U.S. patent application number 10/796844 was filed with the patent office on 2005-09-29 for head joint drainage device, wall system and method for draining moisture from a head joint.
Invention is credited to Koester, John H..
Application Number | 20050210787 10/796844 |
Document ID | / |
Family ID | 34976991 |
Filed Date | 2005-09-29 |
United States Patent
Application |
20050210787 |
Kind Code |
A1 |
Koester, John H. |
September 29, 2005 |
Head joint drainage device, wall system and method for draining
moisture from a head joint
Abstract
A wall system, head joint drainage device and method adapted to
allow drainage of moisture from a head joint of a structure meeting
a horizontal interruption when the wall system is formed with a
plurality of building products set with mortar forming a mortar
joint between adjacent ones of the plurality of modular building
products. A spacer has a top portion, having a length approximately
equal to a depth of the plurality of building products and a width
approximately equal to a width of the mortar joint, adapted to
block the mortar from reaching the horizontal interruption and has
a side portion adapted to keep the portion a distance away from the
horizontal interruption, the distance allowing moisture drainage
from the head joint.
Inventors: |
Koester, John H.; (St.
Michael, MN) |
Correspondence
Address: |
IPLM Group, P.A
Post Office Box 18455
Minneapolis
MN
55418
US
|
Family ID: |
34976991 |
Appl. No.: |
10/796844 |
Filed: |
March 9, 2004 |
Current U.S.
Class: |
52/302.1 |
Current CPC
Class: |
E04C 2003/023 20130101;
E04B 1/7046 20130101; E04F 17/00 20130101 |
Class at
Publication: |
052/302.1 |
International
Class: |
E04H 001/00 |
Claims
What is claimed is:
1. A head joint drainage device adapted to allow drainage of
moisture from a head joint meeting a horizontal interruption of a
structure formed with a plurality of building products set with
mortar forming a mortar joint between adjacent ones of said
plurality of modular building products, comprising: a spacer having
a top portion, having a length approximately equal to a depth of
said plurality of building products and a width approximately equal
to a width of said mortar joint, adapted to block said mortar from
reaching said horizontal interruption and having a side portion
adapted to keep said portion a distance away from said horizontal
interruption, said distance allowing moisture drainage from said
head joint.
2. A head joint drainage device as in claim 1 wherein said top
portion is solid.
3. A head joint drainage device as in claim 1 wherein said side
portion is angled back from a front edge of said spacer.
4. A head joint drainage device as in claim 3 further comprising a
second one of said side portion.
5. A head joint drainage device as in claim 4 wherein said side
portion and said second one each have approximately equal
heights.
6. A head joint drainage device as in claim 1 wherein said head
joint drainage device is formed into a plurality of sections, each
of said plurality of sections having a length selected so that a
length of an integral number of said plurality of sections is
approximately equal to said depth of said plurality of modular
building materials.
7. A head joint drainage device as in claim 6 wherein said top
portion has a transverse groove providing an ability for said
plurality of sections to snap apart by hand.
8. A head joint drainage device as in claim 7 wherein said side
portion angles back from said top portion said transverse
groove.
9. A head joint drainage device as in claim 7 wherein said side
portion roughly forms a v-shape.
10. A head joint drainage device as in claim 1 wherein said head
joint drainage device is of a color which approximates a color of
said mortar.
11. A wall system for a structure having a head joint meeting a
horizontal interruption in a wall of a structure, said wall having
a veneer, comprising: an angle positioned at said horizontal
interruption; a plurality of modular building products set on said
angle forming said veneer; mortar set between said adjacent ones of
said plurality of modular building products forming a mortar joint;
a spacer positioned on said angle between said adjacent ones of
said plurality of modular building products, said spacer forming a
moisture drainage channel between said adjacent ones of said
plurality of modular building products between said mortar and said
angle.
12. A wall system as in claim 1 wherein said spacer has a top
portion, having a length approximately equal to a depth of said
plurality of building products and a width approximately equal to a
width of said mortar joint, adapted to block said mortar from
reaching said angle and has a side portion adapted to keep said
portion a distance away from said angle, said distance allowing
moisture drainage from said head joint.
13. A wall system as in claim 12 wherein said top portion of said
spacer is solid.
