US20100095628A1 - Wall system - Google Patents
Wall system Download PDFInfo
- Publication number
- US20100095628A1 US20100095628A1 US12/641,839 US64183909A US2010095628A1 US 20100095628 A1 US20100095628 A1 US 20100095628A1 US 64183909 A US64183909 A US 64183909A US 2010095628 A1 US2010095628 A1 US 2010095628A1
- Authority
- US
- United States
- Prior art keywords
- block
- members
- wall system
- face
- recited
- 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
Links
Images
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
- E04B2/02—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls built-up from layers of building elements
- E04B2/28—Walls having cavities between, but not in, the elements; Walls of elements each consisting of two or more parts kept in distance by means of spacers, all parts being solid
- E04B2/40—Walls having cavities between, but not in, the elements; Walls of elements each consisting of two or more parts kept in distance by means of spacers, all parts being solid the walls being characterised by fillings in all cavities in order to form a wall construction
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
- E04B2/02—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls built-up from layers of building elements
- E04B2/42—Walls having cavities between, as well as in, the elements; Walls of elements each consisting of two or more parts, kept in distance by means of spacers, at least one of the parts having cavities
- E04B2/54—Walls having cavities between, as well as in, the elements; Walls of elements each consisting of two or more parts, kept in distance by means of spacers, at least one of the parts having cavities the walls being characterised by fillings in all cavities in order to form a wall construction
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
- E04B2/56—Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members
- E04B2/58—Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members with elongated members of metal
Definitions
- This disclosure generally relates to building components, and more particularly to a wall system.
- Modern day building construction including construction of commercial and residential buildings, often includes the construction of concrete block wall systems.
- Masonry blocks are stacked in a plurality of rows to construct the wall systems.
- Typical masonry blocks include masonry face members which are outwardly aligned and parallel and include structural cross members that extend between the parallel faces.
- Traditional concrete masonry blocks are of unitary construction, with the cross members and face members all formed of a concrete material. Therefore, the masonry blocks must be transported, in finished form, from the point of fabrication, storage, and/or sale, and ultimately to the construction site.
- Brick wall systems for commercial and residential buildings are also known. These wall systems utilize studs or furring strips of an existing building frame to construct exterior walls. Therefore, the integrity of wall systems of this type is dependent upon the support of one or more existing surfaces. Sheathing or building wrap (such as a plastic moisture barrier) may be installed over the studs and/or furring strips of the building framework. The brick members are then stacked and mortared to one another and anchors are utilized to attach the brick members to the exterior of the wood sheathing and building wrap.
- Sheathing or building wrap such as a plastic moisture barrier
- a wall system includes a bracket assembly and at least one block member.
- the bracket assembly establishes a self-supporting wall frame.
- the at least one block member is supported on the self-supporting wall frame.
- the at least one block member includes an outer face, an inner face, and a top face extending between said outer face and said inner face. The top face locates the at least one block member on the self-supporting wall frame
- a method of constructing a wall system includes positioning stud members at a desired spacing, attaching bracket members to the stud members to establish a self-supporting wall frame independently of any existing surface, and supporting block members on the self-supporting wall frame to construct the wall system.
- a block member for a wall system includes an outer face, an inner face and opposing end faces.
- the outer face extends between the opposing end faces and establishes a first height.
- the inner face extends between the opposing end faces on an opposite side from the outer face and establishes a second height that is greater than the first height.
- the top face extends between the outer face and the inner face and includes a ledge at least partially coextensive with the outer face and extending between the outer face and the inner face.
- FIG. 1 schematically illustrates an example masonry block
- FIG. 2 schematically illustrates a second example masonry block
- FIG. 3 illustrates a block member for use with the masonry blocks illustrated in FIG. 1 and FIG. 2 ;
- FIG. 4 schematically illustrates example features of the block member shown in FIG. 3 ;
- FIG. 5 illustrates an example wall system
- FIG. 6 illustrates a perspective view of a bracket assembly of the wall system illustrated in FIG. 5 ;
- FIG. 7 illustrates a cross-sectional side view of the example wall system illustrated in FIG. 5 ;
- FIG. 8 illustrates a vertical bar of the bracket assembly illustrated in FIG. 6 ;
- FIG. 9 is a flowchart of an example method for constructing the wall system illustrated in FIG. 5 ;
- FIG. 10 illustrates a top view of the bracket assembly illustrated in FIG. 6 ;
- FIG. 11 illustrates a bracket assembly of another example wall system
- FIGS. 12A , 12 B and 12 C illustrate a block member for use with the bracket assembly and wall system of FIG. 11 ;
- FIG. 13 illustrates a cross-sectional view of the wall system of FIG. 11 ;
- FIG. 14 illustrates another view of the wall system of FIG. 13 ;
- FIGS. 15A and 15B illustrate a backer sheet of the wall system of FIGS. 11-14 .
- FIG. 1 illustrates an example masonry block 10 that includes a first block member 12 , a second block member 14 , and a cross member 16 .
- Each block member 12 , 14 includes an outer face 18 and an inner face 20 opposite of the outer face 18 .
- the cross member 16 extends between the inner faces 20 of the block members 12 , 14 .
- the cross member 16 may include openings 21 to provide an installer of the masonry blocks 10 with the ability to insulate and vertically reinforce the masonry block 10 .
- the block members 12 , 14 and the cross member 16 are formed of concrete as a single-piece construction.
- the first block member 12 , the second block member 14 and the cross member 16 may include any other materials known to be suitable by those skilled in the art having the benefit of this description.
- the masonry blocks 10 are stacked and positioned in a plurality of rows to construct a free-standing wall system.
- Each block member 12 , 14 of the masonry block 10 includes a depression 44 , for example.
- each block member 12 , 14 includes a plurality of depressions 44 .
- An insert 17 is receivable within the depressions 44 .
- the insert 17 includes a porous material.
- the insert 17 is a Styrofoam rope. The inserts 17 reduce the build up of mortar or other substances within the depressions 44 during installation of the masonry blocks 10 , thereby improving water drainage of the masonry blocks.
- FIG. 2 illustrates a second example masonry block 24 .
- the masonry block 24 also includes a first block member 26 , a second block member 28 and a cross-member 30 .
- the first block member 26 and the second member block member 28 are substantially identical to the first block member 12 and second block member 14 of the masonry block 10 .
- the cross member 30 is a bracket member 32 which comprises a material different from that of the block members 26 , 28 .
- the bracket member 32 is metal, such as 25 gauge galvanized sheet metal, for example.
- the bracket member 32 is plastic.
- the example block members 12 , 14 , 26 or 28 of the masonry blocks 10 , 24 may be utilized to construct various wall systems, as is further discussed below.
