US20050246994A1 - Preshaped form - Google Patents
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- US20050246994A1 US20050246994A1 US10/679,720 US67972003A US2005246994A1 US 20050246994 A1 US20050246994 A1 US 20050246994A1 US 67972003 A US67972003 A US 67972003A US 2005246994 A1 US2005246994 A1 US 2005246994A1
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- United States
- Prior art keywords
- plaster
- members
- relief
- channel
- wire
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B44—DECORATIVE ARTS
- B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
- B44C5/00—Processes for producing special ornamental bodies
- B44C5/04—Ornamental plaques, e.g. decorative panels, decorative veneers
- B44C5/0461—Ornamental plaques, e.g. decorative panels, decorative veneers used as wall coverings
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C5/00—Reinforcing elements, e.g. for concrete; Auxiliary elements therefor
- E04C5/01—Reinforcing elements of metal, e.g. with non-structural coatings
- E04C5/02—Reinforcing elements of metal, e.g. with non-structural coatings of low bending resistance
- E04C5/04—Mats
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F13/00—Coverings or linings, e.g. for walls or ceilings
- E04F13/02—Coverings or linings, e.g. for walls or ceilings of plastic materials hardening after applying, e.g. plaster
- E04F13/04—Bases for plaster
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F13/00—Coverings or linings, e.g. for walls or ceilings
- E04F13/02—Coverings or linings, e.g. for walls or ceilings of plastic materials hardening after applying, e.g. plaster
- E04F13/04—Bases for plaster
- E04F13/06—Edge-protecting borders
- E04F13/068—Edge-protecting borders combined with mesh material or the like to allow plaster to bond therewith
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F13/00—Coverings or linings, e.g. for walls or ceilings
- E04F13/02—Coverings or linings, e.g. for walls or ceilings of plastic materials hardening after applying, e.g. plaster
- E04F13/04—Bases for plaster
- E04F13/06—Edge-protecting borders
- E04F2013/063—Edge-protecting borders for corners
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F19/00—Other details of constructional parts for finishing work on buildings
- E04F19/02—Borders; Finishing strips, e.g. beadings; Light coves
- E04F19/04—Borders; Finishing strips, e.g. beadings; Light coves for use between floor or ceiling and wall, e.g. skirtings
- E04F2019/0404—Borders; Finishing strips, e.g. beadings; Light coves for use between floor or ceiling and wall, e.g. skirtings characterised by the material
- E04F2019/0418—Borders; Finishing strips, e.g. beadings; Light coves for use between floor or ceiling and wall, e.g. skirtings characterised by the material of stone or stone like material, e.g. ceramics, concrete; of glass
Landscapes
- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Finishing Walls (AREA)
Abstract
A prefabricated relief form member for use as an architectural feature on a structure formed alternatively by use of welded wire mesh, double wire welded wire mesh, corner beads fixed together, or woven wire mesh and optionally using corner beads at the corners of the top and sides, and having backing paper.
Description
- This application is a continuation of patent application Ser. No. 441,251, filed May 15, 1995, issued as U.S. Pat. No. 5,685,116 on Nov. 11, 1997, which is a continuation of patent application Ser. No. 222,826 filed Apr. 5, 1994 now abandoned. The contents of the two prior applications are incorporated herein by reference.
- 1. Field of the Invention
- The invention relates to prefabricated, light-weight, plaster relief forms to provide quick, low cost, installation of support members for constructing plaster coated decorative “plant-on's” or “bump-outs” to the outside walls of dwelling structures.
- 2. Previous Art
- Ornamentation and decoration of building structures such as residences and businesses is one important aspect of architecture. Marketing and sale of residences is enhanced by additional decorative detail. Pride of ownership is also enhanced by improved appearance of one's building or residence. Ornamentation and decorative details are used extensively to add desirability and attractiveness to structures.
- In certain regions of the country, such as the West and Southwest, the homes in the Mission style, and the Mediterranean style are quite popular. One of the popular methods of ornamentation used for these styles of homes is referred to in the building trades as “plant-ons” or “bump-outs”. The plant-ons may extend for a considerable length along the horizontal or vertical dimension of a wall or walls of a home or business. The plant-ons add a band or bands of relief to an otherwise blank facade that is presented by an unbroken expanse of plaster or stucco. The bands may extend completely around the outside perimeter of a building. For a conventional home of 2500 sq. ft., this may amount to 300-500 ft of bands for one single layer. The support for these bands are generally made of overlapping wooden boards including a first layer of 2×12 inches and a second layer of 2×8 inches. The boards are placed end to end in standard lengths of 8 to 12 ft to create a continuous relief band around the home. Similar bands may be constructed around door and window openings.
- Attractive relief borders around windows and doors are also used to provide enhancements to the architecture of homes and buildings. Such window and door borders have been constructed using the above methods and materials.
- These features are not necessary to the structural integrity of the building, but do add a pleasing visual aesthetic appearance to a home or business.
- One example of architectural relief products for attachment to homes are pre-shaped foam members such as cornices, bases, sills and balusters, for example, supplied by High Tech Foam Products, Inc of Corona, Calif. Foam members may be provided in a wide variety of shapes and sizes. The disadvantage of these members as supports for relief bands include the expense of the items themselves, on the order of $5 to $6 per linear foot, and the additional labor and material involved in adding a layer of screening or lath material over the foam to provide a matrix for the plaster to adhere.
