Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
CA 02455376 2004-O1-19
Gowlings Ref: T8467966US1
FINAL VERSION
Applicant/Inventor: Patrick Timony
Title: Hanger for Insulated Concrete System and
Method of Installation Thereof and Method
of Installing a Retrofit Hanger in an Insulated
Concrete System
Assignee: 1391038 Ontario Ltd.
JURISDICTION: Canada
DATE: January 19, 2004
TOR LAW15585157 vl
CA 02455376 2004-O1-19
BACKGROUND OF THE INVENTION
FIELD OF THE INVENTION
[0001] In one of its aspects, the present invention relates to a hanger for an
insulated
concrete system. In another of its aspect, the present invention relates to a
method of
installing a hanger in an insulated concrete system. In yet another of its
aspects, the
present invention relates to a method of installing a retrofit hanger in an
insulated
concrete system.
DESCRIPTION OF THE PRIOR ART
(0002] Hangers are known for insulated concrete systems formed of composite
walls
having exterior foam panels and an interior cement core.
[0003] For example, United States patent 5,228,261 [Watkins] teaches a joist
hanger
having a U-shaped body. A plurality of nailing apertures are formed in the
forward end
of this U-shaped joist hanger for receiving nails to secure a joist thereto. A
pair of
support apertures are formed in the rearward end of the U-shaped joist hanger
through
which conventional reinforcing bars are journalled in horizontal orientation.
A slot
extending forwardly from the rearward edge of the base of the U-shaped hanger
receives
a vertical reinforcing bar.
[0004] The joist hanger taught in Watkins is installed by cutting a U-shaped
slot into
an exterior foam panel at a pre-determined position. Rods are loosely
installed through
locating apertures between the front and rearward edge of the U-shaped
bracket; these
rods limit the extent of insertion of the bracket into the U-shaped slot.
Reinforcing bars
are then positioned between the foam panel walls and journalled through
support
apertures. Concrete is then poured between the foam panel walls and allowed to
cure,
thereby fixing the reinforcing bars and the rearward end of the hanger in
position within
the wall. The rods are then removed from the locating apertures. The joist is
then rested
within the projecting forward end of the bracket and nails or other fasteners
are installed
through the nailing apertures.
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[0005] Disadvantages exist with regard to the above-described system. The U-
shape
of the bracket requires that, for proper installation, U-shaped slots of a pre-
determined
size must be cut in the foam wall at predetermined positions. In addition,
retaining the U-
shaped bracket requires that reinforcing bars be journalled through apertures
in the rear
end of the bracket, which thereby constrains the arrangement of reinforcing
bars.
[0006] United States Patent 4,889,310 issued to Boeshart ("Boeshart") teaches
ties
for a concrete form system having opposed polystyrene panels that form a pair
of
parallel, spaced apart walls. At least one of the polystyrene walls has a
smooth inner face
to allow the panel to be removed after formation of the concrete wall. The
ties are used
to interlock the two vertical panels in order to form the concrete wall. Each
tie has a pair
of spaced apart paddle members which retain the thickness of the panel
therebetween.
Once the concrete wall has been formed, the outer paddle is removed by
applying a blow
thereto. In one embodiment, the tie uses an enlarged outer paddle disposed
outwardly of
the outward face of the panels. This enlarged paddle may have fastener
apertures and
may be connected to vertical whalers. The tie taught by Boeshart is designed
for holding
two polystyrene panels together to permit forming and does not provide
sufficient support
to hang objects from a face of the wall once formed.
[0007] Accordingly, it would be desirable to have a hanger system which
overcomes
the above-mentioned disadvantages of the prior art. It would be further
desirable to have
a retrofit hanger system useful in an insulated concrete system.
SUMMARY OF THE INVENTION
[0008] It is an object of the present invention to provide a novel hanger
system,
particularly for hanging a joist) that obviates or mitigates at least one of
the above-
mentioned disadvantages of the prior art.
[0009] Accordingly, in one of its aspects, the present invention provides a
hanger for
hanging an object from a composite wall, the composite wall having a concrete
core, a
foam outer wall and a second outer wall, the hanger comprising:
a first plate having an embedded portion far retention within the concrete
core
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and a hanging portion extending from the foam outer wall for connection to the
object;
the embedded portion having an edge in addition to its distal edge, the edge
being substantially transverse to the longitudinal axis of the first plate.