- FIG. 3 illustrates the example block member 12 .
- the block member 12 is shown and described as substantially typical of each of the block members 12 , 14 , 26 and 28 .
- the block member 12 is formed of concrete, brick, or any other suitable material.
- the block member 12 includes a water resistant additive that reduces any susceptibility to cracking and water penetration.
- the example block member 12 includes a length L 1 .
- the length L 1 of the block member 12 is approximately 16 inches. In another example, length L 1 is approximately 8 inches.
- the block member 12 may be manufactured to the specifications of any desired length.
- the length L 1 extends between opposing end faces 34 , 36 .
- the block member 12 includes a slot 38 .
- the slot 38 is positioned between the outer face 18 and the inner face 20 of the block member 12 .
- the slot 38 includes a horizontal portion 40 and a vertical portion 42 .
- the vertical portion 42 is transverse to the horizontal portion 40 , in one example. In another example, the vertical portions 42 of the slot 38 are perpendicular to the horizontal portion 40 .
- the horizontal portion 40 of the slot 38 is coextensive with the length L 1 of the block member 12 .
- the horizontal portion 40 of the slot 38 extends along a top face 41 (which extends between the end faces 34 , 36 and the inner face 20 and the outer face 18 ) of the block member 12 , for example.
- the vertical portion 42 is coextensive with a height H of the block member 12 and extends along each of the first end face 34 and the second end face 36 of the block member 12 .
- the slot 38 extends along each of the first and second end faces 34 , 36 and along the entire length L 1 of the block member 12 . That is, the slot 38 of the block members 12 is continuous and uninterrupted along the height H and length L 1 of the block member 12 .
- the slot 38 is positioned within a plane of the block member 12 which is offset from each plane defined by the outer face 18 and the inner face 20 of the block member 12 . That is, no portion of the slot 38 extends into the outer face 18 or the inner face 20 .
- the outer face 18 is positioned within a first plane 43
- the inner face 20 is positioned within a second plane 45 different from the first plane 43
- the slot 38 is positioned within a third plane 47 which is different from both the first plane 43 and the second plane 45 (See FIG. 4 ).
- the horizontal portion 40 and the vertical portions 42 of the slot 38 are positioned within the same plane.
- the vertical portions 42 of the slot 38 are offset from the horizontal portion 40 of the slot 38 .
- the vertical portions 42 may be offset in either direction relative to the horizontal portion 40 (i.e., either towards the outer face 18 or towards the inner face 20 of the block member 12 ).
- a person of ordinary skill in the art having the benefit of this disclosure would understand how to design the slot 38 of the block member 12 , including the various dimensions associated with the slot 38 such as the offset distance between the vertical portions 42 and the horizontal portion 40 of the slot, the slot depth, and numerous other dimensions.
- the block member 12 may also include a plurality of depressions 44 disposed along the length of the block member 12 adjacent to the horizontal portion 40 of the slot 38 .
- the depressions 44 are utilized to divert water into the horizontal portion 40 of the slot 38 , which may enter through the joints (i.e., the horizontal and vertical gaps between adjacent block members 12 in a wall system) of a wall system from adjacent block members 12 .
- the horizontal portion 40 communicates the water to the vertical portions 42 of the slot 38 .
- the vertical portions 42 then communicate the water downwardly until the water escapes the wall system. Therefore, the depressions 44 and the slot 38 reduce water penetration and water build-up within the block members 12 , as is further discussed below.
- the block members 12 may include a beveled edge 35 .
- the beveled edge 35 extends along both the top face 41 and the end faces 34 , 36 of the block member 12 (See FIGS. 7 and 10 ).
- the beveled edges 35 allow adjacent block members 12 of a wall system to be positioned closer to one another thereby reducing the size of the mortar joints between the block members 12 .
- the block member 12 (which is typical of block members 12 , 14 , 26 and 28 ) may be utilized to construct numerous types of wall systems.
- the block members 12 are utilized to assembly a plurality of the masonry blocks 10 , which are stacked and positioned in a plurality of rows to build a wall system.
- the block members 12 may be utilized with a preexisting wall 46 to establish a block veneer wall system 48 , as is illustrated in FIG. 5 .
- the preexisting wall 46 includes a plurality of stud members 50 that extend adjacent to one another in a vertical manner, in one example.
- the spacing between the stud members 50 is not significant, and the stud members 50 can be spaced at 8′′ on center, 12′′ on center, 16′′ on center, or any other spacing requirements.
- the preexisting wall 46 is illustrated with stud members 50 , it should be understood that the preexisting wall may include any type of wall having any type of wall components.
- the stud members 50 may include metal studs, for example.
- the stud members 50 include wooden studs.
- the stud members 50 include plastic studs.
- a person of ordinary skill in the art having the benefit of this disclosure would understand that the block veneer wall system 48 may be utilized with any preexisting wall 46 .
- the block veneer wall system 48 includes a plurality of ledger clips 52 and a plurality of the block members 12 .
- the stud members 50 are positioned horizontally adjacent to one another along a length X to establish the pre-existing wall 46 .
- the stud members 50 extend vertically to a desired height Z of the wall system 48 .
- the ledger clips 52 extend horizontally across the stud members 50 to form a wall frame including a plurality of rows 54 A- 54 n .
- the wall system 48 may include any number of rows 54 .
- the example ledger clips 52 are manufactured in strips of approximately 10 to 12 feet in length, in one example. However, the ledger clips 52 may be manufactured to any specification. In one example, the stud members 50 are spaced apart a distance of approximately 16 inches and each ledger clip 52 is spaced apart a distance of approximately 8 inches. It should be understood that the spacing and other dimensional relationships that exist between the stud members 50 and the ledger clips 52 may vary to provide a block veneer wall system 48 of any size.
- FIG. 6 illustrates a portion of the bracket assembly 51 of the block veneer wall system 48 that includes a ledger clip 52 attached to a stud member 50 .
- the ledger clip 52 is attached to the stud member 50 with a threaded fastener 56 .
- other attachment methods are contemplated as within the scope of this disclosure.
- Each ledger clip 52 generally includes a Z-shaped body having a top face 58 and leg members 60 , 62 extending transversely from the top face 58 .
- the leg members 60 , 62 extend away from the top face 58 in opposite directions relative to the top face 58 .
- the leg member 60 is received against the stud member 50 and is attached to the stud member 50 with the threaded fastener 56 , for example.
- the leg member 62 extends in a downward direction relative to the top face 58 and receives a slot 38 of the block member 12 to support the block member 12 on the block veneer wall system 48 . Therefore, the block veneer wall system 48 establishes a wall framework independent of the block members 12 . That is, placement of the block members 12 is dictated by the ledger clips 52 .