- A conventional method of construction of plant-ons uses one or more planks of overlapping boards attached to a wall at a particular height. To achieve a continuous band or strip of relief, multiple lengths of uniform cross section boards are aligned end to end and attached to the studs of a prepared wall. For conventional construction, the studs must be no more than 24 inches on center, or less, according to the applicable local, state or national building codes. The attachment is done with hammer driven nails, power gun driven nails, large staple guns or the like. The boards are attached to the wall prior to the application of a plaster coat or coats and prior to the application of a lath sheeting which will form a matrix or lattice for supporting the plaster when it is applied. The lath is conventionally made of chicken wire or expanded metal and attached with nails, staples or the like. The lath sheeting may be suspended away from the wall and boards by a furring strip or strips interposed between the surface of the wall and the sheeting. Self furred sheeting or wire may also be used to maintain the spacing between the wall and the sheeting. An example of such wire is self furred metal lath made by California Expanded Metal Products Company of Industry, Calif. “Dimpled” or ribbed type self furring metal lath provides a 1/4 inch indentation in the metal lath to hold it away from the wall allowing the plaster to fill the space between, insuring the lath is embedded. The spacing between the lath and the wall or boards provides the opening for the plaster coat to surround the lath and thereby bond firmly to the wall. A moisture barrier layer, of building paper, for example, is applied between the boards and the lath sheeting by means of staples, nails, an adhesive coating or the like.
- The boards provide the relief pattern or bump-out desired. Additional screening is cut and shaped by hand to conform to the protruding bump-out and nailed or stapled to the boards and the wall.
- Plaster is then applied to the bump-out and the wall to form the finished surface.
- With reference to
FIG. 10A , there is shown a schematic diagram of an exploded view of one previous art method of assembly for a manually fabricated plaster relief form as described above. A plurality of boards of desired width with the same cross section are aligned end to end and nailed to the prepared wall to form a continuous plaster relief band to the desired length. Additional lengths of wire screen or lath sections may be placed over the boards and formed by hand to the contour of the boards. The additional sections are then typically nailed in place.FIG. 10B illustrates a cross section of such a relief form having a board attached to a stud framed wall. A layer of moisture barrier paper and metal screen or lath are typically placed against the wall and attached by nails to the studs. A plurality of spacers, such as furring strips or dimples in the additional screen sections, are provided between the boards and the additional wire screen sections to allow the subsequent plaster layer to flow into the openings of the wire screen sections and fill the space between the screens and the top of the boards. Plaster is then typically applied by hand using a hawk and trowel method or applied with a nozzle connected to a machine as described above. - With reference to
FIG. 10C , an additional improvement to the previous art method is shown. Guide edge members are attached, typically by nailing into the form boards, to the edges of the wire screen sections over the plaster form boards. The guide edges are spaced apart from and aligned to be parallel with the plaster form boards. The guide edge members provide a guide to the trowel or plaster dispensing nozzle as the plaster is applied, thereby allowing a uniform depth of plaster to be applied easily. Representative guide edge members used in the trade are made from 14 gauge wire such as the “CEMCORNER” corner reinforcement made by Cemco, Covina Lane, Calif. Or the “CornerAid” cover nose wire made by Stockton Products, Burbank, Calif. - The above-described method requires a number of hand operations, such a nailing the boards, cutting the additional wire screen sections, hand forming the screen sections over the boards and attaching the guide edge members, which significantly increases the cost of applying plaster relief bands. It would be an advantage to provide a system to reduce the number of hand operations required to apply plaster relief bands.
- It is important to select boards made of wood which are of uniform cross section, in order to achieve a visually pleasing effect. Boards which are not uniform in thickness or width will show angular offsets at the ends where they meet. It is also important to select wood which is well cured and has stable dimensional shape. If the wood twists or otherwise deforms after the plaster has dried, unsightly cracks may appear. Cracks may also allow moisture to penetrate the plaster and attack the wood beneath, or provide additional unwanted access to wood destroying pests. Boards of suitable quality currently sell for $2 to $3 per linear foot. On a double band board structure, the cost could be from $15 to $18 per linear foot, after including the costs of boards, lath application and finished plaster.
- The use of wood for forming the support structure for the plaster of decorative bands is well known in the trade. As the costs of wood continue to increase, and the availability of high quality boards continues to diminish, there is an urgent need to provide an alternative low cost structure which will satisfy the desire for aesthetic enhancements to the various stucco and plaster styles of home and office.
- The non-uniformity of wooden boards in width and thickness can cause unsightly mismatch in the appearance of the relief bands on a home. Either higher quality and thus higher cost boards must be purchased, or labor intensive and expensive modification must be made on the job site. This slows down the assembly process and further adds to the cost of building. It would be an advantage to provide a support structure for plaster relief bands which would guarantee uniformity in cross section aspect and thus match precisely when aligned at the ends.
- The weight of the wood used for the band support structure creates several concerns. Handling and aligning long lengths of boards takes considerable strength and capability. Moving and holding a 12 foot length of board may require two workers to align successive boards. The cost of shipping the wood used in making the band supports is also a factor in the cost of building plaster or stucco homes. Wood often is shipped in a condition wherein it contains an appreciable amount of water which significantly increases the weight of the wood. Wood typically contains 30% or more water by weight. Such additional weight is of no use and in fact may be harmful as described above. Wood used for decorative support may also be stored outdoors while awaiting construction. It is possible for the wood to absorb moisture from the surroundings thereby increasing its' weight even if it had been shipped in an originally dry state. It would be an advantage to have a band support structure which is lighter in weight, thereby reducing the cost and time of installation and the cost of shipping to the job site. It would be an additional advantage to provide a band support structure which could not absorb water while stored at a building site.
