U.S. patent application number 13/801084 was filed with the patent office on 2014-09-18 for channel anchor with insulation holder and anchoring system using the same.
This patent application is currently assigned to MITEK HOLDINGS, INC.. The applicant listed for this patent is MITEK HOLDINGS, INC.. Invention is credited to Ronald P. Hohmann, JR..
Application Number | 20140260033 13/801084 |
Document ID | / |
Family ID | 51520925 |
Filed Date | 2014-09-18 |
United States Patent
Application |
20140260033 |
Kind Code |
A1 |
Hohmann, JR.; Ronald P. |
September 18, 2014 |
Channel Anchor with Insulation Holder and Anchoring System Using
the Same
Abstract
A channel anchoring system for cavity walls is disclosed and
includes a channel anchor and veneer tie. The anchoring system is
used in conjunction with building structures that have a masonry
construction veneer anchored to a steel stud frame or a masonry
backup wall. The channel anchoring system secures both the veneer
and the insulation to the framing or backup wall. The channel
anchor includes a pocket compartment for the insulation that
provides a non-invasive means for securing the insulation, thereby
maintaining the insulation integrity.
Inventors: |
Hohmann, JR.; Ronald P.;
(Hauppauge, NY) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
MITEK HOLDINGS, INC.; |
|
|
US |
|
|
Assignee: |
MITEK HOLDINGS, INC.
Wilmington
DE
|
Family ID: |
51520925 |
Appl. No.: |
13/801084 |
Filed: |
March 13, 2013 |
Current U.S.
Class: |
52/404.2 ;
52/404.4; 52/562 |
Current CPC
Class: |
E04B 1/7616 20130101;
E04B 1/4185 20130101 |
Class at
Publication: |
52/404.2 ;
52/562; 52/404.4 |
International
Class: |
E04B 1/76 20060101
E04B001/76; E04B 1/41 20060101 E04B001/41 |
Claims
1. A channel anchoring system for the interconnection of an inner
wythe and an outer wythe having a cavity therebetween, for use in
connection with a masonry inner wythe having insulation thereon,
the anchoring system comprising: a channel anchor mountable on the
inner wythe, the channel anchor comprising: a back plate having an
aperture therethrough for receiving attachment hardware; a front
plate having elongated slots for interconnection with a veneer tie,
the front plate substantially parallel to the back plate; a central
plate interconnecting the back plate and the front plate, the
central plate having a first face and a second face; and, a
compartment flange substantially parallel to the central plate, the
compartment flange adjacent the front plate and adapted to be set
at a predetermined distance from the inner wythe; attachment
hardware for attaching the channel anchor to the inner wythe; and,
a veneer tie adjustably mounted within the elongated slots.
2. The anchoring system of claim 1 wherein the channel anchor
further comprises an insulation compartment formed from the
compartment flange, the central plate first face and the central
plate second face, the insulation compartment configured to form a
tight fitting pocket for the securement of the insulation
therewithin.
3. The anchoring system of claim 2 wherein the outer wythe has a
plurality of courses of masonry units with bed joints therebetween,
and wherein the veneer tie further comprises: a buckle portion for
keyed interlocking within the elongated slots; an interconnecting
portion encased within the buckle portion; and, an insertion
portion contiguous with the interconnecting portion for insertion
within the bed joint of the outer wythe.
4. The anchoring system of claim 3 wherein the veneer tie further
comprises: a swaged side leg formed from the insertion portion;
and, a reinforcement wire disposed in the swaged side leg and
configured for disposition in the bed joint of the outer wythe.
5. The anchoring system of claim 2 wherein the insulation is
selected from a group consisting of rigid insulation, board
insulation, and spray-on insulation.
6. The anchoring system of claim 5 wherein the rigid insulation is
a rock-based mineral fiber insulation.
7. The anchoring system of claim 2 wherein the attachment hardware
is a fastener having a self-drilling portion for insertion within
the inner wythe and a fastener head contiguous with the
self-drilling portion with a dimension greater than the back plate
aperture.
