065] The stepped cylinder 42 is a metal leg constructed from sheet metal
such
as hot dipped galvanized, stainless and bright basic steel and contains a
wallboard step
52 that forms a shoulder 53 between the first external diameter 52 and the
second
external diameter 55. A wallboard seal 57 is disposed on the shoulder 53 and
is
thermally isolating and constructed of compressible nonconductive material
which
precludes the passage of fluids through the inner wythe 14. A substantially
similarly
constructed insulation seal 58 is disposed on the surface mounted portion 53
surround
the stepped cylinder portion 42.
[0066] At intervals along the outer wythe surface, the anchors 40 are surface-
mounted using fastener and seal assemblies 60 which consist of a fastener 48
and a seal
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43. The fastener 48 extends though the shaftway 50 for attachment to the inner
wythe
14. The seal 43 seals the surface mounted portion 53. The fasteners or self-
tapping or
self-drilling screws 48 are inserted through the stepped cylinders 42. In this
structure,
the stepped cylinders 42 sheath the exterior of mounting hardware 48. The
fasteners 48
are thermally-isolated from the anchor 40 through the use of the seal 43 which
is
composed of compressible nonconductive material such as neoprene. The seal 43
is
disposed about the fastener 48 and seals the shaftway 50. The fastener 48 is
sheathed
by the stepped cylinder 42 upon insertion to limit insulation 17 tearing.
100671 The stepped cylinder 42 is cylindrical and constructed of sheet metal.
An aperture or shaftway 50 runs the length of the cylinder 42 allowing for the
insertion
and sheathing of the fastener 48. The cylinder 42 contains a wallboard step 52
which is
optimally located, when inserted within the outer wythe 14, at the
intersection of the
dry wall 16 and the insulation 17 to provide a seal at such intersection. A
thermally-
isolating wallboard seal 57 is disposed on the stepped cylinder 42 at the
shoulder 53
thereby minimizing thermal transfer. The stepped cylinder 42 has an insulation
step 55
which is affixed to the anchor 40 through a welding, compression or similar
process,
thereby forming a high-strength bond. An insulation seal 58 is disposed on the
insulation step 55 adjacent to the juncture of the insulation step 55 and the
surface
mounted portion 53. Upon insertion of the assembly 12 into the layers of the
inner
wythe 14, the anchor 40 rests snugly against the opening formed by the
insertion of the
stepped cylinder 42 and serves to provide further sealing of the stepped
cylinder 42
insertion opening in the insulation 17 precluding the passage of air and
moisture
therethrough. This construct maintains the insulation integrity.
[0068] The anchor 40 contains a receptor aperture 83 formed in the receptor
portion 82 adapted to engage a veneer tie 44 and to limit displacement of the
outer
wythe toward and away from the inner wythe 14. The veneer tie 44 has an
insertion 46
end for disposition in the outer wythe 18 and an interengaging end 49 for
disposition in
the receptor aperture 83. In this embodiment the interengaging end 49 is a
pair of
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pindes 75 which are spaced to restrain lateral movement of the outer wythe 18.
The
diameter of each pintle 75 is dimensioned to restrain movement of the outer
wythe 18
toward and away from the inner wythe 14.
[0069] The description which follows is a second embodiment of the L-shaped
sheetmetal anchor with tubular leg and anchoring assembly for horizontal
surface
mounting in a cavity wall. For ease of comprehension, wherever possible
similar parts
use reference designators 100 units higher than those above. Thus, the stepped
cylinder
142 of the second embodiment is analogous to the stepped cylinder 42 of the
first
embodiment. Referring now to FIG. 4, the second embodiment of the assembly is
shown and is referred to generally by the numeral 110. As in the first
embodiment, a
wall structure similar to that shown in FIG. 1 is used herein.
100701 The assembly 112 is surface mounted to the exterior surface 24 of the
inner wythe 14. In this embodiment like the previous one, insulation 17 is
disposed on
wallboard 16 and, in turn, on columns 17. Successive bed joints 26 and 28 are
substantially planar and horizontally disposed and formed between courses of
bricks
20 forming the outer wythe 18, and are constructed to receive therewithin the
insertion
portion 146 of the veneer tie 144. Being surface mounted onto the inner wythe
14, the
assembly 110 is constructed cooperatively therewith, and as described in
greater detail
below, is configured to penetrate through the wallboard 16 at a covered
insertion point.
[0071] The tubule-type anchoring system 112 is shown having a tubule and
bracket assembly or anchor 140 with a stepped cylinder portion 142 which
penetrates
the wallboard 16 and insulation 17. The stepped cylinder 142 has at least a
first
external diameter or wallboard step 152 and a second external diameter or
insulation
step 155 arrayed about a common longitudinal axis 147 which is substantially
normal
to the surface mounted portion 154 of the anchor 140. The stepped cylinder 142
has a
shaftway or aperture therethrough 150 to sheath a fastener 148 and is affixed
to the
anchor 140, which is an L-shaped plate with a surface mounted portion 154 and
a
receptor portion 182 which form a juncture 184 therebetween. The receptor
portion 182
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extends into the cavity 22 and contains a receptor aperture 183 which is
substantially
parallel to the juncture 184.