- The use of wood as a building material combined with increased demands from a growing population puts increasing pressure on our forest preserves. It would be an advantage to provide a substitute material which would reduce the need to use wood except where it is most effective, thereby preserving our valuable resources.
- Even though the wood for plant on bands is covered by fire-resistant plaster, the building codes still require the bands to be considered flammable structures. It would be an advantage to provide a substitute material which was impervious to fire, and thereby add increased safety to homes and buildings.
- The general purpose of the invention is to provide light weight, low cost prefabricated plaster relief form members which can be shipped to a construction job site in final form to simplify the application of relief bands to the exterior of homes and buildings which are to be coated with a cementitous coating, typically plaster or stucco.
- According to one embodiment of the invention a prefabricated plaster relief form member is provided for receiving and retaining a fluid cementitious coating, such as plaster, when the member is attached to a prepared structural wall.
- The member is configured from an openwork lattice sheet, preferably of an expanded metal lath. The lattice sheet is adapted to receive and retain the plaster when the plaster when the plaster is applied by hand or by spraying with a nozzle of a machine. The lattice sheet is formed into a longitudinal channel having a top with opposed outer edges.
- Two spaced apart sides extend away from the respective opposed outer edges, to respective base edges. The respective base edges are aligned parallel to the top such that a mounting plane is defined parallel to the top of the channel.
- Two mounting flange portions, each extending outward and away from the base edges of the respective sides, lie within the mounting plane parallel to the channel.
- The member is thus defined as a channel having a length between two opposed ends and a width between the two opposed sides. The channel is configured to have an essentially uniform lateral cross section, perpendicular to the longitudinal dimension, protruding away from the mounting plane.
- The flange sections are adapted for mounting to the prepared structural wall such that a plurality of such members mounted on the structural wall and adjoined end-to-end form a continuous relief band protruding from the wall. The flange sections may be nailed or stapled to the studs of a prepared wall after adjacent form members are aligned and adjoined end-to-end.
- The regular cross section of similar prefabricated form members ensures an aesthetically pleasing effect is easily achieved without shaving, trimming or selecting wooden boards.
- The light weight and regular shape of these prefabricated members enable for easy and low cost installation of the support forms needed for applying relief bands to stucco homes and buildings.
- The metal lath or lattice work is light, but has sufficient strength to support the plaster coating and hold it in place while it cures. The prefabricated shape enables the construction of plaster relief bands without the use of wood boards and the additional weight and shipping cost involved. The cells and strands of the lattice work provides openings for the plaster to flow and provides a secure network for the plaster to take hold while it hardens.
- The uniform shape of the form member is dimensionally stable and not subject to absorbing water. This eliminates the potential of warping that occurs with the use of wood as support members for relief bands.
- The combination of the structural support and the open lattice in the one element of the prefabricated form member reduces the labor that otherwise is involved in attaching sheets of screen wire to the wood planks used in conventional construction.
- In another embodiment of the prefabricated form member, there is provided at least one edge guide segment parallel to and spaced apart a preselected distance from at least one of the channel outer edges. The edge guide segment is aligned parallel to the length of the member and is configured to provide a guide edge for a tool. A connecting frame is provided for rigidly connecting the edge guide segment to the member such that the edge guide segment provides a secure guide edge for a tool used to apply the plaster or stucco coating to a preselected thickness along the length of the member. A preferred thickness of plaster coating is about 7/8 inch minimum in the finished state.
- The prefabricated form member is typically formed from expanded, galvanized metal having a preformed weight of about 3.4 pounds per square yard. The lattice is shaped into an array of elongated hexagons, the hexagons having a major axis of about ½ inch and a minor axis of about 3/8 inch. The adjacent hexagons along the minor axis being connected at opposed sides by respective common side segments of about 1/8 inch in length, and adjacent hexagons along the major axis being connected at the ends of respective 3/8 inch common end segments, while the respective side and end segments are connected by corresponding right and left angled linking segments.
- A prefabricated form member as described above is non-permeable to water, non-flammable and semi-rigid and has a lateral strength sufficient to support a plaster coating having a thickness from about ½ inch in thickness, to about 2 inches in thickness.
- It is an advantage in accordance with this invention to provide plaster relief form members which eliminate the use of lumber in achieving architectural enhancement effects.
- It is a further advantage in accordance with this invention to provide plaster relief form members which reduce cost of installation.
- It is a further advantage in accordance with this invention to provide plaster relief form members which are lower in weight than equivalent lumber elements.
- It is a further advantage in accordance with this invention to provide plaster relief form members which reduce the cost of shipping members to the job site.
- It is a further advantage in accordance with this invention to provide plaster relief form members which are uniform in cross section and impervious to warping or cracking.
- It is a further advantage in accordance with this invention to provide plaster relief form members which reduce the number of hand operations and thereby reduce the cost of installation.
- It is a further advantage in accordance with this invention to provide plaster relief form members which are non-flammable.
- It is a further advantage in accordance with this invention to provide plaster relief form members which may be mass-produced in a wide variety of standard shapes at low cost.
- It is a further advantage in accordance with this invention to provide plaster relief form members which can be easily joined end-to-end to form visually uniform relief bands on outer walls, around door or window openings and along the facia of a building. The relief bands have stable shape with age and are resistant to warping and cracking due to moisture absorption/desorption.
- It is a further advantage of the present invention to use welded wire lath to form the form member absent any other structural support member.
- It is a further advantage to add edge guides to the welded wire form member.
- It is a further advantage to form the member out of rib lath, preferably by placing the rib members at the corners of the top and sides of the channel and in addition to depress the top from the corners so that the ribs provide edge guides, and absent any other structural support member.