8. A channel anchoring system for the interconnection of a masonry
veneer to an inner wythe of stud framing with drywall thereon, the
masonry veneer and inner wythe having a cavity and insulation
therebetween, the anchoring system comprising: a channel anchor
mountable on the inner wythe, the channel anchor comprising: a back
plate having an aperture therethrough for receiving a fastener; a
front plate having elongated slots for interconnection with a
veneer tie, the front plate substantially parallel to the back
plate; a central plate interconnecting the back plate and the front
plate, the central plate having a first face and a second face;
and, a compartment flange substantially parallel to the central
plate and adjacent the front plate, the compartment flange being
adapted to be set at a predetermined distance from the inner wythe
substantially coextensive with the depth of the insulation; a
fastener for attaching the channel anchor to the stud framing; and,
a veneer tie adjustably mounted within the elongated slots.
9. The anchoring system of claim 8 wherein the channel anchor
further comprises an insulation pocket formed by the compartment
flange, the central plate first face and the central plate second
face, the insulation pocket configured to form a tight fitting
pocket for the securement of the insulation therewithin.
10. The anchoring system of claim 9 wherein the masonry veneer has
a plurality of courses of masonry units with bed joints
therebetween, and wherein the veneer tie further comprises: a
buckle portion for keyed interlocking within the elongated slots;
an interconnecting portion encased within the buckle portion; and,
an insertion portion contiguous with the interconnecting portion
for insertion within the bed joint of the outer wythe.
11. The anchoring system of claim 10 wherein the veneer tie further
comprises: a swaged side leg formed from the insertion portion;
and, a reinforcement wire disposed in the swaged side leg and
configured for disposition in the bed joint of the outer wythe.
12. The anchoring system of claim 9 wherein the insulation is
selected from a group consisting of rigid insulation, board
insulation, and spray-on insulation.
13. The anchoring system of claim 12 wherein the rigid insulation
is a rock-based mineral fiber insulation.
14. The anchoring system of claim 9 wherein the fastener further
comprises a self-drilling portion for insertion within the stud
framing and a fastener head contiguous with the drilling portion
with a dimension greater than the back plate aperture.
15. A channel anchoring system for the interconnection of an inner
wythe and an outer wythe having a cavity therebetween, for use in
connection with a masonry inner wythe having insulation thereon,
the anchoring system comprising: a channel anchor mountable on the
inner wythe, the channel anchor comprising: a back plate having an
aperture therethrough for receiving a fastener; a front plate
having elongated slots for interconnection with a veneer tie, the
front plate substantially parallel to the back plate; a central
plate interconnecting the back plate and the front plate, the
central plate having a first face and a second face; a compartment
flange substantially parallel to the central plate, the compartment
flange adjacent the front plate, the compartment flange being
adapted to be set at a predetermined distance from the inner wythe
substantially coextensive with the depth of the insulation; and, an
insulation compartment formed from the compartment flange, the
central plate first face and the central plate second face, the
insulation compartment configured to form a tight fitting pocket
for the securement of the insulation therewithin; a fastener for
attaching the channel anchor to the inner wythe; and, a veneer tie
adjustably mounted within the elongated slots.
16. The anchoring system of claim 15 wherein the outer wythe has a
plurality of courses of masonry units with bed joints therebetween,
and wherein the veneer tie further comprises: a buckle portion for
keyed interlocking within the elongated slots; an interconnecting
portion encased within the buckle portion; and, an insertion
portion contiguous with the interconnecting portion for insertion
within the bed joint of the outer wythe.
17. The anchoring system of claim 16 wherein the veneer tie further
comprises: a swaged side leg formed from the insertion portion;
and, a reinforcement wire disposed in the swaged side leg and
configured for disposition in the bed joint of the outer wythe.
18. The anchoring system of claim 15 wherein the insulation is an
insulation panel having a semi-rigid, rectangular body.
19. The anchoring system of claim 18 wherein the rigid insulation
is a rock-based mineral fiber insulation.