[0010] Accordingly, in another of its aspects, the present invention provides
a method
for installing a hanger on a composite wall formed from a foam wall and a
second wall
defining a cavity fillable with concrete, the hanger including a first plate
having an
embedded portion and a hanging portion, wherein the embedded portion comprises
an
edge in addition to its distal edge, the edge being substantially transverse
to the
longitudinal axis of the first plate, the method comprising the steps o~
(a) cutting a slit through the foam wall so that the slit extends to a hanging
position;
(b) sliding the first plate in the slit to the hanging position, wherein the
embedded portion of the first plate extends into the cavity and the hanging
portion
extends from the composite wall;
(c) pouring concrete into the cavity and allowing it to cure to form the
composite wall.
[0011) In yet another of its aspects, the present invention provides a method
of
hanging a hanger from a foam wall of a composite wall having a cured concrete
core and
at least one foam outer wall, the hanger comprising a substantially L-shaped
bracket
having a retaining portion and a hanging portion for connection to an object
to be hung,
the hanging portion disposed at substantially a 90 degree angle to the
retaining portion,
the method comprising the steps of
(a) forming a cavity at a hanging position in the foam wall to accommodate
the retaining portion;
(b) securing the retaining portion to the concrete core.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Embodiments of the present invention will be described with reference
to the
accompanying drawings, wherein like reference numerals denote like parts, and
in which:
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Figure 1 illustrates a perspective view of a partially assembled embodiment of
the present hanger.
Figure 2 illustrates a side cross-section view of a partially assembled
embodiment of the present hanger.
Figure 3 illustrates a perspective view of a partially assembled embodiment of
the present hanger.
Figure 4 illustrates a perspective view of an assembled embodiment of the
present hanger.
Figure 5 illustrates a side cross-section view of an embodiment of the present
hanger.
Figure 6 illustrates a side view of an embodiment of a plate of the present
hanger.
Figure 7 illustrates a perspective view of an embodiment of a plate of the
present hanger.
Figure 8 illustrates a perspective view of an embodiment of a partially
assembled retrofit bracket of the present invention.
Figure 9 illustrates a side cross-section view of an installed plate of an
embodiment of a retrofit bracket of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0013) With reference to Figures 1 through 5, there is illustrated a hanger
100 of an
embodiment of the present invention for use in an insulated concrete form
system 105.
Insulated concrete form system 105 includes a composite wall 110. Composite
wall 110
is formed using a pair of outer walls 115a and 115b, at least one of which,
and preferably
both of which, are formed of rigid foam. The type of foam is not particularly
restricted
and is within the purview of a person skilled in the art. The rigid foam may
be a
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polyurethane foam, a phenolic foam, or a polyethylene foam. Preferably, the
rigid foam
is polystyrene foam. Foam wall 115 may be an integral structure or may be
formed from
foam panels.
[0014] Prior to forming of composite wall 110, outer walls 115a and 115b form
a
cavity 120 finable With concrete. Composite wall 110 may also comprise
reinforcing
bars 125a, 125b, 125c, 125d and 125e. The reinforcing bars may be vertical or
horizontal
and are installed in cavity 120 prior to pouring of the concrete. Preferably,
reinforcing
bars 125a, 125b, 125c, 125d and 125e are formed from steel. The number and
arrangement of reinforcing bars is not particularly restricted and is Within
the purview of
a person skilled in the art. It should be clearly noted that, in the
illustrated arrangement,
reinforcing bar 125a is optional.
[0015] Hanger 100 consists of a plate 130. In a preferred embodiment, hanger
100
consists of a pair of plates 130a and 130b. Plates 130a and 130b may be
attached by one
or more members (not shown). Plates 130a and 130b are preferably formed of
metal and,
more preferably, are formed of stamped metal sheet. Preferably, the metal is
steel such as
galvanized steel (preferably 22 gauge) or another cold rolled metal. Plates
130a and 130b
are inserted into slits 135a and 135b cut into an outer wall 115b. Slits 135a
and 135b are
cut to approximately the height at which the installer wishes to hang an
object 138.
[0016] The objects for which hanger 100 is suitable are not particularly
restricted and
are within the purview of a person skilled in the art. Hanger 100 is
particularly suitable
for the hanging of joists and, in particular, floor joists for an interior
floor. Hanger 100 is
also suitable for other purposes including hurncane truss tie down anchorage,
anchorage
or fastening an exterior or interior applied framed partition wall to a
composite wall,
hanging an exterior or interior applied roof truss to a composite wall, and
mounting
exterior floor joists for, for example, an exterior deck application. The uses
of hanger
100 are not particularly restricted and are within the purview of a person
skilled in the art.