- It is a further advantage to form the member out of woven wire lath also known as chicken wire, and preferably of the self furring form, absent any other structural support member, and in addition, preferably with edge guides applied to the corners of the top and side of the channel.
- It is a further advantage, where edge guides applied to corners of the top and sides of the channel are cut-down to have shorter side extensions.
- For a further understanding of the objects and advantages of the present invention, reference should be had to the following detailed description, taken in conjunction with the accompanying drawings, in which like parts are given like reference numerals and wherein;
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FIG. 1 is an exploded perspective view of prefabricated plaster relief forms members aligned end to end in accordance with this invention. -
FIG. 2 is a plan view of a section of expanded metal lath used as the open work lattice material to make a preformed plaster relief form member in accordance with this invention. -
FIG. 3 is a perspective view of an alternative prefabricated relief form member having a paper backing. -
FIG. 4 is a perspective view of an alternative prefabricated plaster relief form member angled to fit around intersecting walls. -
FIG. 5 is a perspective view of an alternative prefabricated plaster relief form member angled to fit around door or window casings. -
FIG. 6 is a perspective view of an alternative prefabricated plaster relief form member having a prefabricated guide edge member in accordance with this invention. -
FIG. 7 is a cross section taken along viewing plane 7-7 ofFIG. 6 . -
FIGS. 8 a and 8 b are cross sections of two alternative plaster relief form members in accordance with this invention. -
FIG. 9 is an exploded perspective view of two plaster relief form members aligned end-to-end on a structural wall. -
FIG. 10A is a perspective view of a previous art method of attaching hand made plaster relief forms made of wood and wire screen. -
FIG. 10B is a cross section of a previous art hand made plaster relief form. -
FIG. 10C is a cross section of a previous art hand plaster relief form having separate guide edge members manually attached. -
FIG. 11 is a perspective exploded diagrammatic view of a channel formed from welded-wire lath in accordance with this invention. -
FIG. 12 is an end view of a preferred form of the invention shown inFIG. 11 in accordance with this invention. -
FIG. 13 is a diagrammatic view of the invention as shown inFIGS. 11 and 12 with edge guides added, in accordance with this invention. -
FIG. 14 is a diagrammatic, exploded end view, of a form member made from edge guides in accordance with this invention. -
FIG. 15 is a diagrammatic end view of a form member made from rib lath in accordance with this invention. -
FIG. 16 is a diagrammatic perspective view of a form member made from woven wire also known as chicken wire, with edge guides attached in accordance with the invention. -
FIG. 17 a is an end view of a type of corner bead. -
FIG. 17 b is a top view of the corner bead ofFIG. 17 a with the side extensions rotated into a plane. -
FIG. 18 is a diagrammatic end view of a generic form member with a cut-down edge guides in accordance with the invention. - With reference to
FIG. 1 , there is shown an embodiment of the prefabricated plaster relief form member in accordance with this invention, generally referred to by the numeral 20. Themember 20 is shown aligned end-to-end withsimilar members member 20 is formed from anopen lattice material 22 such as 3.4 lb/sq. yd. diamond mesh expanded metal made by Western Metal Lath Company of San Leandro, Calif. Thelattice material 22 is bent on a tool such as a sheet metal brake in a metal shop to form a longitudinal channel having aprotuberant contour 30 with atop surface 31, opposedsides sides lattice material 22 are bent to formflanges respective sides member 20. Theflanges plane 46 indicated by the arrows x, y. The mountingplane 46 andflanges member 20. The depth D of themember 20 is typically about 1 1/2 inches, the width W typically about 6 to 12 inches and the length L typically 6 to 10 feet. Theflanges side member 20 is configured so that eachend end members - The
members - A preferred manufacturing method for the
prefabricated members 20 is an automated means such as high speed punches and presses operated with appropriately configured molds to achieve a desire contour.Finished members 20 would then be shipped to a job site for installation by lower cost tradespeople. - With reference to
FIG. 2 , there is shown a detail of atypical lattice material 22. Apreferred lattice 22 is typically formed of galvanized steel expanded to provide an hexagonal close packedarray 48 ofcells 50 bounded bystrands 52. Thestrands 52 are formed of galvanized sheet steel typically about 0.020 inches thick. Thecells 50 are elongated hexagons withmajor axis 54 about 1 1/16 inch long and minor axis 56 about 5/16 inch wide. Alternatively, thelattice 22 may be formed of lighter or heavier expanded metal, such as 1.75 lb/sq. yd. Or 2.5 lb/sq. yd. For smaller or larger preformed members. A suitable material is the galvanized steel diamond mesh of 3.4 lb/sq. yd. Made by Western Metal Lath Co. La Mirada, Calif.\ - With reference to
FIG. 3 , an alternative embodiment of a prefabricated plaster support member in accordance with this invention is shown. A paper backed lattice material may be used to make a member generally indicated bynumeral 60. An example of such a paper backed lattice material is “CEM-LATH K” made by Cemco, of Industry, Calif. “CEM-LATH K” is a 3.4 lb/sq. yd. Diamondmesh metal lath 62 backed with asphalt saturated “Kraft”paper 64 which may be used to form aplaster support member 60 in accordance with this invention. Thepaper backing 64 may be used to limit the amount of plaster which is needed to cover themember 60 after themember 60 is applied to a prepared structural wall (not shown). - The