14. A wall system as in claim 12 wherein said side portion of said
spacer is angled back from a front edge of said spacer.
15. A wall system as in claim 14 wherein of said spacer further
comprises a second one of said side portion.
16. A wall system as in claim 15 wherein said side portion of said
spacer and said second one of said spacer each have approximately
equal heights.
17. A wall system as in claim 12 wherein said spacer is formed into
a plurality of sections, each of said plurality of sections having
a length selected so that a length of an integral number of said
plurality of sections is approximately equal to said depth of said
plurality of modular building materials.
18. A wall system as in claim 17 wherein said top portion of said
spacer has a transverse groove providing an ability for said
plurality of sections to snap apart by hand.
19. A wall system as in claim 18 wherein said side portion of said
spacer angles back from said top portion said transverse
groove.
20. A wall system as in claim 18 wherein said side portion of said
spacer roughly forms a v-shape.
21. A wall system as in claim 11 wherein said spacer is of a color
which approximates a color of said mortar.
22. A method of providing drainage of moisture from a head joint
meeting a horizontal interruption of a wall of a structure, said
wall having a veneer constructed from a plurality of modular
building products set with mortar forming a mortar joint between
adjacent ones of said plurality of modular building products,
comprising the steps of: placing one of said plurality of modular
building products on an angle at said horizontal interruption;
setting a spacer on said angle adjacent said one of said plurality
of modular building products; applying said mortar to said one of
said plurality of modular building products forming said mortar
joint; and placing another of said plurality of modular building
products on said angle adjacent to said spacer.
23. A method as in claim 22 wherein said spacer has a top portion,
having a length approximately equal to a depth of said plurality of
building products and a width approximately equal to a width of
said mortar joint, adapted to block said mortar from reaching said
angle and has a side portion adapted to keep said portion a
distance away from said angle, said distance allowing moisture
drainage from said head joint.
24. A method as in claim 23 wherein said top portion of said spacer
is solid.
25. A method as in claim 23 wherein said side portion of said
spacer is angled back from a front edge of said spacer.
26. A method as in claim 25 wherein said spacer further comprises a
second one of said side portion.
27. A method as in claim 26 wherein said side portion of said
spacer and said second one of said spacer each have approximately
equal heights.
28. A method as in claim 23 wherein said spacer is formed into a
plurality of sections, each of said plurality of sections having a
length selected so that a length of an integral number of said
plurality of sections is approximately equal to said depth of said
plurality of modular building materials.
29. A method as in claim 28 wherein said top portion of said spacer
has a transverse groove providing an ability for said plurality of
sections to snap apart by hand.
30. A method as in claim 29 wherein said side portion of said
spacer angles back from said top portion said transverse
groove.
31. A method as in claim 29 wherein said side portion of said
spacer roughly forms a v-shape.
32. A method as in claim 22 wherein said spacer is of a color which
approximates a color of said mortar.
Description
TECHNICAL FIELD
[0001] This invention relates to moisture drainage products and,
more particularly, to moisture drainage products intended for
incorporation in wall systems and methods for providing moisture
drainage in wall systems.
BACKGROUND
[0002] Warm, moisture-laden air can exist in buildings including
buildings in colder climates. A significant amount of moisture can
be placed into the air through common household activities, such as
cooking, bathing and showering.
[0003] Especially in colder climates, insulation in a wall
structure helps to reduce heat loss from buildings which are heated
due to the cold climate. As moisture-laden air passes through the
wall structure of such buildings, the moisture-laden air encounters
steadily decreasing temperatures. As the air is cooled while moving
from the interior of a wall structure to the exterior of the wall
structure, the air can eventually reach its dew point and water
vapor in the air condenses to form moisture. The result can be a
moisture buildup in the wall structure.
[0004] Vapor barriers are commonly employed on the warm side of
wall structures in order to prevent moisture-laden air from
entering the wall structure. However, vapor barriers are not
usually perfect. In a typical building, multiple penetrations of a
vapor barrier can occur, e.g., from electrical and plumbing lines
and from window and door openings.
[0005] If the exterior temperature is cold enough, moisture
existing in the wall structure could eventually turn to frost or
ice and, thus, be prevented from draining from the wall structure,
at least until the exterior temperature increases. When that
happens, however, the moisture can still cause significant damage
to the wall structure.