- each ledger clip 52 includes a flange portion 63 .
- the flange portions 63 push the leg member 62 against a back wall 61 of the horizontal portion 40 of the slot 38 (See FIG. 7 ) to reduce the amount of “slop” in the wall. That is, the flange portions 63 secure the block members 12 to the ledger clips 52 .
- the top face 58 of each ledger clip 52 includes a plurality of teeth 64 .
- the teeth 64 grip a bottom surface of a block member 12 from a vertically adjacent row 54 of the block veneer wall system 48 (see FIG. 7 ).
- the top face 58 also includes a plurality of openings 66 for receiving a vertical bar (see FIG. 8 ) installed between horizontally adjacent block members 12 once positioned onto the block veneer wall system 48 .
- the example ledger clip 52 includes a second set of openings 68 provided on the leg members 62 . The openings 68 receive shims to adequately secure the block members 12 to the ledger clips 52 and ensure that the top face 58 is level relative to the ground as the block members 12 are received onto the leg member 62 of the ledger clip 52 .
- FIG. 9 illustrates an example method 100 of constructing a wall system, such as the block veneer wall system 48 , for example.
- the ledger clips 52 are horizontally positioned across the stud members 50 of a pre-existing wall 46 to establish a wall frame including a plurality of rows 54 .
- wood sheathing such as plywood for example, is installed over top of the existing stud members 50 .
- building wrap may be installed to cover the wood sheathing and provide a moisture barrier.
- a block member 12 is positioned on the block veneer wall system 48 .
- the top face 41 of the block member 12 is tilted toward the ledger clip 52 and pushed upward such that the horizontal portion 40 of the slot 38 of the block member 12 is received by the lower leg member 62 of the ledger clip 52 .
- the bottom of the block member 12 is next pushed in an inward direction (i.e., toward the stud members 50 ) until the inner face 20 of the block member 12 rests against the upper leg member 60 of the ledger clip 52 (except for block members 12 of the first row 54 A).
- the block member 12 is then eased slightly downward until a bottom face of the block member 12 is seated on the top face 58 of the ledger clip 52 (or a starting strip where installing the block members 12 of the first row 54 A).
- an adhesive is applied to the top face 58 of a lowest exposed ledger clip 52 along the portion of the block member 12 which rests against the top face 58 . That is, the adhesive is applied to the ledger clip 52 of the first row 54 A of the block veneer wall system 48 . Any known adhesive may be utilized at this step.
- Shims may be inserted into the openings 68 of the bottom leg member 62 to improve the attachment of the block member 12 to the ledger clip 52 and to ensure that the block member 12 is level relative to the ground at step block 108 .
- an additional block member 12 is positioned horizontally adjacent to the block member 12 positioned at step blocks 102 through 108 .
- step block 112 and after the block members 12 are positioned side by side, the vertical bar 70 ( FIG. 8 ) is installed downwardly through openings 66 of the ledger clips 52 to maintain the positioning of the adjacent block members 12 .
- the vertical bars 70 are at least partially received within the vertical portions 42 of the slots 38 of the block members 12 (See FIG. 10 ).
- step blocks 102 through 112 are repeated to construct the block veneer wall system 48 having a desired width and height.
- step block 116 mortar is applied to each of a plurality of horizontal joints 72 (See FIG. 7 ) and vertical joints 74 (See FIG. 10 ) between the block members 12 after a desired number of block member 12 are attached to the ledger clips 52 .
- FIGS. 11-15 illustrate portions of another example wall system 148 .
- the wall system 148 is similar to the wall system 48 described in FIGS. 5-10 .
- like reference numerals designate like elements where appropriate, and reference numerals with the addition of 100 or multiples thereof designate modified elements. It is to be understood that the modified elements incorporate the same features and advantages of the corresponding original elements, except where stated otherwise.
- FIG. 11 illustrates a portion of a bracket assembly 151 of the wall system 148 that includes a bracket member 152 attached to a stud member 150 (no block members shown in FIG. 11 for clarity).
- the bracket assembly 151 establishes a self-supporting wall frame. That is, the bracket assembly 151 can be erected without the assistance of any other existing surface, and the integrity of the wall system 148 is not dependent on other wall systems.
- each stud member 150 includes a generally U-shaped body having a face portion 80 and flanges 82 , 84 that extend transversely from the face portion 80 at opposite sides 90 , 92 of the stud member 150 .
- the flanges 82 , 84 extend in the same direction away from the face portion 80 .
- each stud member 150 also optionally include a plurality of openings 86 .
- the openings 86 are punctures that are formed through the flanges 82 , 84 .
- Other known methods for forming the openings 86 are known and would be recognized by those of ordinary skill in the art having the benefit of this disclosure.
- An adhesive 94 is optionally applied between the stud members 150 and the block members 12 .
- the adhesive 94 is applied to each flange 82 , 84 of the stud members 150 prior to affixing the block members to the bracket assembly 151 .
- the adhesive 94 may also be also applied to portions of the top face 58 and the leg members 60 , 62 of the bracket members 152 , for example.
- a worker of ordinary skill in the art would be able to select an appropriate adhesive to bond the block members and the stud members 150 relative to one another.
- the bracket member 152 optionally includes a plurality of teeth 64 disposed on the top face 58 and a plurality of punched holes 57 formed on the leg 62 .
- the teeth 64 grip a bottom surface of a block member from a vertically adjacent row of the wall system 148 .
- the punched holes 57 provide a surface for the mortar to adhere to during application of the mortar to the mortar joints 172 , 174 (See FIGS. 13 , 14 ) of the wall system 148 .
- FIGS. 12A-12C illustrate an example block member 112 for use within the wall system 148 .
- the block member 12 includes a length L 1 .
- the block member 112 may be manufactured to the specifications of any desired length.
- the length L 1 extends between opposing end faces 134 , 136 .
- An outer face 118 and an inner face 120 are disposed on opposite sides of the opposing end faces 134 , 136 .
- a top face 141 extends between the outer face 118 and the inner face 120 .
- the opposing end faces 134 , 136 include finished surfaces which are free from any indentations, protrusions, slots or other formations.
- the outer face 118 defines a first height H 1 .
- the inner face 120 defines a second height H 2 .
- the second height H 2 is greater than H 1 . Therefore, a ledge 119 of the top face 141 extends between the outer face 118 and the inner face 120 .
- the ledge 119 extends transversely from the outer face 118 in a direction toward the inner face 120 , and includes a height that is substantially equal to the first height H 1 of the outer face 118 .
- the ledge 119 extends between the outer face 118 and an inner surface 121 of the inner face 120 .
- the inner surface 121 of the inner face 120 extends in a direction toward the outer face 118 .