paper 64 extends a suitable distance such as 1½ to 2 inches beyond theflanges 3 nds metal lath 62. Thepaper 64 extension provides an overlap with adjacent paper backed members (not shown), when aligned end to end, to ensure a continuous moisture barrier which may be required by local or state building codes. - It is contemplated that the
paper 64 may be applied to the back of thelath 62 before forming themember 60. Application of thepaper 64 to the back of thelath 62 may be made by adhesive means such as a hot glue (not shown) between thepaper 64 and thelath 62. Thepaper 64 and thelath 62 may then be positioned between an upper mold and a lower mold having a desired shape (not shown). Application of sufficient pressure between the upper mold and lower mold will cause thelath 62 andpaper 64 combination to be shaped into the desiredmember 60. - Other preformed shapes for prefabricated plaster form members in accordance with this invention are contemplated. With reference to
FIG. 4 there is shown an embodiment of a prefabricatedangled member 80. Theangled member 80 provides a means to fit a continuous relief band around the corner of a building (not shown) without cutting and fitting straight members. Themember 80 is made from open work lattice material as described above. Themember 80 includes afirst portion 82 and asecond portion 84 joined at acommon edge 86. Theportions portion 82 andportion 84 are indicated at right angles to each other, but can be any desired angle to accommodate intersecting structural walls at other than 90 degree angles. Theportions portions common edge 86 to respective ends 38, 40. Theportions top surfaces edge 86. Theportions respective sides top surfaces flanges respective sides Flanges - The
member 80 is attached to the studs of a prepared structural wall by means of nails or staples driven through the respective flanges 92 a-94 b. Self-tapping sheet metal screws are typically used to attach the flanges 92 a-94 b to metal studs. Sharp pointed “Streaker” self-tapping sheet metal screws available from Pacific Steel and Supply, San Leandro, Calif., may be used for light gauge metal studs. - The ends 38 and 40 of
member 80 are configured as before to abut or overlap contiguously with respective ends of prefabricated plaster form members having the same cross section as themember 80. One such abutting relationship with aplaster form member 20 having the same cross section asmember 80 is indicated by the exploded view ofmember 20 shown inFIG. 4 . - It is often desired to fit the perimeter of door or window openings with decorative plaster elements. With reference to
FIG. 5 , another embodiment of an angled prefabricated plaster form member in accordance with this invention is shown and generally indicated bynumeral 100. In one embodiment, themember 100 is made from expanded metal lath as before described. Afirst portion 102 is joined with asecond portion 104 at acommon edge 106.Portion 102 includes a sheet of expanded metal lath bent for form spaced apart sides 110 a and 110 b, atop surface 114 and respective mountingflanges Portion 104 includes a sheet of expanded metal lath bent to form spaced apart sides 118 a and 118 b, atop surface 115 and respective mountingflanges Portions common edge 106. The mountingflanges Flanges top surfaces 114 and 118 by the dependingsides flanges - The previous art method of attaching separate guide edge members to the hand formed plaster relief forms incurs extra handling and additional cost due to high rate labor charges. With reference to
FIG. 6 , there is illustrated a perspective view of a portion of an alternative preformed plaster relief form in accordance with this invention, and generally referred to asnumeral 150. As before described with reference toFIG. 1 , wherein similar reference numerals are used to designate similar elements, themember 150 is formed of an openwork lattice material 22. A preferred lattice material is a diamond mesh expanded metal such as 3.4 lb/sq. yd galvanized metal lath made by CEMCO of Covina Lane, Industry, Calif. Thelattice material 22 ofmember 150 is preformed to include atop surface 31 having opposed ends 38, 40. Thetop surface 31 has a bending line along thesurface 31. The bending line is normal to the opposed ends and defines anedge 33. Thelattice material 22 is bent along theedge 33 to define aside 34 extending downward fromtop surface 31. Theside 34 extends downward a suitable distance from thetop surface 31, to asecond bending line 35, for example, 1½ inches. Thelattice material 22 is bent along thesecond bending line 35, to form a mountingflange 42 extending laterally outward from theside 34 of themember 150 to a suitable distance F, e.g. 1½ inches. A similar bending line, edge, side and flange (not shown) may be formed in a symmetrical relationship to theside 34 as before described and shown inFIG. 1 . - A prefabricated
guide edge member 160 is shown in exploded relationship to themember 150 asmember 160 for clarity.Guide edge member 160 is attached at a plurality ofpoints 162 along a first edge 164 to thetop surface 31 of themember 150. Theedge member 160 is attached at a second plurality ofpoints 166 to theside 34 ofmember 150. The method of attachment may be spot welding, or bonding with an adhesive such as hot glue. A preferredguide edge member 160 is the standard Bullnose regular cover nose wire having standard 1 1/2 inch legs made by Stockton Products, Covina, Calif. Theguide member 160 includes aguide edge 168 spaced apart from, and parallel to, the intersection of thetop surface 31 and theside 34. Theguide edge 168 is spaced apart a suitable distance, e.g. 5/8 inch from thetop surface 31 of themember 150. Theguide edge 168 provides an edge to guide a tool, such as a trowel, while applying plaster to themember 150, in such a manner that a uniform plaster coating thickness is easily achieved on thetop surface 31. Theguide member 160 includes a plurality ofwire support members guide edge 168 and the respective top 31 andside 34 of themember 150. Asimilar guide edge 174 spaced apart form theside 34 by a suitable distance, e.g. 5/8 inch provides an edge to guide a tool along themember 150 to achieve a uniform plaster coating thickness along theside 34. - The exploded view of the
