Note: Descriptions are shown in the official language in which they were submitted.
BUILDING VENEER SYSTEM
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable
REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING
COMPACT DISK APPENDIX
Not Applicable
TECHNICAL FIELD AND INDUSTRIAL APPLICABILITY OF THE INVENTION
The present invention is in the technical field of masonry products, and
includes a system
using such products. More particularly, the present invention is in the
technical field of masonry
veneer products installed without a scratch coat and lath system.
1
Date Recue/Date Received 2021-03-09
BACKGROUND OF THE INVENTION
Masonry veneer systems are commonly used for exterior cladding, as
architectural or
aesthetic features on residential and commercial buildings. As described in
detail by the Masonry
Veneer Manufacturers Association (MVMA), proper installation of stone on a
framed building
requires the installation of a weather resistant barrier (WRB), then
application of a lath secured to the
framing with corrosion resistant fasteners and a nominal Y2 inch scratch coat.
The lath must be
properly applied to the wall in order to avoid intrusion of water, and to
provide an acceptable
structure to which the cladding will be adhered. The lath must be corrosion
resistant, applied in an
overlapping fashion, and with a corrosion resistant nail that penetrates the
studding according to the
MVMA recommendations. Additionally, the scratch coat must be applied using a
correct mortar at
the proper moisture content and thickness, embedded properly in the lath,
allowed to cure to "thumb
dry", the scratched to provide grooves, and allowed to cure. These additional
products and steps add
cost, additional labor and provide opportunities for human error, which can
result in a poor
installation and future problems. The installation of the WRB, lath and
scratch coat must be
performed up to 48 hours or more before the installation of the veneer
product, allowing the scratch
coat to properly cure. Further details are set forth by the MVMA.
Once the scratch coat is properly applied and cured, adhered concrete masonry
veneer
(ACMV) products are then adhered to the scratch coat using a mortar applied to
the ACMV. The
MVMA guidelines recommend that the scratch coat should be moist cured to
prevent cracking, and
that both the scratch coat and the ACMV should be "dampened" when applying the
ACMV, adding
2
Date Recue/Date Received 2021-03-09
CA 02867967 2014-10-16
additional requirements on the installer. The installer typically will take
individual ACMV
products, "butter" the back of each individual product with mortar, and apply
the "buttered"
product to the scratch coat, forcing the mortar into the scratch coat to
adhere the ACMV to the
wall. The consistency of the scratch coat, mortar and skill of the installer
each play a role in the
reliability of the installation. Additionally, the installation should not be
performed during rain or
cold weather, thus limiting the time available (and time delay) for completion
of the building.
These all add to cost and customer dissatisfaction during the construction
process.
ACMV products are typically installed as discrete individual stones or brick
adhered to a
scratch coat on the exterior of a building as described above. Stones are
typically installed from the
top of the building, and the wall is covered in a downward direction. If the
wall is struck (e.g. if
drywall is installed on the interior of the building) before the mortar is
cured, the stone may be
dislodged from the wall. This creates re-work for the installer, or partially
dislodged stones may
become loose at a later date.
An optional installation technique described in the MVMA guidelines includes a
rainscreen
drainage plane system, which provides a space to permit incidental water to
escape. The
recommended ways to provide this space include a drainage mat, formed polymer
sheeting (such as
Delta -Dry Stucco and Stone, available from Cosella-Dorken, ref.
http://www.cosella-
dorken.com), strapping or furring to provide the recommended MVMA air gap of
3/16 to 3/4 inch.
These systems allow moisture to escape from behind the veneer, but add
additional material and
labor cost, time and complexity during installation of the ACMV product, and
are not used in many
installations.
3
CA 02867967 2014-10-16
A panelized veneer product, Versetta Stone, is sold by Boral Stone, LLC.
(http://masonry.owensconting.com/versettastone). These panelized veneer
products are secured to
the exterior of a building using mechanical fasteners driven through a flange
embedded in the top
of the veneer product. These systems reduce some of the issues with the
adhered ACMV products,
because the lath, scratch coat and adhesive mortar can be eliminated in many
installations of these
panelized veneer products. However, these panelized veneer products are
relatively large (typically
about 8-10 inches high and approximately 32-36 inches wide) and have a limited
drainage plane
gap. While this enables fast installation on structures where penetrations are
not present (such as
windows or outlets) or corners, the presence of these penetrations on most
buildings results in a
large number of panels being trimmed and a fairly large amount of waste
(Boral's installation
instructions instructs an installer to initially estimate 10% scrap). The
large number of cuts takes
time and produces excess waste. Additionally, these products are more
expensive to manufacture,
and the designs present challenges in manufacturing.