[0006] Various products have been created to allow drainage of
moisture from wall structures once the moisture has formed in the
wall structure.
[0007] U.S. Pat. No. 3,654,765, Healy et al, Subterranean Wall
Drain, discloses a subterranean wall drain unit including a drain
pipe having openings therein and a longitudinally extending planar
core defining channels normal to the pipe. A water pervious sheet
material covers one face of the core and the openings in the pipe
to form a filter therefore. The other face of the core may be
covered with a plastic sheet or other vapor barrier.
[0008] U.S. Pat. No. 3,888,087, Bergsland, Foundation Wall
Protective Sheet, discloses improvements in protective membranes or
sheets for foundation walls. The sheets have regular courses of
protrusions for spacing the sheet from the foundation wall and a
porous backing for drainage outwardly of the sheet. The protrusions
provide air channels between the protective sheet and the
foundation for thermal insulation and for facilitating drying of
the foundation wall. Small vertical ribs between the courses of the
protrusions provide convenient water passages to take care of
drainage water in the porous backing without interfering with the
air spaces and incidentally providing bending vertical lines for
more facile installation handling. Modifications of the sheet
include transverse ribs at lower portions of the sheet to allow
horizontal bending thereof wall for footing and drainage
configurations. A barrier for preventing back fill falling between
the protective sheathing and foundation is also disclosed.
[0009] U.S. Pat. No. 3,318,056, Thompson, Ventilating Wall
Construction With Stud Location Indicators, discloses a sheet of
building material placed between wall veneers for moisture
protection that includes vertical drainage channels and
perforations.
[0010] U.S. Pat. No. 6,298,620, Hatzinilolas, Moisture Control
Panel, discloses a moisture control panel used in exterior walls. A
wall constructed with the panel has an inner back-up wall component
and an outer wall component of a moisture pervious material, for
example, stucco. The moisture control panel is positioned between
the two. It has a base sheet on the inner face of the outer wall
component. A set of drying perforations slope downwardly toward the
inside through this sheet. This drains moisture from the inside of
the outer wall component. On the inside, the base sheet has a set
of upwardly sloping bosses which provide an air space on the inside
the moisture control panel providing for air circulation and
drainage of any moisture.
[0011] U.S. Pat. No. 4,381,630, Koester, Foundation Vent Structure,
discloses a foundation vent structure positioned upon the footings
of the building below the lowermost row of concrete blocks of the
basement wall and extends below the concrete floor of the basement.
The vent structure is formed of a plastic material, preferably in
strips, and is shaped to define alternate tunnels and channels
having openings therein. The vent structure intercommunicates the
openings in the hollow, concrete blocks with the drain area located
along the marginal area below the basement wall to permit moisture
to be vented into this drain area.
[0012] However, these products encounter a problem when the wall
structure is interrupted by a horizontal structural member such as
a wall opening, e.g., a window or door opening, or a shelf angle
typically placed at building floor levels or upon a certain
vertical distance. Such interruptions disrupt the otherwise
downward flow of moisture to the bottom of the wall structure and
may interfere with the proper operation of some of the above
solutions. Such products are not typically designed to operate
effectively at a head joint where the wall structure is interrupted
by a wall opening or shelf angle.
SUMMARY OF THE INVENTION
[0013] This problem is exacerbated when the exterior veneer of the
wall structure is formed with modular building products, such as
brick. Mortar is typically used to form a mortar joint between
otherwise adjacent bricks and between layers of bricks. Such mortar
can interfere with the proper flow of moisture wall through the
wall cavity and, ultimately, outside of the wall cavity. When
mortar is used to set bricks, for example, on a steel lintel or
shelf angle, the mortar can effectively hinder the passage of
moisture from the wall cavity to the exterior of the wall
structure. Such horizontal interruption is collectively referred to
herein as a horizontal interruption.
[0014] The present invention is a wall structure, method and a head
joint drainage device which allows a channel for moisture which
otherwise might collect in a wall structure where a head joint
encounters a horizontal interruption to properly escape to the
exterior of the wall structure.