Hanger 100 is particularly suitable for hanging weight bearing structural
members.
[0017) Preferably, the ultimate load capacity of a single concrete insert
plate (130a or
130b) is at least about 2000 lbs, more preferably at least about 3000 lbs,
even more
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preferably at least about 4000 lbs. The most preferred ultimate load capacity
is about
5,000 lbs. When combined in pairs and applying anticipated shear load to the
assembly
with the bearing bracket attached as described below, the entire assembly is
expected to
attain a factored rated load capacity (in total) substantially same,
respectively, as the
ultimate load capacity referred to above. This specification will vary for
each required
bearing condition, depending on the load anticipated and may be readily
determend
[0018] With reference to Figures 1 through 7, plates 130a and 130b have an
embedded portion I40, which extends into the cavity 120 for retention therein
upon
pouring and curing of concrete core I50. Plate 130 further has a hanging
portion 160 for
connection to object 138. Hanging portion 160 extends out from composite wall
110.
The plate axis extending from embedded portion 140 to hanging portion 160 will
be
referred to herein as the longitudinal axis, although this label is not
intended to limit the
size or shape of plate I30. Embedded portion 140 has an edge transverse to the
longitudinal axis. This edge is in addition to the distal (or most embedded)
edge of
embedded portion 140. This edge helps retain embedded portion 140 in concrete
core
150. The edge may form part of slots or cut-outs, such as slots 155a, 155b,
155c and
155d about the periphery of plate 130. In a preferred embodiment, embedded
portion 140
forms part of an aperture 145 therein which improves retention of embedded
portion 140
within concrete core 150.
[0019] In a preferred embodiment, slots 155a, 155b, 155c, and 155d are shaped
and
sized to accommodate horizontal reinforcing bars, such as reinforcing bar
125e. The
number of slots 155a, 155b, 155c, and 155d is not particularly restricted and
is within the
purview of a person skilled in the art.
[0020] Hanger 100 further comprises a support 165. Support 165 is preferably a
U-
shaped bracket. Preferably, support 16S if formed of metal. More preferably,
support 165
is formed of stamped metal sheet. Preferably, the metal is steel such as
galvanized steel
(preferably 22 gauge) or another cold rolled metal. Support 165 is sized to
hold at least a
part of object 138, such as an end portion of a joist. The size of support 165
is not
particularly restricted and is within the purview of a person skilled in the
art. Support
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165 is securable to hanging portion 160 of plate 130. Preferably support 165
is inserted
between and secured to hanging portions 160a and 160b of plates 130a and 130b.
[0021] In a preferred embodiment, hanging portion 160 comprises a plurality of
apertures 170 and support 165 comprises a plurality of corresponding apertures
175.
Securing means 180 are inserted through apertures 170 and corresponding
apertures 175
once support 165 is in position between hanging portions 160a and 160b. The
plurality
of apertures 170 and corresponding apertures 175 permit the hanging height of
object 138
to be adjusted post-insertion of plates 130a and 130b and the pouring and
curing of
concrete core 150. Further, apertures 170 and corresponding apertures 175
permit the
installer to accommodate moderate discrepancies in the heights of plates 130a
and 130b
after setting of concrete core 150. The specific number and arrangement of
apertures 170
and corresponding apertures 175 is not particularly restricted and is within
the purview of
a person skilled in the art. The arrangement of apertures 170 and
corresponding apertures
175 may be such that support 165 may be secured so as to hang object 138 on an
angle.
[0022] In a preferred embodiment, plate 130 further comprises an outer
projection
185. Outer projection 185 extends at substantially a 90 degree angle from
plate 130 and
when plate 130 is in a hanging position, abuts an exterior surface of outer
wall 115a.
Outer projection 185 may project from either face of plate 130. In another
embodiment,
plate 130 may comprise a plurality of similarly structured outer projections.
In another
embodiment, in addition or in the alternative to outer projection 185, plate
130 may
contain one or more inner projections 190. Inner projection 190 extends at
substantially a
90 degree angle from plate 130 and when plate 130 is inserted in a hanging
position,
abuts an interior surface of outer wall 115a, and concrete core 150. As will
be evident to
a person skilled in the art, inner projection 190 comprises an edge transverse
to the
longitudinal axis and present in addition to the distal edge of the embedded
portion.