Accordingly, it would be desirable to provide an improved product and system
for installing
veneer products and to eliminate the lath and scratch coat.
Summary of the Invention
In accordance with the purposes of the present invention as described herein,
an improved
masonry veneer product ("MVP") and system ("MVS") are provided. Such a product
and system
includes a bracket embedded in the product, the bracket having a first end for
securing the upper
end of the product to a building. In one embodiment, the bracket also creates
an integral air gap
behind the product for the escape of moisture. The bracket may include a
second end for retaining
4
CA 02867967 2014-10-16
the bottom end of the product to the building through an interference fit to
an adjacent MVP. The
system further includes a projection between adjacent MVP to impede moisture
from passing
between MVP's, and a WRB installed adjacent the structure and air gap to keep
moisture from
entering the structure.
BRIEF DESCRIPTION OF THE DRAWINGS
Fig. 1 provides a front view of a pair of masonry veneer products according to
the present
invention;
Fig. 2 provides a front view of a corner masonry veneer product according to
the present invention;
Figs 2A and 2B provide isometric views of a drip ledge corner product
according to the present
invention;
Fig. 3 provides an isometric view of a masonry veneer product according to the
present invention;
Fig. 4 provides an isometric view of a first wire retainer according to the
present invention;
Fig. 5 provides an isometric view of a second wire retainer according to the
present invention;
CA 02867967 2014-10-16
Fig 6 provides an isometric view of a masonry veneer product according to the
present invention
having a long width dimension;
Fig. 7 provides an isometric view of a masonry veneer product according to the
present invention
useful as an accessory;
Fig. 8 provides an isometric view of a masonry veneer product installed into a
starter strip over a
WRB according to the present invention;
Fig. 9 provides an end view of a starter strip profile according to the
present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to Fig. 1 there are shown a pair of masonry veneer products 10,
10'
illustrated schematically and described herein typically as a dry stack stone
product body 12,
similar to a typical box material in appearance. However, the new MVP and MVS
have additional
inventive features as described herein. The present invention could be applied
to nearly any texture
of manufactured stone or brick, but is primarily illustrated with a dry stack
installation for the sake
of simplicity (and as a representative installation). Although not
illustrated, one skilled in the art
appreciates that an embodiment of the present invention may be used with a
grouted texture, and
would preferably include a flange on one of the top and bottom of the stone
and a second flange on
either the left or right end, the flanges each serving as a ledge for a
grouted joint. One skilled in the
6
CA 02867967 2014-10-16
art could modify the current design to utilize the present invention with
other textures and
configurations.
The embodiment shown in Fig 1 includes a pair of brackets 14, 14' embedded in
the
product body 12. Each bracket includes a top end 16 and bottom end 18. The top
end 16 is
illtistrated as having a looped construction forming an eye for receiving a
fastener 40 as illustrated
in Fig 8. The ends 16, 18 are designed to extend and nest under an adjacent
stone as illustrated in
Fig 1 at 21. Each end preferably includes a curved shape 17, 19 as illustrated
in Figs 4 and 5 for
holding the body 12 away from the wall to create an air gap for drainage and
to allow for deflection
of the ends 16, 18 when attached to the wall. In a preferred embodiment as
illustrated in Fig 4, the
wire 14 includes two attachment eyes 25, 26 at the bottom end 18 and two
attachment eyes 27, 28
at the top end 16, formed in a unitary bracket 14. A lateral connector 13 is
provided to enable the
formation of the bracket into a single piece, preferably as a unitary
construction, to enable efficient
manufacture of the product 10. Although shown connecting the top ends 16,
another embodiment
includes a connector for connecting the bottom ends or intermediate portions
20.
As further illustrated in Fig 3, the bracket 14 is embedded into the stone
body 12, with an
intermediate portion 20 as shown in Figs. 4 and 5. The intermediate portion 20
is embedded in the
product body 12 a depth sufficient to ensure adequate engagement to support
the stone body 12
when attached to a building (not shown), preferably for the life of the
building. The depth and
shape may affect the pullout strength, and should be coordinated with the
size, shape and weight of
the product. In a preferred embodiment, the embedded depth is approximately
3/4 -1 inch, but may
be more or less depending on the surface area of the bracket, the
characteristics of the body
composition, and the size and shape of the body. In one embodiment the depth
is 1/2 inch. In a
7
CA 02867967 2014-10-16
heavier product, the depth may be 1.5 inch or more, depending on requirements.