[0015] In one embodiment, the present invention provides a head
joint drainage device adapted to allow drainage of moisture from a
head joint meeting a horizontal interruption of a structure formed
with a plurality of building products set with mortar forming a
mortar joint between adjacent ones of the plurality of modular
building products. A spacer has a top portion, having a length
approximately equal to a depth of the plurality of building
products and a width approximately equal to a width of the mortar
joint, adapted to block the mortar from reaching the horizontal
interruption and has a side portion adapted to keep the portion a
distance away from the horizontal interruption, the distance
allowing moisture drainage from the head joint.
[0016] In another embodiment, the present invention provides a wall
system for a structure having a head joint meeting a horizontal
interruption in a wall of a structure, the wall having a veneer. An
angle is positioned at the head joint. A plurality of modular
building products are set on the angle forming the veneer. Mortar
is set between the adjacent ones of the plurality of modular
building products forming a head joint of mortar. A spacer is
positioned on the angle between the adjacent ones of the plurality
of modular building products, the spacer forming a moisture
drainage channel between the adjacent ones of the plurality of
modular building products between the mortar and the angle.
[0017] In another embodiment, the present invention provides a
method of providing drainage of moisture from a head joint meeting
a horizontal interruption of a wall of a structure, the wall having
a veneer constructed from a plurality of modular building products
set with mortar forming a mortar joint between adjacent ones of the
plurality of modular building products. One of the plurality of
modular building products is placed on an angle at the horizontal
interruption. A spacer is set on the angle adjacent the one of the
plurality of modular building products. The mortar is applied to
the one of the plurality of modular building products forming the
mortar joint. Another of the plurality of modular building products
is placed on the angle adjacent to the spacer.
[0018] In a preferred embodiment, the plurality of modular building
products comprise a plurality of bricks.
[0019] In a preferred embodiment, the spacer has a top portion,
having a length approximately equal to a depth of the plurality of
building products and a width approximately equal to a width of the
mortar head joint, adapted to block the mortar from reaching the
angle and has a side portion adapted to keep the portion a distance
away from the angle, the distance allowing moisture drainage from
the head joint.
[0020] In a preferred embodiment, the top portion of the spacer is
solid.
[0021] In a preferred embodiment, the side portion of the spacer is
angled back from a front edge of the spacer.
[0022] In a preferred embodiment, the spacer further comprises a
second one of the side portion.
[0023] In a preferred embodiment, the side portion of the spacer
and the second one of the spacer each have approximately equal
heights.
[0024] In a preferred embodiment, the spacer is formed into a
plurality of sections, each of the plurality of sections having a
length selected so that a length of an integral number of the
plurality of sections is approximately equal to the depth of the
plurality of modular building materials.
[0025] In a preferred embodiment, the top portion of the spacer has
a transverse groove providing an ability for the plurality of
sections to snap apart by hand.
[0026] In a preferred embodiment, the side portion of the spacer
angles back from the top portion the transverse groove.
[0027] In a preferred embodiment, the side portion of the spacer
roughly forms a v-shape.
[0028] In a preferred embodiment, the spacer is of a color which
approximates a color of the mortar.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] FIG. 1 is a front elevation of wall system utilizing an
embodiment of the present invention;
[0030] FIG. 2 is a perspective view of a partially constructed wall
system in accordance with an embodiment of the present
invention;
[0031] FIG. 3 is a close-up perspective view of a spacer in
accordance with an embodiment of the present invention;
[0032] FIG. 4 is another view perspective view of the spacer of
FIG. 3;
[0033] FIG. 5 is a front view of a detail of a wall system in
accordance with an embodiment of the present invention;
[0034] FIG. 6 is a front view of a wall system incorporating the
head joint drainage device of the present invention;
[0035] FIG. 7 is a perspective view a strip of spacer elements;
[0036] FIG. 8 illustrates a head joint of a wall system in
preparation for the installation of the present invention;
[0037] FIG. 9 illustrates the removal of one or spacer elements
from a strip of spacer elements;
[0038] FIG. 10 illustrates the placement of a spacer at the head
joint of a wall system;
[0039] FIG. 11 is a side view of a spacer placed next to a modular
building product at the head joint of a wall system;
[0040] FIG. 12 is a front view of two spacers installed between two
modular building products;
[0041] FIG. 13 illustrates the spreading of a bed of mortar over a
row of modular building products;
[0042] FIG. 14 illustrates tuck pointing of mortar between modular
building products; and
[0043] FIG. 15 illustrates of a front view of an installed head
joint drainage device and wall system using a head joint drainage
device showing the weep holes created.