20. The anchoring system of claim 15 wherein the fastener further
comprises: a self-drilling portion for insertion within the inner
wythe; and, a fastener head contiguous with the self-drilling
portion, the fastener head having a dimension greater than the back
plate aperture.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to an improved anchoring and
insulation arrangement for use in conjunction with building
structures having a masonry construction veneer anchored to steel
stud framing or a masonry backup wall. More particularly, the
invention relates to a channel anchoring system that secures both
the veneer and the insulation to the framing or backup wall without
compromising the insulation. The invention is applicable to
seismic-resistant structures and to structures requiring
insulation.
[0003] 2. Description of the Prior art
[0004] The move toward more energy-efficient insulated veneer wall
structures has led to the need to create a highly-insulated
building envelope, which separates the interior environment and the
exterior environment of a cavity wall structure. The building
envelope is designed to control temperature changes, while
maintaining structural integrity. Thermal insulation is used within
the building envelope to maintain temperature and therefore
restrict the formation of condensation within the cavity. High
R-value thermal insulation that is secured to the backup wall or
framing is essential to maintaining an energy-efficient building
structure. The present invention provides a non-invasive
compartment for insulation installation, while simultaneously
providing a fast track anchoring channel to interconnect with a
veneer tie for embedment in the mortar joints of the masonry
veneer.
[0005] The present anchoring system provides a secure insulation
compartment for rigid, batt, board, spray-on and, in particular,
Roxul.RTM. insulation. Roxul.RTM. insulation is a common choice of
insulation in commercial construction. Roxul.RTM. is a rock-based
mineral fiber insulation comprised of basalt rock and recycled slag
which are melted together and spun into fibers and complies with
the greater insulation requirements imposed by government
standards. It is commonly referred to as stone wool. Roxul.RTM.
products are corrosion resistant, moisture and mold resistant, fire
resistant, energy efficient, and minimize thermal bridging. The
structural nature of the Roxul.RTM. insulation combined with the
anchor insulation compartment of this invention, provide a secure
insulation attachment to the backup wall or framing.
[0006] In the past, anchoring systems have taken a variety of
configurations. Where the applications included masonry backup
walls, wall anchors were commonly incorporated into ladder--or
truss-type reinforcements and provided wire-to-wire connections
with box-ties or pintle-receiving designs on the veneer side. In
the late 1980's, surface-mounted wall anchors were developed by
Hohmann & Barnard, Inc., now a MiTek-Berkshire Hathaway
Company, and patented under U.S. Pat. No. 4,598,518. The invention
was commercialized under trademarks DW-10.RTM., DW-10-X.RTM., and
DW-10-HS.RTM.. 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.RTM.
Seismiclip.RTM. interlock system which added a Byna-Tie.RTM. wire
formative, a Seismiclip.RTM. snap-in device--described in U.S. Pat.
No. 4,875,319 (319), and a continuous wire reinforcement.
[0007] 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 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--became necessary.
[0008] 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.
[0009] 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.
[0010] There have been significant shifts in public sector building
specifications, such as the Energy Code Requirement, Boston, Mass.
(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, which have resulted in
architects and architectural engineers requiring larger and larger
cavities in the exterior cavity walls of public buildings. These
requirements are imposed without corresponding decreases in wind
shear and seismic resistance levels or increases in mortar bed
joint height. Thus, wall anchors are needed to occupy the same
3/8-inch high space in the inner wythe and tie down a veneer facing
material of an outer wythe at a span of two or more times that
which had previously been experienced.
[0011] As insulation became thicker, the tearing of insulation
during installation of the pronged DW-10X.RTM. wall anchor, see
infra, 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.
[0012] As concerns for insulation integrity grow, the ability to
install high R-value thermal insulation, without breaching the
insulation with a fastener or anchor, becomes an essential part of
the construction process. The present invention provides a response
by offering a pocket component formed by the anchors for
insulation, which secures the insulation to the backup wall or
framing without piercing the insulation or degrading the insulative
properties.