- a portion of the bracket assembly 151 is received against the top face 141 , and in one example, directly against the ledge 119 , as is further discussed below.
- the inner face 120 of the block member 112 includes a plurality of protrusions 123 that protrude from the inner face 120 in a direction away from the outer face 118 .
- a plurality of indentations 125 are disposed between adjacent protrusions 123 .
- the actual number of protrusions 123 and indentations 125 included on the block member 112 will vary depending upon design specific parameters, including but not limited to, the size of the block member 112 .
- FIG. 12C illustrates two block members 112 connected via connector 127 , such as when the block members 112 are molded during a manufacturing molding process.
- the connector 127 maintains the positioning of the two block members 112 relative to one another within the mold.
- the connector 127 is detachable at connection points 129 to separate the block members 112 from the connector 127 to prepare the block members 112 for use within the wall system 148 .
- FIG. 13 illustrates the bracket assembly 151 of the wall system 148 with supported block members 112 .
- the wall system 148 is depicted as including block members 112 , a person of ordinary skill in the art having the benefit of this disclosure would be able to configure any block member for use with the bracket assembly 151 . That is, slight modifications of the block member 112 are contemplated as within the scope of this disclosure.
- the block members 112 may be positioned on both sides of the stud members 150 .
- FIG. 13 is not shown to the exact scale it would be in practice, and certain details are shown enlarged for clarity.
- the bracket members 152 receive the block members 12 in a similar manner as described above with respect to the wall system 48 .
- other details of the wall system 48 such as the use of shims, the application of mortar joints and the like are applicable to the example wall system 148 where necessary.
- the wall system 148 establishes a wall framework independent of the block members 112 , or any other existing surface of another wall system. That is, placement of the block members 112 is dictated by the bracket assembly 151 .
- bracket assembly 151 and the block members 112 are positioned horizontally across each stud member 150 of the wall system 148 .
- the leg 60 of each bracket member 152 is secured relative to the stud members 150 via a fastener 56 to construct the bracket assembly 151 .
- the block members 112 are received by the bracket members 152 .
- the legs 62 of the bracket members 152 can contact the inner surface 121 of the inner face 120 of each block member 112 , and the top face 58 of the bracket members 152 generally receives the bottom of the block members 112 . In this way, the bracket members 152 maintain the positioning of the block members 112 until the mortar or other adhesive sets and the construction of the wall system 148 is completed.
- the legs 62 of the bracket members 152 act as a stop which prevents movement of the block members 112 in a direction D that is away from the stud members 150 .
- Horizontal mortar joints 172 extend between vertically adjacent block members 112 .
- FIG. 14 An additional aspect of the example wall system 148 is illustrated in FIG. 14 .
- Vertical mortar joints 174 extend between horizontally adjacent block members 112 .
- a backer sheet 75 is disposed between each horizontally adjacent block member 112 .
- the backer sheets 75 reduce the amount of mortar required to fill the vertical mortar joints 174 and provide for moisture drainage. For example, water or other moisture may seep through the mortar joints 172 , 174 .
- the backer sheets 75 divert and communicate the moisture downwardly until the moisture can escape the wall system 148 .
- the backer sheets 75 therefore reduce water penetration and moisture build-up within the wall system 148 .
- FIGS. 15A and 15B illustrate an example backer sheet 75 for use within the wall system 148 .
- the backer sheet 75 is manufactured from a non-corrosive material. In one example, the backer sheet 75 is plastic.
- the backer sheet 75 includes slots 77 for receiving the legs 62 of the bracket members 152 (See FIG. 15A and FIG. 13 (shown in phantom).
- the backer sheets 75 can also include a plurality of vertical ribs 81 disposed on an outer surface 83 of the backer sheet 75 to divert and communicate moisture downwardly.
- the backer sheet 75 is generally flexible such that the backer sheet 75 can be manipulated (such as shown in FIG. 15A ) and positioned between adjacent block members 112 . When folded, the vertical ribs 81 of the backer sheets 75 face in a direction away from an interior 85 of the backer sheets 75 .
Abstract
A wall system includes a bracket assembly and at least one block member. The bracket assembly establishes a self-supporting wall frame. The at least one block member is supported on the self-supporting wall frame. The at least one block member includes an outer face, an inner face, and a top face extending between said outer face and said inner face. The top face locates the at least one block member on the self-supporting wall frame.
Description
- This application is a continuation-in-part of co-pending U.S. patent application Ser. No. 11/675,906, filed Feb. 16, 2007, which is a continuation-in-part of co-pending U.S. patent application Ser. No. 11/615,200, filed Dec. 22, 2006.
- This disclosure generally relates to building components, and more particularly to a wall system.
- Modern day building construction, including construction of commercial and residential buildings, often includes the construction of concrete block wall systems. Masonry blocks are stacked in a plurality of rows to construct the wall systems. Typical masonry blocks include masonry face members which are outwardly aligned and parallel and include structural cross members that extend between the parallel faces. Traditional concrete masonry blocks are of unitary construction, with the cross members and face members all formed of a concrete material. Therefore, the masonry blocks must be transported, in finished form, from the point of fabrication, storage, and/or sale, and ultimately to the construction site.
- Brick wall systems for commercial and residential buildings are also known. These wall systems utilize studs or furring strips of an existing building frame to construct exterior walls. Therefore, the integrity of wall systems of this type is dependent upon the support of one or more existing surfaces. Sheathing or building wrap (such as a plastic moisture barrier) may be installed over the studs and/or furring strips of the building framework. The brick members are then stacked and mortared to one another and anchors are utilized to attach the brick members to the exterior of the wood sheathing and building wrap.
- A wall system includes a bracket assembly and at least one block member. The bracket assembly establishes a self-supporting wall frame. The at least one block member is supported on the self-supporting wall frame. The at least one block member includes an outer face, an inner face, and a top face extending between said outer face and said inner face. The top face locates the at least one block member on the self-supporting wall frame
- A method of constructing a wall system includes positioning stud members at a desired spacing, attaching bracket members to the stud members to establish a self-supporting wall frame independently of any existing surface, and supporting block members on the self-supporting wall frame to construct the wall system.
- A block member for a wall system includes an outer face, an inner face and opposing end faces. The outer face extends between the opposing end faces and establishes a first height. The inner face extends between the opposing end faces on an opposite side from the outer face and establishes a second height that is greater than the first height. The top face extends between the outer face and the inner face and includes a ledge at least partially coextensive with the outer face and extending between the outer face and the inner face.
- The various features and advantages of this disclosure will become apparent to those skilled in the art from the following detailed description. The drawings that accompany the detailed description can be briefly described as follows.