Inner projection 190 may project from either face of plate 130. The number of
outer
projections 185 and inner projections 190 is not particularly restricted and
is within the
purview of a worker skilled in the art. In a preferred embodiment, outer
projections 185
and inner projections 190 are formed by punching out portions of plate 130.
Preferably,
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plate 130 comprises an outer projection. Preferably, when a pair of plates
130a are used
they include outer proj ections offset relative to each other.
[0023] In a preferred embodiment, hanger I00 is installed by first cutting
slits 135a
and 135b through foam wall 115b to a desired hanging position, prior to
pouring of
concrete core 150. Plates 130a and I30b are then slid into slits 135a and 135b
to a
desired hanging position. Reinforcing bars 125 may then be positioned between
outer
walls 115a and I 15b. Concrete core 150 is then poured and allowed to cure.
[0024] Object 138 is then positioned within support 165. Support 165 is
positioned
between hanging portions 160a and 160b of plates 130a and 130b so that one or
more of
apertures 170 align with one or more corresponding apertures I75. Securing
means 180
are inserted through these aligned apertures to secure plate 130 to support
165.
Preferably, securing means 180 are further forced into object 138 thereby
securing plate
130, support 165 and object 138 to each other. The number and type of securing
means
180 used is not particularly restricted and is within the purview o.f a person
skilled in the
art, though, in some applications, suitable securing means should include
screws only to
provide adequate compression of the elements together, thereby effectively
reducing the
shear forces on parts 180.
[0025] With reference to Figure 5, it should be noted that object 138 can
translated
such that the bottom thereof is below the bottom edge of securing plate 130
(i.e., this can
be seen, for example in Figure 4).
[0026] When hanger 100 is used in a hurricane tie application, plates 130a and
130b
are wet set into concrete core 150 at the top of a finished poured composite
wall 110
parallel to truss or rafter placement. Once concrete core 150 is cured, the
truss or rafter is
secured in position between plates 130a and 130b. Support 165 may then be used
as a tie
down element by being slid downward upside down over the top of the truss or
rafter
member. Securing means 180 may then be used to secure plate 130 to support 165
and
the truss or rafter.
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[0027] When hanger 100 is used in a partition anchorage application, one or
more of
plates 130 can be used. The number of plates necessary for a partition
anchorage
application is within the purview of a person skilled in the art. Generally, a
series of two
or three plates 130 or pairs of plates 130a and 130b are required for a
standard 8 or 9 foot
high partition. Prior to pouring of concrete core 150, slits are made into
foam wall 115b
on one or both sides of where the partition will be installed. Plates 130 are
then inserted
through these slits. Once the concrete is poured and cured, partition members,
such as
wood and steel partition members, can be secured to the hanging portions) 160
of insert
plates) 130 through apertures 170. If a single series of plates 130 are used,
the partition
can be pre-assembled and tilted up into place against plates 130. Drywall
finishes can
then be installed as per normal installation practices directly over the
insert plates.
Preferably, a series of opposing pairs of plates 130a and 130b are used in a
partition
anchorage application.
[002$] With reference to Figures 8 and 9, there is illustrated a retrofit
bracket 195 of
another embodiment of the present invention for use in insulated concrete form
system
205. In this embodiment, parts identified in the first embodiment are here
numbered in
the two-hundreds, however, when the same numbers appear as second and third
digits,
they denote a part corresponding to the part having the same digits in the
first
embodiment.
[0029) Retrofit bracket 195 comprises a retrofit plate 230. In a preferred
embodiment, retrofit bracket 195 comprises two retrofit plates 230a and 230b.
Retrofit
plate 230 has a retaining portion 203, which comprises one or more retaining
apertures
207a and 207b to accommodate concrete securing means 209a and 209b. Preferably
these securing means are concrete fasteners. In a preferred embodiment,
concrete
fasteners 209a and 209b are expansion (e.g., lag-type) anchors. Suitable
screws are Tap-
ConTM screws. Retrofit bracket 195 further comprises hanging portion 260.
Hanging
portion 260 comprises a plurality of apertures 270.