[0013] In the course of preparing this application, several
patents, became known to the inventors hereof and are acknowledged
hereby:
TABLE-US-00001 Patent Inventor Issue Date 4,703,604 Muller Nov. 3,
1987 4,869,038 Catani Sep. 26, 1989 5,063,722 Hohmann Nov. 12, 1991
5,671,578 Hohmann Sep. 20, 1997 7,059,577 Burgett Jun. 13, 2006
7,481,032 Tarr Jan. 27, 2009 7,562,506 Hohmann, Jr. Jul. 21, 2009
8,122,663 Hohmann, Jr., et al. Feb. 28, 2012 8,215,083 Toas et al.
Jul. 10, 2012
[0014] [U.S. Pat. No. 4,703,604--Muller--Issued Nov. 3, 1987
Discloses a method of building a structure formed from a masonry
wall with an outer face carrying frame members, insulation and
sheathing. The insulation is fitted between the frame members and
against the brace panel with the anchors fixed to the insulation
and framework with the stems of the anchor projecting away from the
panel and past the insulation.
[0015] U.S. Pat. No. 4,869,038--Catani--Issued Sep. 26, 1989
Discloses a veneer wall anchoring system that interconnects a
backup wall of block construction with a brick veneer wall. A wall
of rigid insulation is placed against an outer face of the backup
wall with the plates extending through the insulation. The plate
includes a spring clip fastener which engages the insulation
wall.
[0016] U.S. Pat. No. 5,063,722--Hohmann--Issued Nov. 12, 1991
Discloses a gripstay channel veneer anchor assembly that engages an
insulation layer and the inner wythe. A clip securement projects
through the channel, pierces the insulation and engages the support
member.
[0017] U.S. Pat. No. 5,671,578--Hohmann--Issued Sep. 30, 1997
Discloses a surface-mounted seismic construction system. The system
includes a wire formative anchor and box tie. The anchor includes a
seismic clip and reinforcement wire and the anchor eye portions are
oriented to secure the insulation panels which are protected by
insulation shields
[0018] U.S. Pat. No. 7,059,577--Burnett--Issued Jun. 13, 2006
Discloses an insulated concrete wall system. The system includes
insulation panels which are secured by t-shaped wall studs. The
wall studs are anchored within the concrete.
[0019] U.S. Pat. No. 7,481,032--Tarr--Issued Jan. 27, 2009
Discloses a stud system for supporting spray insulation to a
concrete structure. The stud includes a laterally extending web to
promote adherence of the insulation.
[0020] U.S. Pat. No. 7,562,506--Hohmann, Jr.--Issued Jul. 21, 2009
Discloses a notched, surface-mounted wall anchor and anchoring
system. The folded sheetmetal anchor includes a notch that, upon
surface-mounting, form small wells in the portion of the notch
extending into the insulation to entrain water vapor, condensate
and water to prevent entry into the wallboard.
[0021] U.S. Pat. No. 8,122,663--Hohmann, Jr. et al.--Issued Feb.
28, 2012 Discloses an anchor and reinforcement device for a cavity
wall. The device interlocks with a veneer anchor and veneer
reinforcements. The system is composed of wire formatives. The wall
anchor and reinforcement devices are compressively reduced in
height to span insulation mounted on the exterior of the backup
wall.
[0022] U.S. Pat. No. 8,215,083--Toas et al.--Issued--Jul. 10, 2012
Discloses a unitary building exterior envelope product that
includes a mineral fiber insulation board. The product is mounted
to exterior wall framing members.
[0023] None of the prior art listed above provide a channel
anchoring system that secures both the veneer and the insulation to
the framing or backup wall without impacting the insulation and its
insulative properties. As will become clear in reviewing the
disclosure which follows, the cavity wall structures benefit from
the recent developments described herein that lead to solving the
problems of maintaining thermal insulation within the cavity wall.
The wall anchor assembly provides a novel pocket compartment for
securing the insulation without the use of fasteners that perforate
the insulation. The prior art does not provide the present novel
cavity wall construction system as described herein below.