The brackets 14
penetrate the stone body 12 to a depth that provides sufficient engagement
between the bracket and
cured concrete stone, but also which retains a thickness of concrete that will
ensure the face of the
stone body 12 does not expose the wire or fracture during the life of the
building. The brackets 14
are preferably formed from a wire that is corrosion resistant, such as a
stainless steel or galvanized
steel, and having sufficient strength and sufficient stiffness to not deform
and to provide the
installation with an interference fit at the bottom as described below. The
bracket 14 should be
rigid enough to withstand handling, packaging, transport and installation
without excessive
deformation. In another embodiment, the brackets 14 are formed from a
fiberglass material, or any
material known to one skilled in the art that is not corroded and will support
the masonry product
10. In yet another embodiment (not shown), the brackets 14 are stamped from
sheet metal or
formed or molded from another non-corrosive material in a more flattened cross
section. One
skilled in the art appreciates the bracket preferably has adequate strength
and shape retention or
memory.
As shown in the embodiment illustrated in Figs 1 and 3, the product may
include water
shedding feature, which is described herein to include a flashing lip 22 along
the top surface 29 of
the stone body 12. This lip 22 is intended to inhibit the passage of moisture,
such as wind driven
rain, between the stone body 12 and an adjacent stonel 0' as illustrated in
Fig. In such an
embodiment, each stone body 12 may also include a corresponding recess 24 on
the bottom surface
30 of the stone body 12 to correspond with the opposing lip 22 of the adjacent
stone. This lip 22
and recess 24 also serve to obscure a view of the WRB installed beneath the
stone to create a
visually appealing dry stack installation. It also enables easier leveling
during installation.
8
CA 02867967 2014-10-16
Although not illustrated here, the lip 22 may contact the body within the
recess, thereby
setting the gap between the products. In a similar manner, each stone
preferably includes a lip
along one end of the stone body, and a corresponding recess along the opposite
end of the stone
body, which will inhibit moisture intrusion, obscure visibility behind the
product, and set the side
to side gap.
While the lip and recess 22, 24 are illustrated in Figs 1 and 3 as an angled
or chamfered
protrusion and recess, one skilled in the art appreciates that while not
illustrated as such, the lips
22, 24 could be simple ridge, a rabbet, shiplap, or other type of
configuration that provides a
moisture block and an improved line of sight.
As illustrated in the embodiment of Fig 3, the bracket 14 includes a first
protrusion
34 formed in the bracket 14. The protrusion extends below the back surface 32
of the stone body
12 to bear against the structure 39 illustrated in Fig. 9 and create an air
gap Cl under the product
when installed on a structure, preferably installed over a WRB 38. In the
illustrated
embodiment, the bracket 14 includes a bend 36 which holds the top end 16 away
from the structure
39 and WRB 38 to create a second gap G2. When the bracket 14 is secured
through the WRB 38 to
the structure 39 as illustrated in Fig 8, the top end is urged by the fastener
40 toward the structure
39. This force on the top end 16 acts as a lever, which urges the opposite
second end 18 of the
bracket 14 away from the structure 39 and toward the back surface 32' of a
second body, such as an
adjacent product 10', or into a channel on e.g. a starter strip 42. Because
the second end 18 is
wedged below the lower product 10', this causes a second protrusion 35 at the
bottom end 18 to be
held securely against the structure 39 and therefore the product is secured
both at the top by the nail
and at the bottom by a wedging action against the second product 10'. In a
preferred embodiment,
9
CA 02867967 2014-10-16
the top end is positioned approximately 1/8 inch further away from the
structure to ensure the
wedging action occurs. This dimension can be modified depending on the
stiffness of the wire and
the surface against which it bears to provide a gap greater than the height
off the wall to enable a
cam locking action.
As illustrated in Fig 3, in a preferred embodiment, the gap under the top GT
is
approximately 1/2 inch and the gap under the bottom GB is approximately 3/8
inch. One skilled in
the art appreciates this dimension may be modified based on the air gap
desired, concrete
penetration and the deformation of the bracket 14. As illustrated in Fig 1 the
top end 16 preferably
extends a distance B2 above the body 12 and bottom end 18 extends a distance
B1 below the body
12. In a preferred embodiment B1 extends approximately 1/2 inch further than
B2. In one
embodiment B1 is approximately 1 5/8 inch and B2 is approximately 1 1/8 inch.
In another
embodiment, B1 is approximately 1 V4 inch and B2 is approximately 3/4 inch.