-
FIG. 1 schematically illustrates an example masonry block; -
FIG. 2 schematically illustrates a second example masonry block; -
FIG. 3 illustrates a block member for use with the masonry blocks illustrated inFIG. 1 andFIG. 2 ; -
FIG. 4 schematically illustrates example features of the block member shown inFIG. 3 ; -
FIG. 5 illustrates an example wall system; -
FIG. 6 illustrates a perspective view of a bracket assembly of the wall system illustrated inFIG. 5 ; -
FIG. 7 illustrates a cross-sectional side view of the example wall system illustrated inFIG. 5 ; -
FIG. 8 illustrates a vertical bar of the bracket assembly illustrated inFIG. 6 ; -
FIG. 9 is a flowchart of an example method for constructing the wall system illustrated inFIG. 5 ; -
FIG. 10 illustrates a top view of the bracket assembly illustrated inFIG. 6 ; -
FIG. 11 illustrates a bracket assembly of another example wall system; -
FIGS. 12A , 12B and 12C illustrate a block member for use with the bracket assembly and wall system ofFIG. 11 ; -
FIG. 13 illustrates a cross-sectional view of the wall system ofFIG. 11 ; -
FIG. 14 illustrates another view of the wall system ofFIG. 13 ; and -
FIGS. 15A and 15B illustrate a backer sheet of the wall system ofFIGS. 11-14 . -
FIG. 1 illustrates anexample masonry block 10 that includes afirst block member 12, asecond block member 14, and across member 16. Eachblock member outer face 18 and aninner face 20 opposite of theouter face 18. Thecross member 16 extends between theinner faces 20 of theblock members cross member 16 may includeopenings 21 to provide an installer of themasonry blocks 10 with the ability to insulate and vertically reinforce themasonry block 10. - In the illustrated example, the
block members cross member 16 are formed of concrete as a single-piece construction. However, thefirst block member 12, thesecond block member 14 and thecross member 16 may include any other materials known to be suitable by those skilled in the art having the benefit of this description. Themasonry blocks 10 are stacked and positioned in a plurality of rows to construct a free-standing wall system. - Each
block member masonry block 10 includes adepression 44, for example. In another example, eachblock member depressions 44. Aninsert 17 is receivable within thedepressions 44. In one example, theinsert 17 includes a porous material. In another example, theinsert 17 is a Styrofoam rope. Theinserts 17 reduce the build up of mortar or other substances within thedepressions 44 during installation of themasonry blocks 10, thereby improving water drainage of the masonry blocks. -
FIG. 2 illustrates a secondexample masonry block 24. Themasonry block 24 also includes afirst block member 26, asecond block member 28 and across-member 30. Thefirst block member 26 and the secondmember block member 28 are substantially identical to thefirst block member 12 andsecond block member 14 of themasonry block 10. In one example, thecross member 30 is abracket member 32 which comprises a material different from that of theblock members bracket member 32 is metal, such as 25 gauge galvanized sheet metal, for example. In another example, thebracket member 32 is plastic. Theexample block members -
FIG. 3 illustrates theexample block member 12. Theblock member 12 is shown and described as substantially typical of each of theblock members block member 12 is formed of concrete, brick, or any other suitable material. In one example, theblock member 12 includes a water resistant additive that reduces any susceptibility to cracking and water penetration. Theexample block member 12 includes a length L1. In one example, the length L1 of theblock member 12 is approximately 16 inches. In another example, length L1 is approximately 8 inches. However, theblock member 12 may be manufactured to the specifications of any desired length. - The length L1 extends between opposing end faces 34, 36. In one example, the
block member 12 includes aslot 38. Theslot 38 is positioned between theouter face 18 and theinner face 20 of theblock member 12. - The
slot 38 includes ahorizontal portion 40 and avertical portion 42. Thevertical portion 42 is transverse to thehorizontal portion 40, in one example. In another example, thevertical portions 42 of theslot 38 are perpendicular to thehorizontal portion 40. Thehorizontal portion 40 of theslot 38 is coextensive with the length L1 of theblock member 12. Thehorizontal portion 40 of theslot 38 extends along a top face 41 (which extends between the end faces 34, 36 and theinner face 20 and the outer face 18) of theblock member 12, for example. Thevertical portion 42 is coextensive with a height H of theblock member 12 and extends along each of the first end face 34 and thesecond end face 36 of theblock member 12. Therefore, theslot 38 extends along each of the first and second end faces 34, 36 and along the entire length L1 of theblock member 12. That is, theslot 38 of theblock members 12 is continuous and uninterrupted along the height H and length L1 of theblock member 12. - The
slot 38 is positioned within a plane of theblock member 12 which is offset from each plane defined by theouter face 18 and theinner face 20 of theblock member 12. That is, no portion of theslot 38 extends into theouter face 18 or theinner face 20. In one example, theouter face 18 is positioned within afirst plane 43, theinner face 20 is positioned within asecond plane 45 different from thefirst plane 43, and theslot 38 is positioned within athird plane 47 which is different from both thefirst plane 43 and the second plane 45 (SeeFIG. 4 ). - In one example, the
horizontal portion 40 and thevertical portions 42 of theslot 38 are positioned within the same plane. In another example, thevertical portions 42 of theslot 38 are offset from thehorizontal portion 40 of theslot 38. Thevertical portions 42 may be offset in either direction relative to the horizontal portion 40 (i.e., either towards theouter face 18 or towards theinner face 20 of the block member 12). A person of ordinary skill in the art having the benefit of this disclosure would understand how to design theslot 38 of theblock member 12, including the various dimensions associated with theslot 38 such as the offset distance between thevertical portions 42 and thehorizontal portion 40 of the slot, the slot depth, and numerous other dimensions. - The
block member 12 may also include a plurality ofdepressions 44 disposed along the length of theblock member 12 adjacent to thehorizontal portion 40 of theslot 38. Thedepressions 44 are utilized to divert water into thehorizontal portion 40 of theslot 38, which may enter through the joints (i.e., the horizontal and vertical gaps betweenadjacent block members 12 in a wall system) of a wall system fromadjacent block members 12. Thehorizontal portion 40 communicates the water to thevertical portions 42 of theslot 38. Thevertical portions 42 then communicate the water downwardly until the water escapes the wall system. Therefore, thedepressions 44 and theslot 38 reduce water penetration and water build-up within theblock members 12, as is further discussed below. - The
block members 12 may include abeveled edge 35. Thebeveled edge 35 extends along both the top face 41 and the end faces 34, 36 of the block member 12 (SeeFIGS. 7 and 10 ). The beveled edges 35 allowadjacent block members 12 of a wall system to be positioned closer to one another thereby reducing the size of the mortar joints between theblock members 12. - The block member 12 (which is typical of
block members block members 12 are utilized to assembly a plurality of the masonry blocks 10, which are stacked and positioned in a plurality of rows to build a wall system. In another example, theblock members 12 may be utilized with a preexistingwall 46 to establish a blockveneer wall system 48, as is illustrated inFIG. 5 . - The preexisting