DETAILED DESCRIPTION
[0044] A head joint is formed in a wall structure when the wall
structure has an opening in what would otherwise be an unbroken
expanse of wall. Openings are commonly made in wall structures for
windows and doors, for example. The wall structure essentially
stops at the top of the window or door opening and, in the case of
a window opening, may start again below the opening. The wall
structure above the opening is typically supported by a structural
header, designed to carry the load of the wall structure above the
opening and spread the weight of that load the load bearing
capacity of the wall structure on either side of the opening.
[0045] In the case of a wall structure having an a brick exterior,
typically an exterior veneer of brick set in mortar, the weight of
the wall structure above an opening is also distributed by a
structural member to either side of the opening. With a brick wall
structure, the load bearing member is typically called a lintel. A
lintel is commonly constructed of a piece of steel, or other
material capable of transferring weight. The lintel allows the
weight of bricks placed on the lintel to be transferred to other
structural wall members on either side of the opening. Typically, a
lintel is fashioned from an "L-shaped" steel member, or angle iron,
which is fastened to structural wall elements either behind the
lintel or below the lintel but on either side of the opening.
[0046] Further, a wall structure may have a shelf angle installed
periodically or as needed at certain points or a certain vertical
distances. Typically, a shelf angle can be installed at every
building floor or perhaps for every sixteen (16) feet of vertical
rise. A shelf angle performs a similar function as a lintel
performs above an opening in the wall structure. A shelf angle is
secured to a structural member and then bears the load of bricks,
or other modular building components, placed above the shelf angle.
A shelf angle can be fashioned from the same or similar members as
a lintel as described above. A "head joint" is also formed between
adjacent building components at the top of each shelf angle.
[0047] Either a lintel or a shelf angle creates a horizontal
interruption in the otherwise uninterrupted wall structure of the
exterior veneer. For purposes of this application, the term "angle"
is used to describe both the lintel, as typically used above
openings in wall structures, such as windows and doors, and the
shelf angle, as typically used in periodic vertical increments in
otherwise uninterrupted wall structures. References hereinafter
referring to a lintel apply equally well to a shelf angle. For
purposes of this application, discussion related to draining of
moisture, or related activity, from head joints refers to both head
joints occurring at lintels and to similar joints occurring at
shelf angles.
[0048] FIG. 1 is a front elevation view of a building 2 having wall
system 10 constructed in accordance with an embodiment of the
present invention. Building 2 has a door opening 4 and four window
openings 22. At the top edge of door opening 4 and each window
opening 22, lintel 24 provides structural support for bricks 20.
Lintels 24 are used at horizontal interruptions in wall system 10
created by door opening 4 and window openings 22. Additionally,
shelf angles 6 are placed in periodic vertical distances on wall
system 10. Shelf angles 6 also provide structural support for
bricks 20.
[0049] FIG. 2 illustrates a partially constructed brick veneer wall
system 10 utilizing an embodiment of the present invention. Wall
system 10 is constructed from a structural wall 12, in this case
using commonly available concrete blocks 14. Structural wall 12 may
be reinforced with reinforcing rods 16. An exterior veneer wall 18
is constructed on the exterior side of structural wall 12. Veneer
wall 18 is constructed conventionally from modular building
products, such as bricks 20.
[0050] Window opening 22 is formed into wall system 10. Lintel 24
is placed at the top edge of window opening 22 and secured to
structural wall 12. Drip plate 26 can be placed directly on top of
lintel 24 as an aid in preventing moisture from draining back along
the underside of lintel 24 into wall structure 10. "Z-shaped"
flashing 28 is then placed above lintel 24 and drip plate 26 to
direct moisture which may exist in wall structure 10 to the
exterior of wall structure 10 to prevent that moisture from
entering window opening 22. Veneer wall 18 can then continue to be
constructed above window opening 22 with lintel 24 supporting the
weight of bricks 20.