member 160 illustrates corresponding attachment points 162 and 166, the connectingwires 170′ and 172′ and theguide edge 168′. - With reference to
FIG. 7 , there is shown in cross section along the viewing plane indicated by 7-7 ofFIG. 6 , the contour of theedge guide member 160 attached to the top 31 and theside 34 of themember 150 at attachment points 162, 166 respectively. Thetop guide edge 168 andside guide edge 174 are shown as wires attached to theconnection wires top surface 31 and theside 34 by a suitable distance, typically ⅝ inch. - With reference to
FIGS. 8 a and 8 b there are shown alternative cross sections for prefabricated plaster relief form members in accordance with this invention.FIG. 8 a illustrates amember 200 having opposedsides -
FIG. 8 b illustrates a cross section of a prefabricated plasterrelief form member 204 having a stair-stepped aspect with fourcorner edges guide edge members side guide edge 214 a, b-220 a,b spaced apart from the respective corner edges 206-212 by a suitable distance, e.g. 5/8 inch laterally outward and vertically upward. - With reference to
FIG. 9 , the use of the prefabricated plaster relief form is herein described. In use, a structural wall is prepared having a plurality ofstuds 180 spaced a suitable distance apart and mounted vertically along afoundation 182. A layer of asphalted “Kraft”paper 184 for a moisture barrier is applied to thestuds 180. A first layer of wire mesh or screen 186 (commonly called chicken wire) is then attached to the wall over thepaper 184. A line is defined along the wall wherein the desired decorative architectural structure was to be placed. A plurality of prefabricated plasterrelief form members 200 is aligned end to end along the line and attached to the wall by means of nails orstaples 186 driven through respective mountingflanges studs 180. The light weight but substantiallyrigid lattice material 22 and uniformity of shape provided by the preformedmembers 200 would make the task of creating a uniform, continuous relief band extremely easy. With reference again to the detail ofFIG. 2 , thearray 48 ofopen cells 50 of thelattice material 22 provides ready access for the application of plaster to envelop thestrands 52 and bond firmly with thelattice 22. - The prefabricated guide edges 160 and 190 of the preformed
plaster relief form 200 provide guides for guiding a tool to apply plaster to a uniform thickness along therelief form members 200. - One method of applying a cementitious coating is the well known three step process. A first coat of cementitious material, typically plaster, called a scratch coat, would be applied, either by hand trowel or by spraying from a nozzle connected to a gun feeder, hopper/mixer and pumps as is well known to those skilled in the art.
- One preferred formulation for the scratch coat is set forth in Table 1. It is within the teachings of this patent to use any other suitable cementitious material to form the coating for the wall and
prefabricated plaster form 20.TABLE 1 1 part Colton Portland Cement type II 3 parts common coarse sand 5 to 8 gallons of water per sack of cement, depending on the water content of the sand - The scratch coat covers the wall and the sides and top surface of the
form members 20 to a uniform depth of about 3/8 inch. The scratch coat is cured for a suitable time, such as 24 to 48 hours, according to the State of California Uniform Building Code 1988 Edition page 4706, herein incorporated by reference. - A second coat of plaster about ¼ to 3/4 inches, with a preferred thickness or 3/8 inch, called the brown coat, is applied similarly to the wall and plaster forms 20. The brown coat is cured for a suitable time such as 7 to 14 days minimum. A suitable formulation for the brown coat is the same as Table 1, with the addition of a 3 to 5 shovelsful of sand per sack of cement.
- A final plaster coast incorporating the desired color is applied similarly to a depth of about 1/16 to 1/8 inch. The formulation for the color coat is typically a mechanically blended compound of portland cement, hydrated lime and inert aggregates ( 16/20 or 20/30 sand), such as that supplied by La Habra Stucco, Anaheim, Calif. Material standards preferably meet Federal Specification SS-L-351, Type F for hydrated lime, and Type 1 ASTM C150-56: Federal Specification SS-C-192B, for white portland cement.
- A further embodiment of the invention is illustrated in
FIG. 11 . This embodiment takes advantage of an existing product used in construction. In this embodiment therelief form member 200 is made of ametal mesh 202 of the type known as welded wire, preferably in the form of 2″×2″ mesh, using 16 or 17 gauge wire. Paper backing comes attached to the wire mesh when it is made and sold as by manufacturers for plastering purposes. In this form it is referred to in the industry as welded wire lath. An example is that used in a product sold as Stucco-Rite by K-Lath of Fontana, Calif. The attached Appendix A is a copy of K-Lath's catalogue A465,09200/KLC, Bayline 5409 showing various forms of lath. - Referring to
FIG. 11 , the weldedwire mesh 202 is formed as described above into a channel shape having mountingflanges 204,sides 206 and a top 208. The mountingflanges 204 are preferably 1/2 inch to 1½ inch extending away from thesides 206. The height of theside 206 is dictated by the desired design dimension, 1½ inches being exemplary.Paper backing 210 follows the form of the channel and is attached to thewire mesh 202 by an interweaving as known in its preparation as lath. The width of the top 208 is also a design choice, 6 to 12 inches being exemplary. The relief form member can be of any selected length for the use, and can be preformed in exemplary lengths such as 6 to 10 feet. - This embodiment has a further alternative in which a product known as double wire mesh is used. The double wire mesh material is used in a lath product sold as Stucco Rite Double Wire by K-Lath of Fontana, Calif., as described in the catalogue identified above. The double wires are provided at selected intervals. The double wire form provides a nailing space between the double wires to catch the nail head and prevent movement during installation.