wall 46 includes a plurality ofstud members 50 that extend adjacent to one another in a vertical manner, in one example. The spacing between thestud members 50 is not significant, and thestud members 50 can be spaced at 8″ on center, 12″ on center, 16″ on center, or any other spacing requirements. Although the preexistingwall 46 is illustrated withstud members 50, it should be understood that the preexisting wall may include any type of wall having any type of wall components. Thestud members 50 may include metal studs, for example. In another example, thestud members 50 include wooden studs. In yet another example, thestud members 50 include plastic studs. A person of ordinary skill in the art having the benefit of this disclosure would understand that the blockveneer wall system 48 may be utilized with any preexistingwall 46. - The block
veneer wall system 48 includes a plurality of ledger clips 52 and a plurality of theblock members 12. As is known, thestud members 50 are positioned horizontally adjacent to one another along a length X to establish thepre-existing wall 46. Thestud members 50 extend vertically to a desired height Z of thewall system 48. - The ledger clips 52 extend horizontally across the
stud members 50 to form a wall frame including a plurality ofrows 54A-54 n. Thewall system 48 may include any number of rows 54. The example ledger clips 52 are manufactured in strips of approximately 10 to 12 feet in length, in one example. However, the ledger clips 52 may be manufactured to any specification. In one example, thestud members 50 are spaced apart a distance of approximately 16 inches and eachledger clip 52 is spaced apart a distance of approximately 8 inches. It should be understood that the spacing and other dimensional relationships that exist between thestud members 50 and the ledger clips 52 may vary to provide a blockveneer wall system 48 of any size. -
FIG. 6 illustrates a portion of thebracket assembly 51 of the blockveneer wall system 48 that includes aledger clip 52 attached to astud member 50. In one example, theledger clip 52 is attached to thestud member 50 with a threadedfastener 56. However, other attachment methods are contemplated as within the scope of this disclosure. - Each
ledger clip 52 generally includes a Z-shaped body having atop face 58 andleg members top face 58. Theleg members top face 58 in opposite directions relative to thetop face 58. Theleg member 60 is received against thestud member 50 and is attached to thestud member 50 with the threadedfastener 56, for example. Theleg member 62 extends in a downward direction relative to thetop face 58 and receives aslot 38 of theblock member 12 to support theblock member 12 on the blockveneer wall system 48. Therefore, the blockveneer wall system 48 establishes a wall framework independent of theblock members 12. That is, placement of theblock members 12 is dictated by the ledger clips 52. - The
leg member 62 of eachledger clip 52 includes aflange portion 63. Theflange portions 63 push theleg member 62 against aback wall 61 of thehorizontal portion 40 of the slot 38 (SeeFIG. 7 ) to reduce the amount of “slop” in the wall. That is, theflange portions 63 secure theblock members 12 to the ledger clips 52. - In one example, the
top face 58 of eachledger clip 52 includes a plurality ofteeth 64. Theteeth 64 grip a bottom surface of ablock member 12 from a vertically adjacent row 54 of the block veneer wall system 48 (seeFIG. 7 ). Thetop face 58 also includes a plurality ofopenings 66 for receiving a vertical bar (seeFIG. 8 ) installed between horizontallyadjacent block members 12 once positioned onto the blockveneer wall system 48. Theexample ledger clip 52 includes a second set ofopenings 68 provided on theleg members 62. Theopenings 68 receive shims to adequately secure theblock members 12 to the ledger clips 52 and ensure that thetop face 58 is level relative to the ground as theblock members 12 are received onto theleg member 62 of theledger clip 52. -
FIG. 9 , with continuing reference toFIGS. 1-8 , illustrates anexample method 100 of constructing a wall system, such as the blockveneer wall system 48, for example. At step block 102, the ledger clips 52 are horizontally positioned across thestud members 50 of apre-existing wall 46 to establish a wall frame including a plurality of rows 54. In one example, wood sheathing, such as plywood for example, is installed over top of the existingstud members 50. In another example, building wrap may be installed to cover the wood sheathing and provide a moisture barrier. - At
step block 104, ablock member 12 is positioned on the blockveneer wall system 48. The top face 41 of theblock member 12 is tilted toward theledger clip 52 and pushed upward such that thehorizontal portion 40 of theslot 38 of theblock member 12 is received by thelower leg member 62 of theledger clip 52. The bottom of theblock member 12 is next pushed in an inward direction (i.e., toward the stud members 50) until theinner face 20 of theblock member 12 rests against theupper leg member 60 of the ledger clip 52 (except forblock members 12 of thefirst row 54A). Theblock member 12 is then eased slightly downward until a bottom face of theblock member 12 is seated on thetop face 58 of the ledger clip 52 (or a starting strip where installing theblock members 12 of thefirst row 54A). - Next, at
step block 106, an adhesive is applied to thetop face 58 of a lowest exposedledger clip 52 along the portion of theblock member 12 which rests against thetop face 58. That is, the adhesive is applied to theledger clip 52 of thefirst row 54A of the blockveneer wall system 48. Any known adhesive may be utilized at this step. - Shims may be inserted into the
openings 68 of thebottom leg member 62 to improve the attachment of theblock member 12 to theledger clip 52 and to ensure that theblock member 12 is level relative to the ground atstep block 108. Atstep block 110, anadditional block member 12 is positioned horizontally adjacent to theblock member 12 positioned at step blocks 102 through 108. - At
step block 112, and after theblock members 12 are positioned side by side, the vertical bar 70 (FIG. 8 ) is installed downwardly throughopenings 66 of the ledger clips 52 to maintain the positioning of theadjacent block members 12. Thevertical bars 70 are at least partially received within thevertical portions 42 of theslots 38 of the block members 12 (SeeFIG. 10 ). Next, at step block 114, step blocks 102 through 112 are repeated to construct the blockveneer wall system 48 having a desired width and height. Finally, atstep block 116, mortar is applied to each of a plurality of horizontal joints 72 (SeeFIG. 7 ) and vertical joints 74 (SeeFIG. 10 ) between theblock members 12 after a desired number ofblock member 12 are attached to the ledger clips 52. -
FIGS. 11-15 illustrate portions of anotherexample wall system 148. In this example, thewall system 148 is similar to thewall system 48 described inFIGS. 5-10 . In this disclosure, like reference numerals designate like elements where appropriate, and reference numerals with the addition of 100 or multiples thereof designate modified elements. It is to be understood that the modified elements incorporate the same features and advantages of the corresponding original elements, except where stated otherwise. -
FIG. 11 illustrates a portion of abracket assembly 151 of thewall system 148 that includes abracket member 152 attached to a stud member 150 (no block members shown inFIG. 11 for clarity). Thebracket assembly 151 establishes a self-supporting wall frame. That is, thebracket assembly 151 can be erected without the assistance of any other existing surface, and the integrity of thewall system 148 is not dependent on other wall systems. - In this example, the