SUMMARY
[0024] In general terms, an embodiment of the invention disclosed
hereby is a channel anchoring system for use in a cavity wall
having a masonry veneer and an inner wythe or backup wall of stud
framing or masonry units. The wall anchor and veneer tie secures
the veneer and the insulation to the backup wall without
compromising the insulation integrity. The veneer ties are wire
formatives configured for insertion within the wall anchor channels
and the bed joints of the outer wythe. The veneer ties are
optionally compressed forming a low profile construct and swaged
for interconnection with a reinforcement wire to form a seismic
construct.
[0025] The channel anchor and anchoring system secures insulation
in a pocket within a compartment formed by the consecutive channel
anchors. The channel anchor includes a back plate, which is affixed
to the backup wall by a fastener, a front plate, which includes
elongated slots for interconnection with a veneer tie, a central
plate, which interconnects the front and back plates and a
compartment flange. The central plate contains a first and a second
face.
[0026] A novel insulation compartment is formed from the
compartment flange, the central plate first face and the central
plate second face of adjacent channel anchors. The insulation
compartment is configured to form a tight fitting pocket for the
securement of the insulation therewithin. The insulation is secured
within the compartment without any ripping or tearing of the
insulation, thereby maintaining the insulation integrity. The
insulation for use with the anchoring system is rigid insulation,
board insulation, spray-on insulation, and the like. Rock-based
mineral fiber insulation or Roxul.RTM. is specifically included in
the embodiments.
[0027] The channel anchoring system includes a wire formative
veneer tie with the interconnecting portion of the veneer tie
encased within a buckle for adjustable mounting within the channel
anchor elongated slots. The veneer tie insertion portion is secured
within the bed joint of the outer wythe. A veneer tie having a
swaged side leg with an optional reinforcement wire set therewithin
is for use with a seismic system.
[0028] It is an object of the present invention to provide new and
novel anchoring systems for building structures, which systems
secure insulation.
[0029] It is another object of the present invention to provide a
new and novel high-strength channel anchoring system which provides
a compartment to secure insulation therewithin.
[0030] It is yet another object of the present invention to provide
an anchoring system for a wall having a masonry construction veneer
anchored to steel stud framing or a masonry backup wall.
[0031] It is still yet another object of the present invention to
provide an anchoring system which is constructed to secure both the
veneer and the insulation to the framing or backup wall.
[0032] It is a feature of the present invention that the channel
anchor hereof provides a securement compartment that houses a
portion of the Roxul.RTM. insulation within the anchor, without
tearing or puncturing the insulation.
[0033] It is another feature of the present invention that the wall
anchor is utilizable with a veneer tie that is secured within the
bed joints of the veneer.
[0034] It is another feature of the present invention that the
anchoring system is for use with a seismic or non-seismic
structure.
[0035] Other objects and features of the invention will become
apparent upon review of the drawings and the detailed description
which follows.
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] In the following drawings, the same parts in the various
views are afforded the same reference designators.
[0037] FIG. 1 is a perspective view of the first embodiment of this
invention with an anchoring system having a channel anchor and
veneer tie inserted therein, as applied to a cavity wall with a
backup wall of masonry construction with insulation disposed on the
cavity-side thereof and within the channel anchor compartments and
a veneer of brick;
[0038] FIG. 2 is a perspective view of the anchoring system of FIG.
1 showing Roxul.RTM. insulation set within the channel anchor
compartment;
[0039] FIG. 3 is a perspective view of the anchoring system of FIG.
1 showing a fully constructed backup wall with the channel
anchoring system affixed thereon with Roxul.RTM. insulation set
within the channel anchor compartment and veneer ties inserted
within the channels and secured within the masonry veneer;
[0040] FIG. 4 is a perspective view of the anchoring system of FIG.