[00721 The stepped cylinder 142 is a metal leg constructed from sheet metal
such as hot dipped galvanized, stainless and bright basic steel and contains a
wallboard
step 152 that forms a shoulder 153 between the first external diameter 152 and
the
second external diameter 155. A wallboard seal 157 is disposed on the shoulder
153
and is thermally isolating and constructed of compressible nonconductive
material
which precludes the passage of fluids through the inner wythe 14. A
substantially
similarly constructed insulation seal 158 is disposed on the surface mounted
portion
154 and surrounds the stepped cylinder portion 142.
[0073] At intervals along the outer wythe surface, the anchors 140 are surf
ace-
mounted using fastener and seal assemblies 160 which consist of a fastener 148
and a
seal 143. The fastener 148 extends though the shaftway 150 for attachment to
the inner
wythe 14. The seal 143 seals the surface mounted portion 154. The fasteners or
self-
tapping or self-drilling screws 148 are inserted through the stepped cylinders
142. In
this structure, the stepped cylinders 142 sheath the exterior of mounting
hardware 148.
The fasteners 148 are thermally-isolated from the anchor 140 through the use
of the seal
143 which is composed of compressible nonconductive material such as neoprene.
The
seal 143 is disposed about the fastener 148 and seals the shaftway 150. The
fastener 148
is sheathed by the stepped cylinder 142 upon insertion to limit insulation 17
tearing.
100741 The stepped cylinder 142 is cylindrical and constructed of sheet metal.
An aperture or shaftway 150 runs the length of the cylinder 142 allowing for
the
insertion and sheathing of the fastener 148. The cylinder 142 contains a
wallboard step
152 which is optimally located, when inserted within the outer wythe 14, at
the
intersection of the dry wall 16 and the insulation 17 to provide a seal at
such
intersection. A thermally-isolating wallboard seal 157 is disposed on stepped
cylinder
142 at the shoulder 153 thereby minimizing thermal transfer. The stepped
cylinder 142
has an insulation step 155 which is affixed to the anchor 140 through a
welding,
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compression or similar process, thereby forming a high-strength bond. An
insulation
seal 158 is disposed on the insulation step 155 adjacent to the juncture of
the insulation
step 155 and the surface mounted portion 154. Upon insertion of the assembly
112 into
the layers of the inner wythe 14, the anchor 140 rests snugly against the
opening
formed by the insertion of the stepped cylinder 142 and serves to provide
further
sealing of the stepped cylinder 142 insertion opening in the insulation 17
precluding the
passage of air and moisture therethrough. This construct maintains 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 (not shown) be
placed on
mounting surface 154 for additional sealing.
10075] The anchor 140 contains a receptor aperture 183 formed in the receptor
portion 182 adapted to engage a veneer tie 144 and to limit displacement of
the outer
wythe toward and away from the inner wythe 14. The veneer tie 144 has an
insertion
146 end for disposition in the outer wythe 18 and an interengaging end 149 for
disposition in the receptor aperture 183. In this embodiment the interengaging
end 149
is a pair of pintles 175 which are spaced to restrain lateral movement of the
outer wythe
18. The diameter of each pintle 175 is dimensioned to restrain movement of the
outer
wythe 18 toward and away from the inner wythe 14. The pair of pintles 175 are
spring
mounted with each one of the pair of pintles 175 urged by spring loading
against one
end of the receptor aperture 183. The insertion portion 146 of the veneer tie
144 is
swaged in one or more places 191 and 193 to accommodate a reinforcement wire
171 to
form a seismic construct upon insertion within the outer wythe 18.
100761 The description which follows is a third embodiment of the L-shaped
sheetmetal anchor with tubular leg and anchoring assembly for vertical surface
mounting in a cavity wall. For ease of comprehension, wherever possible
similar parts
use reference designators 200 units higher than those above. Thus, the stepped
cylinder
242 of the third embodiment is analogous to the stepped cylinder 42 of the
first
embodiment. Referring now to FIGS. 5 through 7, the third embodiment of the
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assembly is shown and is referred to generally by the numeral 210. As in the
first
embodiment, a wall structure similar to that shown in FIG. 1 is used herein.
100771 The assembly 212 is surface mounted to the exterior surface 224 of the
inner wythe 214. In this embodiment like the previous one, insulation 229 is
disposed
on wallboard 216 and, in turn, on columns 217. Successive bed joints 226 and
228 are
substantially planar to the z-axis 238 and horizontally disposed and formed
between
courses of bricks 220 forming the outer wythe 218, and are constructed to
receive
therewithin the insertion portion 246 of the veneer tie 244. Being surface
mounted onto
the inner wythe 214, the assembly 210 is constructed cooperatively therewith,
and as
described in greater detail below, is configured to penetrate through the
wallboard 216
at a covered insertion point.