bracket member 152 is a ledger clip. Eachstud member 150 includes a generally U-shaped body having aface portion 80 andflanges face portion 80 atopposite sides stud member 150. In the illustrated example, theflanges face portion 80. - The
flanges stud member 150 also optionally include a plurality ofopenings 86. In one example, theopenings 86 are punctures that are formed through theflanges openings 86 are known and would be recognized by those of ordinary skill in the art having the benefit of this disclosure. - An adhesive 94 is optionally applied between the
stud members 150 and theblock members 12. In one example, the adhesive 94 is applied to eachflange stud members 150 prior to affixing the block members to thebracket assembly 151. The adhesive 94 may also be also applied to portions of thetop face 58 and theleg members bracket members 152, for example. A worker of ordinary skill in the art would be able to select an appropriate adhesive to bond the block members and thestud members 150 relative to one another. - The
bracket member 152 optionally includes a plurality ofteeth 64 disposed on thetop face 58 and a plurality of punchedholes 57 formed on theleg 62. Theteeth 64 grip a bottom surface of a block member from a vertically adjacent row of thewall system 148. The punched holes 57 provide a surface for the mortar to adhere to during application of the mortar to the mortar joints 172, 174 (SeeFIGS. 13 , 14) of thewall system 148. -
FIGS. 12A-12C illustrate anexample block member 112 for use within thewall system 148. Theblock member 12 includes a length L1. Theblock member 112 may be manufactured to the specifications of any desired length. The length L1 extends between opposing end faces 134, 136. Anouter face 118 and aninner face 120 are disposed on opposite sides of the opposing end faces 134, 136. A top face 141 extends between theouter face 118 and theinner face 120. The opposing end faces 134, 136 include finished surfaces which are free from any indentations, protrusions, slots or other formations. - The
outer face 118 defines a first height H1. Theinner face 120 defines a second height H2. In this example, the second height H2 is greater than H1. Therefore, aledge 119 of the top face 141 extends between theouter face 118 and theinner face 120. Theledge 119 extends transversely from theouter face 118 in a direction toward theinner face 120, and includes a height that is substantially equal to the first height H1 of theouter face 118. In this example, theledge 119 extends between theouter face 118 and aninner surface 121 of theinner face 120. Theinner surface 121 of theinner face 120 extends in a direction toward theouter face 118. A portion of thebracket assembly 151 is received against the top face 141, and in one example, directly against theledge 119, as is further discussed below. - The
inner face 120 of theblock member 112 includes a plurality ofprotrusions 123 that protrude from theinner face 120 in a direction away from theouter face 118. A plurality ofindentations 125 are disposed betweenadjacent protrusions 123. The actual number ofprotrusions 123 andindentations 125 included on theblock member 112 will vary depending upon design specific parameters, including but not limited to, the size of theblock member 112. -
FIG. 12C illustrates twoblock members 112 connected viaconnector 127, such as when theblock members 112 are molded during a manufacturing molding process. Theconnector 127 maintains the positioning of the twoblock members 112 relative to one another within the mold. Theconnector 127 is detachable at connection points 129 to separate theblock members 112 from theconnector 127 to prepare theblock members 112 for use within thewall system 148. -
FIG. 13 illustrates thebracket assembly 151 of thewall system 148 with supportedblock members 112. Although thewall system 148 is depicted as includingblock members 112, a person of ordinary skill in the art having the benefit of this disclosure would be able to configure any block member for use with thebracket assembly 151. That is, slight modifications of theblock member 112 are contemplated as within the scope of this disclosure. In addition, although only depicted on one side of thebracket assembly 151, a person of ordinary skill in the art would understand that theblock members 112 may be positioned on both sides of thestud members 150.FIG. 13 is not shown to the exact scale it would be in practice, and certain details are shown enlarged for clarity. - The
bracket members 152 receive theblock members 12 in a similar manner as described above with respect to thewall system 48. In addition, other details of thewall system 48 such as the use of shims, the application of mortar joints and the like are applicable to theexample wall system 148 where necessary. Like thewall system 48, thewall system 148 establishes a wall framework independent of theblock members 112, or any other existing surface of another wall system. That is, placement of theblock members 112 is dictated by thebracket assembly 151. - For example, the
bracket assembly 151 and theblock members 112 are positioned horizontally across eachstud member 150 of thewall system 148. Theleg 60 of eachbracket member 152 is secured relative to thestud members 150 via afastener 56 to construct thebracket assembly 151. Theblock members 112 are received by thebracket members 152. Thelegs 62 of thebracket members 152 can contact theinner surface 121 of theinner face 120 of eachblock member 112, and thetop face 58 of thebracket members 152 generally receives the bottom of theblock members 112. In this way, thebracket members 152 maintain the positioning of theblock members 112 until the mortar or other adhesive sets and the construction of thewall system 148 is completed. In one example, thelegs 62 of thebracket members 152 act as a stop which prevents movement of theblock members 112 in a direction D that is away from thestud members 150. Horizontal mortar joints 172 extend between verticallyadjacent block members 112. - An additional aspect of the
example wall system 148 is illustrated inFIG. 14 . Vertical mortar joints 174 extend between horizontallyadjacent block members 112. In addition, abacker sheet 75 is disposed between each horizontallyadjacent block member 112. Thebacker sheets 75 reduce the amount of mortar required to fill the vertical mortar joints 174 and provide for moisture drainage. For example, water or other moisture may seep through the mortar joints 172, 174. Thebacker sheets 75 divert and communicate the moisture downwardly until the moisture can escape thewall system 148. Thebacker sheets 75 therefore reduce water penetration and moisture build-up within thewall system 148. -
FIGS. 15A and 15B illustrate anexample backer sheet 75 for use within thewall system 148. Thebacker sheet 75 is manufactured from a non-corrosive material. In one example, thebacker sheet 75 is plastic. Thebacker sheet 75 includesslots 77 for receiving thelegs 62 of the bracket members 152 (SeeFIG. 15A andFIG. 13 (shown in phantom). Thebacker sheets 75 can also include a plurality ofvertical ribs 81 disposed on anouter surface 83 of thebacker sheet 75 to divert and communicate moisture downwardly. Thebacker sheet 75 is generally flexible such that thebacker sheet 75 can be manipulated (such as shown inFIG. 15A ) and positioned betweenadjacent block members 112. When folded, thevertical ribs 81 of thebacker sheets 75 face in a direction away from an interior 85 of thebacker sheets 75. - The foregoing description shall be interpreted as illustrative and not in any limiting sense. A worker of ordinary skill in the art would recognize that certain modifications would come within the scope of this disclosure. For these reasons, the following claims should be studied to determine the true scope and content of this disclosure.