1 having veneer ties set within the channel;
[0041] FIG. 5 is a front view of an alternative channel anchor;
[0042] FIG. 6 is a perspective view of an alternative channel
anchor with Roxul.RTM. insulation set within the channel
compartment;
[0043] FIG. 7 is a perspective view of the second embodiment of
this invention with an anchoring system having a channel anchor and
veneer tie inserted therein, as applied to a structure having
interior framing with insulation disposed on the framing-side
thereof and within the channel anchor compartments and a veneer of
brick;
[0044] FIG. 8 is a top plan view of the anchoring system of FIG. 7
with the anchoring system secured to the backup wall with
insulation secured within the channel compartment and having a
veneer tie emplaced on the bed joint of the veneer; and,
[0045] FIG. 9 is a cross-sectional view of the anchoring system of
FIG. 7 secured to the backup wall with insulation secured within
the channel compartment and having a veneer tie set within the
channel and secured within the outer wythe.
DETAILED DESCRIPTION
[0046] Before entering into the Detailed Description, 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 deficits of the prior art
devices.
[0047] In the embodiments described hereinbelow, the inner wythe is
provided with insulation. In both the dry wall stud framing
construction inner wythe and in the masonry block inner wythe, the
insulation is applied to the outer surface thereof. 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 infiltration of air and moisture. The term as
used herein is defined in the same sense as the building code in
that, "insulation integrity" means that, after the installation of
the anchoring system, there is no change or interference with the
insulative properties and concomitantly that there is substantially
no change in the air and moisture infiltration characteristics.
[0048] Anchoring systems for cavity walls are used to secure veneer
facings to buildings and overcome seismic and other forces, i.e.
wind shear, etc, while ensuring insulation integrity. In the past,
some systems have experienced insulation tearing which results in
the loss of insulation integrity. In the present invention,
insulation integrity is preserved because the insulation is secured
in a non-invasive manner, within pockets without causing any
perforations in the insulation.
[0049] 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 (1) maximizing the strength and ease of the securement of
the wall anchor to the inner wythe; and, (2) as previously
discussed, maintaining the integrity of the insulation. The first
concern is addressed using appropriate fasteners such as
self-drilling fasteners for mounting to metal, drywall studs or
directly into the masonry. The latter concern is addressed through
the use of the novel insulation pocket which secures the insulation
to the inner wythe without the use of any invasive fasteners. In
the prior art, the metal anchors and fasteners pierced the
insulation causing a loss of insulative integrity.
[0050] Referring now to FIGS. 1 through 6, the first embodiment
shows a channel anchoring system for use with a masonry inner wythe
or backup wall. This anchoring system, discussed in detail
hereinbelow, has a channel anchor, an interengaging veneer tie and
attachment hardware. For the first embodiment, a cavity wall having
an insulative layer of 4.0 inches (approx.) and a total span of
4.75 inches (approx.) is chosen as exemplary.
[0051] The anchoring system for cavity walls is referred to
generally by the numeral 10. A cavity wall structure 12 is shown
having a masonry inner wythe or masonry backup 14 and an outer
wythe or facing 18 of brick 20 construction. Inner wythes
constructed of wood or steel stud framing (not shown) are also
applicable. Between the inner wythe 14 and the outer wythe 18, a
cavity 22 is formed. The cavity 22 has attached to the exterior
surface 24 of the inner wythe 14 insulation 26. The insulation 26
shown is rigid insulation commonly known as Roxul.RTM. insulation
which is rock-based mineral fiber insulation, but is applicable to
other forms including board insulation, rigid insulation and
spray-on insulation. Optionally, an air/vapor barrier (not shown)
is included between the insulation 26 and the exterior surface 24
of the inner wythe 14.
[0052] Successive bed joints 30 and 32 are substantially planar and
horizontally disposed and, in accord with current building
standards, are 0.375-inch (approx.) in height. Selective ones of
bed joints 30 and 32, which are formed between courses of bricks
20, are constructed to receive therewithin the insertion portion of
the veneer anchor. Being mounted on the inner wythe 14, the channel
anchor or wall anchor 40 is supported thereby and, as described in
greater detail herein below, is configured to secure insulation 26
and the outer wythe 18 to the inner wythe 14.