- When forming the channel shape using the welded wire mesh, the bends can be anywhere, but referring to
FIG. 12 , it is preferable to have lengthwise extendingwires 212 at the bends or corners, as well as having a lengthwise extending wire proximate theouter termination 214. Since the welded wire mesh comes in specified dimensions, whether single or double wire, to place the lengthwise wires at the bends or corners dictates the dimensions of the channel. This structure gives additional rigidity which aids in installation. Thepaper backing 210 is shown attached to thewire mesh 202 by interweaving as is known in the manufacture of welded wire lath. A second layer ofpaper 215 is commonly employed having an asphaltic or other waterproofing component. - The foregoing alternatives using welded wire mesh can be used as described, or with corner beads also known as edge metal or edge guides as previously described and shown diagrammatically in cross-section in
FIG. 13 . Corner beads are sold by various manufacturers such as CEMCO of Industry, Calif. Appendix B is a copy of CEMCO's catalogue of Metal Lath and Accessories. Without the corner beads, certain architecture styles such as Spanish or mission finish are facilitated. With the corner beads or edge guides, a smooth finish is achievable. The corner beads can be attached by any suitable means, such as by hot glue. Referring toFIG. 13 thewire mesh 202 hascorner beads 216 attached at the corners of the top 208 and sides 206.Paper backing 210 is shown Another alternative construction of the invention uses only corner bead members joined together to form the channel. This is shown diagrammatically inFIG. 14 in whichcorner beads flanges 224 and along withcorner beads sides 230 and thecorner beads corner beads - Referring to
FIG. 15 , in another alternative the channel is constructed by using a product known as rib lath. Rib lath is a known product, similar to the expanded metal described above, but having parallel ribs of solid, unexpanded portions extending lengthwise between areas of expanded metal. The rib lath is shown in the CEMCO catalogue. The ribs may be about ⅜″ wide and spaced apart about 1⅛ inch with three expanded portions between them. Referring toFIG. 15 , therib lath 238 has theribs 240 and the expandedmetal portions 242 between the ribs. Therib lath 238 is formed into a channel shape as shown diagrammatically having raised corners where the sides and top meet withribs 240 at the corners to serve as edge guides. InFIG. 15 , thelonger lines 240 represent the ribs and the shorter lines andspaces 242 represent the expanded metal portions. The rib lath structure is preferably also used with paper backing as described above. In this form the corner bead or edge guide is built into the channel form itself. The sides of the channel could be convergent from top to flange to provide an edge guide for the sides, or the sides could be bent, like the top so that the corner protrudes to provide an edge guide for the sides. - Referring to
FIG. 16 , in another alternative series of structures any of the foregoing shapes can be formed using woven wire also known as chicken wire for the basic channel shape. This wire is referred to as Stucco Netting in the K-Lath Catalogue. It is preferably augmented with paper backing and as desired with corner beads as described above. The self-furring form is preferred to keep a space between the wire and the paper backing. The woven wire is formed into a channel 250, withflanges 252,sides 254 and top 256.Corner beads 258 are attached as well aspaper backing 260. - Corner beads are commonly made with lengthwise wires at the apex to form a bullnose or straight shape and undulating and straight wires combined to provide an extension away from the apex. In the CEMCO catalogue this is shown on page 8 as CEMCORNER.
FIGS. 17 a and 17 b shows this structure withwires wires 276 andstraight wires 278 forming side extensions away from the apex. In the present invention, referring toFIGS. 17 a and 17 b, this type of corner bead can be used as shown in the CEMCO catalogue, but in a further embodiment the side extensions can be cut away to make it smaller. Selected places for lengthwise cutting away are shown at A-A, B-B, C-C and D-D. The form created by the cutting away along line D is shown inFIG. 18 . - In all of these alternative constructions, no underlying structural support member is used. In particular any wood boards are absent.
- In all of these further embodiments, the shape of the channel can be made in the stepped form as shown in
FIGS. 8 a and 8 b except that the channel is made of materials as described in these further embodiments and absent any additional underlying support such as wood boards. - While the foregoing detailed description has described the embodiments of the plaster relief form member in accordance with this invention, it is to be understood that the above description is illustrative only and not limiting of the disclosed invention. It will be appreciated that it would be possible to modify the type of lattice material to include larger or smaller cells and strands, to modify the shape of the cells and the material, to modify the cross section to include non-uniform shapes, to add other structures to the plaster relief form member such as flashing for interfacing with roofing members, to modify the coating of that lattice material by paints and/or other rust preventative materials or to include or exclude various elements within the scope and spirit of the invention. Thus the invention is to be limited only by the claims as set forth below.
Claims (11)
1-13. (canceled)
14. A prefabricated relief form member for receiving and retaining cementitious coating when the form member is attached to a prepared structural wall, the member comprising;
woven wire mesh bent to form a top, spaced apart sides and flanges extending oppositely from the sides; to define a channel having a hollow interior;
paper backing fixed to the channel interior; and
absent any other structural support members.
15. The prefabricated relief form member of claim 14 further comprising corner bead members fixed to the corners of the channel formed by the top and the sides.
16. The prefabricated relief form member of claim 14 further wherein the woven wire mesh is of the self furring type.
17. The prefabricated relief form member of claim 15 wherein the corner bead members have a portion of at least one of their side extensions cut off.
18. (canceled)
19. (canceled)
20. A method of making a relief form member for attachment as an architectural feature to an exterior wall comprising;
starting with wire members welded together to form an elongated welded wire structure;
bending the elongated welded wire structure to form a hollow channel defined by a top and sides and to have corner aids at the corners of the top and sides formed integrally from the elongated welded wire structure;
using fasteners, attaching the relief member to the exterior wall of structure;
employing no other structural support member;
applying cementitious material in a plurality of layers, at least the first layer using the corner aids as guides to control application of the cementitious material thereby forming on the exterior wall an architectural feature defined by the shape of the surface of the cementitious material applied over the hollow channel formed by the welded wire members.