[0030] Retrofit bracket 195 further comprises a support 265. Support 265 is
preferably a U-shaped bracket. Support 265 is sized to accommodate an object
238
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Support 265 has a plurality of corresponding apertures 275. Support 265 is
securable to
hanging portion 260 of retrofit plate 230. Preferably, support 265 is inserted
between and
secured to both hanging portions 260a and 260b. Apertures 270 and
corresponding
apertures 275 permit the height of object 238 to be adjusted post fastening of
retrofit
plates 230a and 230b to composite wall 210. Further, apertures 270 and
corresponding
apertures 275 permit an installer to accommodate moderate discrepancies in the
heights
of retrofit plates 230a and 230b after they are fastened to composite wall
210.
[0031] To install retrofit bracket 195, a portion of foam wall 215b sized and
shaped
to accommodate retaining portion 203 is cut away at a desired hanging
position.
Retaining portion 203 is then fastened to concrete core 250. Generally,
fastening of
retaining portion 203 to concrete core 250 will require that holes be drilled
in concrete
core 250 corresponding to retaining apertures 207a and 207b. Retaining portion
203 is
then positioned adjacent concrete core 250 so that retaining apertures 207a
and 207b
align with the drilled holes. Concrete securing means 209a and 209b are then
forced
through retaining apertures 207a and 207b to secure retaining portion 203 to
concrete
core 250.
(0032] Support 265 is positioned between hanging ends 260a and 260b of
retrofit
plates 230a and 230b so that one or more of apertures 270 align with one or
more of
corresponding apertures 275. Object 238 is positioned within support 265.
Either before
or after it is positioned between retrofit plates 230a and 230b. In an
alternate
embodiment, support 265 may be secured to a single plate 230. Securing means
280 are
inserted through these aligned apertures to secure retrofit plate 230 to
support 265.
Preferably, securing means 280 are further forced into object 238 thereby
securing
retrofit plate 230, support 265 and object 238 to each other. The number and
type of
securing means 280 used is not particularly restricted and is within the
purview of a
person skilled in the art. Suitable securing means 280 include screws and
nails.
[0033) While supports 165, 265 and the objects 138, 238 to be hung have been
shown
as separate elements, those skilled in the art will recognize that the support
could be
inherent or integral with the object to be hung.
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[0034] While hanging portions 160, 260 connect to objects 138, 238 the forth
of
connection is not particularly restricted, and is within the purview of a
person skilled in
the art. For example, the connection may be by way of securing means such as
screws,
by friction fit or by gravity.
[0035] The manufacture of various elements of the present system will now be
discussed.
[0036] Concrete Form Insert Plate (130): Preferably, this component is fed,
stamped
and bent in a two-stage operation which involves galvanized steel plate being
supplied in
a coil at the precise cut width of the component. The component is first fed
forward into
the manufacturing from when it is stamped to create the holes and outer
notches and is
cur from the coil. The second stage of the process involves another part of
the die fitting
to the component to break press the protruding tab to its final position about
90° to the
plane of the plate. The component is then ejected from the die to start the
next
component.
[0037] Bearing Bracket (or support 165): Preferably, this component can vary
in
width to suit a variety of different objects, as described in the
specification. The
manufacturing process is similar to above in two stages. Preferably,
galvanized steel coil
is supplied in the width of the component. It is first fed from the coil and
is stamped to
the required size from galvanized steel coil sheet. At the same time as being
stamped, the
material is also slightly perforated in a designated grid pattern that is
designed to line up
with the pre-stamped holes of the concrete form insert plate. The perforations
are such
that, rather than being stamped as clear holes, the material is in fact only
deformed to a
point of piercing and left in place within the part (similar to a cheese
grater) - this
facilitates creation of a friction fit with the joist or other member being
hung. The
stamped component is then break-formed to a U shape with opposing 90°
bends such that
the side to which the perforations are pointing towards are now facing each
other ready to
contact the object they are designed to be fastened to. This forming is all
completed
within another component of the same forming die. The component is then
ejected from
the machine ready to form the next component.
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[0038) Retrofit Bracket or plate 230: Contrary to the other two components, it
is
preferred to manufacture this component from heavier gauge galvanized steel
sheet
which is stamped and break formed to required shape in a single step. The
includes not
only the 90° angle of the component but also the reinforcing "crimps"
down the axis of
the angle in three locations with arrow shaped indentations to providing the
required
increased resistance to loading.
(0039) While this invention has been described with reference to illustrative
embodiments, the description is not intended to be construed in a limiting
sense. Thus,
various modifications of the illustrative embodiments, as well as other
embodiments of
the invention, will be apparent to persons skilled in the art upon reference
to this
description. It is therefore contemplated that the appended claims will cover
any such
modifications or embodiments.
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