[0053] For purposes of discussion, the cavity surface 24 of the
inner wythe 14 contains a horizontal line or x-axis 34 and
intersecting vertical line or y-axis 36. A horizontal line or
z-axis 38, normal to the xy-plane, passes through the coordinate
origin formed by the intersecting x- and y-axes. A wall anchor 40,
while shown as a unitary structure in FIG. 1, may be manufactured
as an assemblage of several wall anchors 40 (see FIG. 6).
[0054] The veneer tie 44 is a wire formative. The veneer tie 44
includes an interconnecting portion 74 encased within a buckle
portion 55 and is adjustably mounted within the elongated slots 57
of the channel anchor 40. The veneer tie 44 insertion portion 76 is
shown in FIGS. 1 and 2 as being emplaced on a course of bricks 20
in preparation for embedment in the mortar of bed joint 32. In this
embodiment, the system is not shown with a wire or outer wythe
reinforcement, however, the veneer tie 144 and the wire formative
reinforcement 146 shown in FIG. 9 are incorporated by reference
herewithin. The veneer tie 144 insertion portion 176 contains a
swaged side leg 182 formed from the insertion portion 176. The
reinforcement 146 is disposed in the swaged side leg 182 and
disposed in the bed joint 132 of the outer wythe 118.
[0055] The channel anchor 40 includes a back plate 62 that is
secured to the inner wythe 14 by a fastener 48 inserted through the
back plate aperture 60. A central plate 64 interconnects the back
plate 62 and the front plate 66. The back plate 62 and the front
plate 66 are substantially parallel the one to the other. The front
plate 66 contains elongated slots 57 for interconnection with the
veneer tie 44. The central plate includes a first face 65 and a
second face 67. A compartment flange 69 is substantially parallel
to the central plate 64 and adjacent the front plate 66. The
compartment flange 69 is set at a predetermined distance from the
inner wythe 14, which distance is substantially equivalent to the
depth of the insulation 26.
[0056] The channel anchor 40 includes an insulation compartment 63
that is formed from the compartment flange 69, the central plate
first face 65 and the central plate second face 67. The insulation
compartment 63 forms a tight fitting pocket 61 to secure the
insulation 26 therewithin. When the insulation 26 is board or
rigid, the insulation 26 is first seated against the first face 65
and pushed against the second face 67 of an adjacent channel anchor
40. This method of installation and use of the pocket 61, ensures a
tight fit of the insulation 26 and an installation of the
insulation 26 that does not tear or otherwise adversely impact the
insulation integrity.
[0057] At intervals along the horizontal surface 24, wall anchors
40 are secured to the inner wythe 14 by attachment hardware or
fasteners 48. The fastener 48 has a self-drilling portion 50 for
insertion in the inner wythe 14 and a fastener head 49 that is
contiguous with the self-drilling portion 50. The fastener head 49
has a dimension greater than the back plate aperture 60.
[0058] The description which follows is a second embodiment of the
anchoring system for insulated cavity walls of this invention. For
ease of comprehension, wherever possible similar parts use
reference designators 100 units higher than those above. Thus, the
veneer tie 144 of the second embodiment is analogous to the veneer
tie 44 of the first embodiment. Referring now to FIGS. 7 through 9,
the second embodiment of the anchoring system is shown and is
referred to generally by the numeral 110. As in the first
embodiment, a wall structure 112 is shown. The second embodiment
has an inner wythe or backup wall 114 with sheetrock or wallboard
116 mounted on metal studs or columns 117 and an outer wythe or
facing wall 118 of brick 120 construction Inner wythes constructed
of masonry materials or wood framing (not shown) are also
applicable. Between the inner wythe 114 and the outer wythe 118, a
cavity 122 is formed. The cavity 122 has attached to the exterior
surface 124 of the inner wythe 114 insulation 126. The insulation
126 shown is rigid insulation commonly known as Roxul.RTM.
insulation which is a rock-based mineral fiber insulation, but is
applicable to other forms including board insulation, rigid
insulation and spray-on insulation. Optionally, an air/vapor
barrier (not shown) is included between the insulation 126 and the
exterior surface 124 of the inner wythe 114.