One skilled in the art
appreciates this dimension may be changed to increase or decrease overlap
depending on the nature
of the wire, the size of the stone, and other manufacturing and installation
factors, and in some
embodiments, the dimensions may be the same or opposite to reflect the overall
design
requirements. One skilled in the art appreciates that the overlap can be
lengthened to the height of
the stone or more if designed with no interference, and greater overlap may
provide a more stable
wall.
In another embodiment (not illustrated), the top end of the bracket 14 does
not have a bend
36, and the bottom end 18 of the bracket is bent to lie in a plane above the
back surface 32 of the
stone body 12, so the bottom end 18 is installed under an adjacent product
(not shown) simply
CA 02867967 2014-10-16
using an interference fit. This interference may be at least 1 mm and could be
2, 3, 4, or 5 mm or
more, depending on the stiffness of the bracket. Accordingly, the
configuration of the bottom
bracket illustrated in Fig. 2 may be used with or without the bent
configuration of the top end 16 as
illustrated in Fig 2. Additionally, the second end 18 may be wedged against
another body, such as
a starter strip or an accessory, such as a ledge. In certain applications, it
may be sufficient to fasten
the second end using adhesives, nails, stapes, screws or the like as a
substitute for the second body.
While the protrusions are illustrated herein as bent wires, one skilled in the
art appreciates that a
different configuration could include a molded protrusion, a weldment, or
other configurations to
provide the desired gap.
$$ Page 10 Top ¨ The overlap of the wire can be greater or less so I would
broaden the claim
dimensions. The overlap can be the entire length of the stone or more in
reality if designed with no
interference. We suggest that it should be a minimum of a half inch and the
longer the better to
provide a stable wall.
= Page 10 bottom ¨Concerning the word "wedged" as it relates to the bottom
clip in to the starter
strip, we should say that "bending and wedging" the bottom legs into a groove
of the starter strip
provide the stability for the stone when the top clip eyelets of the stone are
screwed in to the wall
A system including the product 10 described above preferably includes a
building structure
39 such as a frame and sheathing or concrete structure, a weather resistant
barrier 38 installed over
the structure (similar in nature and installation to that specified by the
MVMA), a plurality of
products 10 attached to the structure over the WRB 38 and attached to the
structure 39 using
fasteners 40 projecting through the brackets 14. The fasteners 40 are
preferably non-corrosive,
11
CA 02867967 2014-10-16
such as galvanized roofing nails, screws or staples; provided however that the
fasteners must
provide sufficient strength to secure the product 10 to the structure 39 for
the life of the structure.
In one embodiment, installation begins from the bottom of the building. In
such an
instance, a starter strip 42 is installed to the building in a level manner. A
preferred starter strip is
illustrated in Fig 9. The starter strip 42 preferably includes a recess 44 to
receive the bottom 18 of
the brackets 14. The starter strip preferably includes weep holes 46 at the
bottom of the recess 44 to
enable water to drain. The recess 44 preferably includes a lead angle 48 to
enable easy installation
of the bracket 14 and preferably narrows to a line to line or interference fit
to wedge the bracket 14
and hold it in place. In one embodiment, the lead angle is approximately
twenty degrees, and the
recess has a bottom radius R1 of 0.06 inch for a 0.12 diameter wire, and a
depth Li of
approximately 1/2 inch. Products having characteristics similar to the starter
strip are also preferably
used as flashing around windows and other openings. The starter strip 42 is
preferably made from
galvanized steel, aluminum, PVC or any common noncorrosive building material
used in similar
applications. Furthermore, the bottom of the bracket may experience bending
and wedging as the
bottom legs are fit into the recess of the starter strip and the brackets are
secured to the wall. e
The starter strip 42 also includes a back portion 50 which extends under the
WRB 38 to
ensure water does not enter under the WRB, to comply with ASTM requirements.
In a preferred
embodiment the back portion 50 has a height L2 of 3.5 inches to satisfy ASTM.
In another
embodiment, 2 inches may be sufficient. The overlap may be less in some
situations or may be
more, but practicality limits one is normally acceptable. In another
embodiment, a simple j-
channel or other starter is used with the products 10 of the present
invention. Similarly, one skilled
in the art appreciates that either a starter strip or weep screed should
provide ventilation at the
12
CA 02867967 2014-10-16
bottom, and therefore accommodations should be made to provide for air
passage. Once the first
row is secured to the wall using the starter strip 42 and the top end 16 of
the brackets is secured as
described above, the second row is installed by inserting the bottom ends 18
of the second row of
products behind the rear surface 32 of the first row of products previously
installed. Then the top
end of successive rows of the product being installed is pushed against the
structure 39 and secured
at the top end 16 as described above.