[0051] As bricks 20 are laid in the construction of veneer wall 18,
mortar 30 is placed between adjacent bricks 20, both vertically and
horizontally. While flashing 28 is designed to direct moisture
which may exist in wall structure of above window opening 22 to the
exterior; it has been found that mortar 30 may inhibit that
function. Mortar 30 may mostly or completely fill the space between
bricks 20 and leave little of no room for moisture otherwise
directed by flashing 28 to escape to the exterior of wall system
10.
[0052] Spacer 32 is placed between horizontally adjacent bricks 20
on top of flashing 28 to provide prevent mortar 30 from completely
filling the space between adjacent bricks 20 and creating a channel
allowing moisture from wall system 10 to be properly directed to
the exterior by flashing 28.
[0053] Spacer 32 is more clearly illustrated in FIG. 3 and FIG. 4.
In a preferred embodiment, spacer 32 has a solid top surface 34
intended to substantially block mortar 30 from occupying the space
created below top surface 34. Top surface 34 is approximately 3/8
inch (0.95 centimeters) wide. Side edges 36 provide support for top
surface 34 to be spaced away from flashing 28 and provide space for
drainage. Sides edges 36 have a height of approximately 3/8 inch
(0.95 centimeters) high. Top surface 34 has a front edge 38
intended to flush with, or nearly flush with, the front edge of
mortar 30 between bricks 20. The length of spacer 32 preferably is
approximately to the depth of mortar 30 placed between adjacent
bricks 20. The width of top surface 34 of spacer 32 is
approximately equal to the width of mortar 30 forming a mortar
joint between adjacent bricks 20. Spacer 32 will preferably fill
the width of the mortar 30 joint between tow adjacent bricks 20.
The height of side walls 36 of spacer 32 is enough to allow
moisture to drain through a channel formed by the underside of top
surface 34 and the interior of side edges 36. Preferably, the
height of side walls 36 is approximately equal to the width of top
surface 34.
[0054] FIG. 5 is a close-up frontal view of spacer 32 installed as
a head joint weep in wall system 10 above window opening 22. Bricks
20 are set side by side on lintel 24 with mortar 30 forming a
mortar joint between bricks 20. Mortar 30 also forms a mortar joint
between side by side bricks 20 and brick 20 set above the side by
side bricks. Spacer 32 is installed between bricks 20 with the
bottom of side edges 36 resting on flashing 38 just above lintel
24. Mortar 30 is preventing from filling the entire joint between
bricks 20 by top surface 34 of spacer 32 creating a weep hole 40
below top surface 34 and between side edges 36.
[0055] Wall system 10 seen from the front in FIG. 5 shows that
front edge 38 of top surface 34 of spacer 32 is visible. The
visibility of spacer 32 can be diminished by matching the color of
front edge 38 of spacer 32 with the color of mortar 30. Spacer 30
then blends in with mortar 30 and, hence, is less visible.
[0056] Side edges 36 are angled, or tapered, away from front edge
38 of top surface 34. Such tapering or angling provides several
advantageous benefits. One benefit is that side edges 36 are not as
visible a front exterior view of wall system helping to diminish
the visibility of spacer 32. Further, tapering or angling of side
edges 36 at the rear of spacer 32 helps to ensure that any moisture
located toward the rear of veneer wall 18 above flashing 28 enter
weep hole 40 and be transported to the exterior of wall system 10.
In a preferred embodiment, side edges 36 of spacer 32 are angled
back from top surface 34 at both ends of spacer 32 allowing spacer
32 to be installed in either front to back orientation.
[0057] FIG. 6 shows a complete window opening 22 in wall system 10.
Spacers 32 are shown installed at five locations along header joint
formed by lintel 24. A spacer 32 is installed between bricks 20c
and 20d, between bricks 20d and 20a, between bricks 20a and 20b,
between bricks 20b and 20c and between bricks 20c and 20f.
[0058] Alternatively, it may not be necessary to install a spacer
32 between every one of bricks 20 along lintel 24. It is desired to
install enough spacers 32 so that adequate drainage is allowed
through weep holes 40 to drain moisture from wall system 10. For
example, it is possible not to install a spacer 32 between bricks
20d and 20a or between bricks 20b and 20e.