[0059] Successive bed joints 130 and 132 are substantially planar
and horizontally disposed and, in accord with current building
standards, are 0.375-inch (approx.) in height. Selective ones of
bed joints 130 and 132, which are formed between courses of bricks
120, are constructed to receive therewithin the insertion portion
of the veneer tie 144. Being mounted on the inner wythe 114, the
channel anchor or wall anchor 140 is supported thereby and, as
described in greater detail herein below, is configured to secure
insulation 126 and the outer wythe 118 to the inner wythe 114.
[0060] For purposes of discussion, the cavity surface 124 of the
inner wythe 114 contains a horizontal line or x-axis 134 and
intersecting vertical line or y-axis 136. A horizontal line or
z-axis 138, normal to the xy-plane, passes through the coordinate
origin formed by the intersecting x- and y-axes. A wall anchor 140,
while shown as a unitary structure in FIG. 9, may be manufactured
as an assemblage of several wall anchors 140 (see FIG. 6).
[0061] The veneer tie 144 is a wire formative. The veneer tie 144
includes an interconnecting portion 174 encased within a buckle
portion 155 and is adjustably mounted within the elongated slots
157 of the channel anchor 140. The veneer tie 144 insertion portion
176 is shown in FIGS. 7, 8 and 9 as being emplaced on a course of
bricks 120 in preparation for embedment in the mortar of bed joint
132. In this embodiment, the system is shown as a seismic system
with a wire or outer wythe reinforcement 146, however, the veneer
tie 44 shown in FIG. 1 is incorporated by reference herewithin as
an alternative design veneer tie 44. The veneer tie 144 insertion
portion 176 contains a swaged side leg 182 formed from the
insertion portion 176. The reinforcement 146 is disposed in the
swaged side leg 182 and disposed in the bed joint 132 of the outer
wythe 118.
[0062] The channel anchor 140 includes a back plate 162 that is
secured to the inner wythe 114 by a fastener 148 inserted through
the back plate aperture 160. A central plate 164 interconnects the
back plate 162 and the front plate 166. The back plate 162 and the
front plate 166 are substantially parallel the one to the other.
The front plate 166 contains elongated slots 157 for
interconnection with the veneer tie 144. The central plate includes
a first face 165 and a second face 167. A compartment flange 169 is
substantially parallel to the central plate 164 and adjacent the
front plate 166. The compartment flange 169 is set at a
predetermined distance from the inner wythe 114, which distance is
substantially equivalent to the depth of the insulation 126.
[0063] The channel anchor 140 includes an insulation compartment
163 that is formed from the compartment flange 169, the central
plate first face 165 and the central plate second face 167. The
insulation compartment 163 forms a tight fitting pocket 161 to
secure the insulation 126 therewithin. When the insulation 126 is
board, rigid, or semi-rigid rectangular insulation 126 the
insulation 126 is first seated against the first face 165 and
pushed against the second face 167 of an adjacent channel anchor
140. This method of installation and use of the pocket 161 ensures
a tight fit of the insulation 126 and an installation of the
insulation 126 that does not tear or otherwise adversely impact the
insulation integrity.
[0064] At intervals along a horizontal surface 124, wall anchors
140 are secured to the inner wythe 114 by attachment hardware or
fasteners 148. The fastener 148 has a self-drilling portion 150 for
insertion in the inner wythe 114 and a fastener head 149 that is
contiguous with the self-drilling portion 150. The fastener head
149 has a dimension greater than the back plate aperture 160.
[0065] In the above description of channeled anchoring systems for
insulated cavity walls of this invention various configurations are
described and applications thereof in corresponding settings are
provided. Because 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. Thus minor
changes may be made without departing from the spirit of the
invention.
* * * * *