The top row of the product may be capped or may extend to the soffit. It is
desirable to
include an air gap where possible to provide for air flow. Where water
drainage does not permit
this, MVMA details may be followed. Where the product extends to the soffit,
an installation
similar to typical brick installation may be performed, i.e. the soffit may be
installed after the
product is installed. Alternatively the soffit j-channel may include a spacer
against the wall to
provide for air flow at the top of the wall.
Although not illustrated, in one embodiment, after the product is secured to
the structure, a
bead of caulk or other material is optionally installed on the product along
one of the top and
bottom, plus one of the ends, so that the joint between adjacent products is
filled with the material
to provide a substantially effective water seal. In yet another embodiment, a
bead of caulk or foam
dam is provided on the top or bottom and one end of each stone at the factory
to provide a
substantially watertight joint between adjacent products without a field-
applied caulk.
One skilled in the art appreciates that while not illustrated here, a grout
product may
optionally be installed between adjacent products for certain textures. Such a
grout is preferably
flexible, so that it can perform for an extended period without cracking. Such
a grout is also
13
CA 02867967 2014-10-16
preferably water resistant to minimize the amount of water that enters between
adjacent products.
Additionally, a grout may be used with the flanged design described above.
As illustrated in Fig 3, the product 10 preferably includes a single bracket
14, but one
skilled in the art appreciates that more than one bracket may be utilized to
provide additional
support and attachment, or to facilitate manufacture. The nature of the
product (size, weight) and
the nature of the brackets, fasteners and structure and environment can affect
these requirements.
As illustrated in Figs 2, 2A 6 and 7, the invention is also applied to corners
and accessories,
such as drip ledge corners, trim stones, keystones, ledges, light fixtures,
outlets, column wraps and
other products. In the case of corners, in one embodiment shown in Fig 2, only
one side of the
stone corners are attached to the structure, and a spacer is provided on the
backside of the return to
provide a consistent air gap and exterior thickness. As shown in Figure 2, the
corner 60 includes a
long leg 62 and a return leg 64. The bracket 14 is used to attach the long leg
62 to the building and
the short leg 64 is supported as part of the body. While the corner 60 is
illustrated with the top 66
installed so the return is on the left side, the corner 60 could be inverted
so the bottom 68 is
installed upwardly so the return 66 is on the right side of the corner 60.
Thus, the corners 60 are
reversible. Preferably the reversible corners have a reversible clip that is
embedded in the concrete
to allow for ease of ordering materials, using as left and right corners and
staggered joints during
installation to give a more authentic stone look.
As illustrated in Fig 2B, a corner may include two wires 214, 214' to ensure
both legs are
sufficiently supported. In this example, the corner may be a ledge corner. In
a similar manner, Fig
6 illustrates an elongate product 10"having two brackets 614, 614' to support
the elongate product.
While not limiting, in this illustration, the elongate product 10" may
comprise a ledge piece. Fig 7
14
CA 02867967 2014-10-16
illustrates another accessory piece 70 including brackets 714 according to the
principles of this
invention. Referring to Figs 7 and 2B, one skilled in the art appreciates that
one can use single or
double clips or a combination of single and double clips and can be installed
in vertical or
horizontal configurations. This principal can be applied to other accessories
including trim stones,
surrounds, drip ledge corners, light boxes and other accessories.
In another embodiment, the installation instructions teach the installer to
set a gap
manually, or to use separate spacers, such as foam or molded parts. In another
embodiment, the
instant invention is applied to a panelized product. In such a case, it may be
necessary to utilize a
greater number of brackets to adequately support and secure the panelized
product due to its size
and weight.
One embodiment of the present invention is applied to individual stones or
bricks. This
makes installation simple, as fewer products will be cut and less scrap
created. Furthermore, it
avoids the potential that an installer will align the panels to create
unsightly lines or an unattractive
panelized wall. Additionally, the individual products also make it simpler to
create accessory
products that are compatible with this system. As noted above, however,
applicant envisions that a
panelized system could utilize the present invention, either alone or in
combination with the
individual products as described above.
While the foregoing written description of the invention enables one of
ordinary skill to
make and use what is considered presently to be the best mode thereof, those
of ordinary skill will
understand and appreciate the existence of variations, combinations, and
equivalents of the specific
embodiment, method, and examples herein. The invention should therefore not be
limited by the
CA 02867967 2014-10-16
above described embodiment, method, and examples, but by all embodiments and
methods within
the scope and spirit of the invention.
16