21. The method of claim 20 further comprising;
applying an elongated paper member on the interior of the channel and applying hot glue to hold the paper to the metal channel member.
22. The method of claim 20 wherein the elongated metal member is made of wire members welded together.
23. The method of claim 20 wherein the shape of the surface defines a rectangular cross section
Priority Applications (2)
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US10/679,720 US20050246994A1 (en) | 1994-04-05 | 2003-10-06 | Preshaped form |
US10/808,261 US7921537B2 (en) | 1994-04-05 | 2004-03-23 | Method of making a prefabricated relief form |
Applications Claiming Priority (5)
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US22282694A | 1994-04-05 | 1994-04-05 | |
US08/441,251 US5685116A (en) | 1994-04-05 | 1995-05-15 | Preshaped form |
US08/967,055 US6591566B1 (en) | 1994-04-05 | 1997-11-10 | Preshaped form |
US10/254,038 US6662513B2 (en) | 1994-04-05 | 2002-09-24 | Preshaped form |
US10/679,720 US20050246994A1 (en) | 1994-04-05 | 2003-10-06 | Preshaped form |
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US10/808,261 Continuation-In-Part US7921537B2 (en) | 1994-04-05 | 2004-03-23 | Method of making a prefabricated relief form |
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US10/679,720 Abandoned US20050246994A1 (en) | 1994-04-05 | 2003-10-06 | Preshaped form |
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Cited By (2)
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US20120088055A1 (en) * | 2009-03-09 | 2012-04-12 | Brian Investments Pty Ltd | Wear plate |
CN105298023A (en) * | 2015-10-20 | 2016-02-03 | 重庆路投科技有限公司 | Two-way honeycomb horn-shaped concrete anti-cracking reinforced metal screen |
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US6591566B1 (en) * | 1994-04-05 | 2003-07-15 | Daniel W. Rodlin | Preshaped form |
US20040055245A1 (en) * | 2002-09-23 | 2004-03-25 | Fitch Kent C. | Wall cap corner aid |
CN1771373A (en) * | 2002-10-30 | 2006-05-10 | 布纳斯特科瑞特设备公司 | Wire mesh screed |
US7028436B2 (en) * | 2002-11-05 | 2006-04-18 | Certainteed Corporation | Cementitious exterior sheathing product with rigid support member |
US7155866B2 (en) | 2002-11-05 | 2007-01-02 | Certainteed Corporation | Cementitious exterior sheathing product having improved interlaminar bond strength |
US6802163B2 (en) * | 2003-03-03 | 2004-10-12 | William Hackman | Plant-on building enhancement |
US6966160B2 (en) | 2003-10-29 | 2005-11-22 | Al Brown | Plant-on trim elements and methods |
US20060037263A1 (en) * | 2004-08-20 | 2006-02-23 | Hacker Edward T Jr | Decorative wall member |
US20060236626A1 (en) * | 2005-03-25 | 2006-10-26 | Timothy Smythe | Multi-angle exterior drywall corner bead |
US20060283106A1 (en) * | 2005-06-17 | 2006-12-21 | Totin Jody J | Framing connector |
US20070119106A1 (en) * | 2005-11-25 | 2007-05-31 | Sacks Abraham J | Wire corner bead for stucco |
US7950078B2 (en) * | 2007-07-23 | 2011-05-31 | Robin Houpt | Preformed structural support for tile |
JP5475340B2 (en) * | 2009-06-24 | 2014-04-16 | ニチハ株式会社 | Wall structure |
US20110225917A1 (en) * | 2010-03-16 | 2011-09-22 | Jennifer Golden | Decorative architectural element and method for making |
US8869491B2 (en) | 2010-11-08 | 2014-10-28 | Basf Corporation | Trim bead and stucco system including same |
CN103201442A (en) * | 2010-11-08 | 2013-07-10 | 建筑研究和技术有限公司 | Trim bead and stucco SYSTEMS including same |
US9556619B2 (en) * | 2011-10-21 | 2017-01-31 | Old Mill Brick Incorporated | Fiber enforced thin brick sheet and process |
US9482010B2 (en) * | 2013-03-15 | 2016-11-01 | David Kartler | Cornerbead/corneraide apparatus and related methods |
US9140005B2 (en) * | 2013-06-03 | 2015-09-22 | Philip Glen Miller | Self-aligning corner bead for fireproofing structural steel member and method of using same |
US9540813B2 (en) | 2013-06-03 | 2017-01-10 | Philip Glen Miller | Self-aligning, double wire corner bead for fireproofing structural steel member and method of using same |
US10415237B1 (en) | 2013-06-03 | 2019-09-17 | Philip Glen Miller | Self-aligning corner bead for fireproofing structural steel member and method of using same |
US9469998B1 (en) * | 2014-01-28 | 2016-10-18 | Plastic Components, Inc. | Wall lath with self-furring ridges |
US8997422B1 (en) * | 2014-04-24 | 2015-04-07 | Daniel Kim | Building construction formed of prefab concrete forms |
CN110847400A (en) * | 2014-08-21 | 2020-02-28 | P·G·米勒 | Method for fireproofing a member comprising a set of surfaces with a fireproofing material |
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CN105298023A (en) * | 2015-10-20 | 2016-02-03 | 重庆路投科技有限公司 | Two-way honeycomb horn-shaped concrete anti-cracking reinforced metal screen |
Also Published As
Publication number | Publication date |
---|---|
US20030079429A1 (en) | 2003-05-01 |
US6591566B1 (en) | 2003-07-15 |
US6662513B2 (en) | 2003-12-16 |
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