[0059] Spacer 32 can be constructed of polyvinylchloride, for
example, using conventional plastic molding techniques. In one
embodiment, spacer 32 is formed into a strip of spacer elements 42.
FIG. 7 illustrates spacers 32 in two strips formed from eight (8)
spacer elements 42 (four in each of the two strips). The two strips
are temporarily joined at the ends with bars 44.
[0060] Each spacer element 42 contains side edges 36 which are
angled back from top surface 34. A transverse groove serving as
break notch 46 is formed between each adjoining spacer element 42
and between bars 44 and spacer elements 42. Spacer elements 42 have
a longitudinal dimension such that an integral number of spacer
elements 42 can be used to form common depth dimensions for common
modular building components. For example, in a preferred
embodiment, each spacer element has a longitudinal dimension of
21/4 inches (5.7 centimeters). This allows two spacer elements 42
to form one spacer 32 having a length of 41/2 inches (11.4
centimeters) which is approximately equal to the width (depth) of
commonly available standard size of brick 20. Up to four (4) spacer
elements 42 can be used together to accommodate a veneer wall 18
thickness of up 9 inches (22.9 centimeters).
[0061] Details of the installation of spacers 32 to form head joint
drainage devices are illustrated in FIGS. 8 through 15. As shown in
FIG. 8, a steel lintel 24 is prepared with flashing 28. No mortar
30 is used on top of lintel 24 or flashing 28. Bar 44 is snapped
from spacers 32 (FIG. 9) and one or more spacer elements 42 are
separated by hand from the remainder of the spacer strip (if any).
The number of spacer elements 42 used corresponds to the depth of
the bricks into which the spacer 32 is to be placed. After a brick
20 is placed on lintel 24 (and flashing 28), spacer 32 is placed
(FIG. 10) beside brick 20 with top surface 34 facing up. A side
view of spacer 32 so placed is shown in FIG. 11. Note that spacer
32 has a length which is at least as great as the depth of brick
20. FIG. 12 illustrates two spacers 32 placed between three bricks
20 creating two weep holes 40. A bed of mortar 30 is spread
conventionally (FIG. 13) to the top of bricks 20 and mortar 30 is
tuck pointed in head joints between bricks 20 (FIG. 14). FIG. 15
illustrates the finished wall system 10 in a close-up detail at the
head joint at the top left corner of window opening 22. The mortar
30 has been tooled and brushed creating a professionally finished
wall veneer 18. Spacers 32 create weep holes 40 allowing moisture
in wall system 10 to drain from the wall at the top of the head
joint.
[0062] Although various embodiments of the present invention have
been described as being constructed from particular materials,
e.g., steel, plastic, polyvinylchloride, it is to be recognized and
understood that other materials could also be used.
[0063] While the present invention has been described through the
use of bricks as modular building products, it is to be recognized
and understood that other modular building products could also be
used such as concrete blocks or stone, either natural or
synthetic.
[0064] While top surface 34 of spacer 32 has been described as
being formed as a solid surface, it is to be recognized and
understood that other constructions are possible. For example, top
surface 34 could be a grid or mesh as long as such top surface 34
substantially prevents mortar 30 from penetrating top surface 34
and clogging weep hole 40.
[0065] Although side edges 36 have been described as being tapered
or angled back along each spacer element, it is to be recognized
and understood that other configurations are also possible and
contemplated. For example, side edges 36 need not be tapered or
angled back to achieve the functional result required. Further,
both ends of sides edges need not be tapered or angled back, i.e.,
perhaps side edges 36 may only to tapered or angled back from front
edge 38 of top surface. Additionally, it is not necessary that side
edges 36 be solid. Side edges could be formed from posts or other
structural elements designed to support top surface 34 from lintel
24/flashing 28 during tuck pointing of mortar 30.
[0066] While various embodiments of the invention have been
described as used in conjunction with lintel 24, it is to be
recognized and understood that such construction techniques,
structures and methods apply equally well to wall systems, head
joints and methods of drainage used in conjunction with shelf
angles.
[0067] Various modifications and alterations of this invention will
be apparent to those skilled in the art without departing from the
scope and spirit of this invention. It should be understood that
this invention is not limited to the illustrative embodiments set
forth above.
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