100781 The tubule-type anchoring system 212 is shown having a tubule and
bracket assembly 240 with a stepped cylinder portion 242 which penetrates the
wallboard 216 and insulation 229. The stepped cylinder 242 has at least a
first external
diameter or wallboard step 252 and a second external diameter or insulation
step 255
arrayed about a common longitudinal axis 247 which is substantially normal to
the
surface mounted portion 254 of the assembly 240. The stepped cylinder 242 has
a
shaftway or aperture therethrough 250 to sheath a fastener 248 and is affixed
to the
anchor or assembly 240, which is an L-shaped plate with a surface mounted
portion 254
and a receptor portion 282 which form a juncture 284 therebetween. The
receptor
portion 282 extends into the cavity 222 and contains a receptor aperture 283
which is
disposed in a substantially vertical plan in the cavity 222 and is
substantially parallel to
the juncture 284.
[0079] The stepped cylinder 242 is a metal leg constructed from sheet metal
such as hot dipped galvanized, stainless and bright basic steel and contains a
wallboard
step 252 that forms a shoulder 253 between the first external diameter 252 and
the
second external diameter 255. A wallboard seal 257 is disposed on the shoulder
253
and is thermally isolating and constructed of compressible nonconductive
material
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which precludes the passage of fluids through the inner wythe 214. A
substantially
similarly constructed insulation seal 258 is disposed on the surface mounted
portion
254 surround the stepped cylinder portion 242.
[00801 At intervals along the outer wythe surface, the anchors 240 are surface-
mounted using fastener and seal assemblies 260 which each consist of a
fastener 248
and a seal 243. The fastener 248 extends though the shaftway 250 for
attachment to the
inner wythe 214. The seal 243 seals the surface mounted portion 254. The
fasteners or
self-tapping or self-drilling screws 248 are inserted through the stepped
cylinders 242.
In this structure, the stepped cylinders 242 sheath the exterior of mounting
hardware
248. The fasteners 248 are thermally-isolated from the anchor 240 through the
use of the
seal 243 which is composed of compressible nonconductive material such as
neoprene.
The seal 243 is disposed about the fastener 248 and seals the shaftway 250.
The fastener
248 is sheathed by the stepped cylinder 242 upon insertion to limit insulation
229
tearing.
[00811 The stepped cylinder 242 is cylindrical and constructed of sheet metal.
An aperture or shaftway 250 runs the length of the cylinder 242 allowing for
the
insertion and sheathing of the fastener 248. The cylinder 242 contains a
wallboard step
252 which is optimally located, when inserted within the outer wythe 214, at
the
intersection of the dry wall 216 and the insulation 229 to provide a seal at
such
intersection. A thermally-isolating wallboard seal 257 is disposed on the
stepped
cylinder 242 at the shoulder 253 thereby minimizing thermal transfer. The
stepped
cylinder 242 has an insulation step 255 which is affixed to the anchor 240
through a
welding, compression or similar process, thereby forming a high-strength bond.
An
insulation seal 258 is disposed on the insulation step 255 adjacent to the
juncture of the
insulation step 255 and the surface mounted portion 254. Upon insertion of the
assembly 212 into the layers of the inner wythe 214, the anchor 240 rests
snugly against
the opening formed by the insertion of the stepped cylinder 242 and serves to
provide
further sealing of the stepped cylinder 242 insertion opening in the
insulation 229
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precluding the passage of air and moisture therethrough. This construct
maintains 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 (not shown) be
placed on
mounting surface 254 for additional sealing.
[0082] The anchor 240 contains a receptor aperture 283 formed in the receptor
portion
282 adapted to engage a veneer tie 244 and to limit displacement of the outer
wythe toward
and away from the inner wythe 214. The veneer tie 244 is a V-shaped body
having side
portions 294 and 296 disposed through the receptor aperture 283. The veneer
tie is adjustably
mounted upwardly and downwardly and the insertion insertion end or insertion
portion 246 is
substantially horizontally disposed in the outer wythe 218. For
interconnection with a
reinforcement wire 271, the insertion portion 246 has two arms 298 and 299
which lie on each
side of the reinforcement wire 271. For further interconnection with the
reinforcement wire
271 one arm 298 is optionally swaged 297 to accommodate the reinforcement wire
271 and
forms a seismic construct upon insertion within the outer wythe 218.
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[0083] In the above description of the L-shaped sheetmetal anchor with tubular
leg and
anchoring assembly for surface mounting in a cavity wall of this invention
sets forth various
described configurations and applications thereof in corresponding anchoring
systems.
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.
[0084]
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