Claims (20)
1. A wall system, comprising:
a bracket assembly which establishes a self-supporting wall frame; and
at least one block member supported on said self-supporting wall frame and having an outer face, an inner face, and a top face extending between said outer face and said inner face, wherein said top face locates said at least one block member on said self-supporting wall frame.
2. The wall system as recited in claim 1 , wherein said bracket assembly includes a wall component and a plurality of ledger clips attached to said wall component, wherein said plurality of ledger clips extend horizontally across said wall component to establish a plurality of rows of said self-supporting wall frame.
3. The wall system as recited in claim 2 , wherein said ledger clips comprise a z-shape, said ledger clips including at least one leg member that is received directly against said top face of said at least one block member to position said at least one block member to said self-supporting wall frame.
4. The wall system as recited in claim 1 , comprising a plurality of block members and wherein said bracket assembly includes a plurality of vertical bars positioned between horizontally adjacent block members of said plurality of block members.
5. The wall system as recited in claim 1 , comprising a plurality of block members and wherein said bracket assembly includes a plurality of backer sheets positioned between horizontally adjacent block members of said plurality of block members.
6. The wall system as recited in claim 1 , wherein said plurality of backer sheets are non-corrosive.
7. The wall system as recited in claim 1 , wherein said top face includes a ledge that locates said at least one block member on said self-supporting wall frame.
8. The wall system as recited in claim 7 , wherein said ledge extends between said outer face and an inner surface of said inner face.
9. The wall system as recited in claim 7 , wherein said ledge extends transverse from said outer face in a direction toward said inner face, wherein at least a portion of said bracket assembly is in direct contact with said at least one block member.
10. The wall system as recited in claim 1 , wherein said self-supporting wall frame establishes said wall system independently of any existing surface.
11. A method of constructing a wall system, comprising the steps of:
(a) positioning stud members at a desired spacing;
(b) attaching bracket members to the stud members to establish a self-supporting wall frame independently of any existing surface; and
(c) supporting block members on the self-supporting wall frame to construct the wall system.
12. The method as recited in claim 11 , comprising the step of:
(d) positioning non-corrosive backer sheets between horizontally adjacent block members.
13. The method as recited in claim 12 , comprising the step of:
(e) applying mortar in each of a plurality of horizontal joints and vertical joints that extend between the block members.
14. The method as recited in claim 12 , comprising the step of:
(e) communicating moisture vertically downward relative to the wall system via the non-corrosive backer sheets.
15. A block member for a wall system, comprising:
an outer face extending between opposing end faces and establishing a first height;
an inner face extending between said opposing end faces on an opposite side from said outer face, wherein said inner face establishes a second height that is greater than said first height; and
a top face extending between said outer face and said inner face and including a ledge at least partially coextensive with said outer face and extending between said outer face and said inner face.
16. The block member as recited in claim 15 , wherein said inner face includes a plurality of protrusions extending from said inner face in a direction away from said outer face.
17. The block member as recited in claim 16 , wherein a plurality of indentations extend between said plurality of protrusions of said inner face.
18. The block member as recited in claim 15 , wherein said ledge extends between said outer face and an inner surface of said inner face, and said ledge defines a height that is less than said second height of said inner face.
19. The block member as recited in claim 18 , wherein said inner surface extends from said inner face in a direction toward said outer face.
20. The block member as recited in claim 15 , wherein said ledge extends transversely from said outer face in a direction toward said inner face.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US12/641,839 US20100095628A1 (en) | 2006-12-22 | 2009-12-18 | Wall system |
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US11/615,200 US20080148675A1 (en) | 2006-12-22 | 2006-12-22 | Composite masonry block |
US11/675,906 US20080148661A1 (en) | 2006-12-22 | 2007-02-16 | Masonry block wall system |
US12/641,839 US20100095628A1 (en) | 2006-12-22 | 2009-12-18 | Wall system |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US11/675,906 Continuation-In-Part US20080148661A1 (en) | 2006-12-22 | 2007-02-16 | Masonry block wall system |
Publications (1)
Publication Number | Publication Date |
---|---|
US20100095628A1 true US20100095628A1 (en) | 2010-04-22 |
Family
ID=42107517
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US12/641,839 Abandoned US20100095628A1 (en) | 2006-12-22 | 2009-12-18 | Wall system |
Country Status (1)
Country | Link |
---|---|
US (1) | US20100095628A1 (en) |
Cited By (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20120131870A1 (en) * | 2010-11-29 | 2012-05-31 | Demaere Jean-Louis | Wall form |
US8820024B1 (en) * | 2013-03-11 | 2014-09-02 | Mohammad A. H. S. H. Abdullah | Wall building system and method |
US20150089825A1 (en) * | 2013-10-02 | 2015-04-02 | Jonathan E. Jones | Concrete Block Spacer System |
EP2990558A1 (en) * | 2014-08-28 | 2016-03-02 | Mohammad A.H.S.H. Abdullah | Wall building system and method |
USD997387S1 (en) * | 2021-09-20 | 2023-08-29 | Allan Block, Llc | Modular block system |
Citations (37)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US904588A (en) * | 1908-02-26 | 1908-11-24 | William T Wightman | Building-block and wall constructed thereof. |
US1052670A (en) * | 1912-01-31 | 1913-02-11 | Walter J La Francis | Building-veneer. |
US1171191A (en) * | 1915-08-21 | 1916-02-08 | William J Gronert | Building-block. |
US1420478A (en) * | 1920-12-11 | 1922-06-20 | Walter R Forbush | Wall construction |
US1588332A (en) * | 1925-03-17 | 1926-06-08 | Frank E Peters | Building wall |
US2106177A (en) * | 1936-12-15 | 1938-01-25 | Victor J Hultquist | Building unit |
US2245785A (en) * | 1939-06-09 | 1941-06-17 | Jr Henry Jentzer | Wall tile |
US2736188A (en) * | 1956-02-28 | Wilhelm | ||
US2924963A (en) * | 1955-04-07 | 1960-02-16 | Structural Clay Products Res F | Method and means for veneer brick |
US3256657A (en) * | 1963-01-30 | 1966-06-21 | Idaho Invest Corp | Wall of interlocked, adhesively secured building blocks and sealing means therebetween |
US3998016A (en) * | 1975-03-13 | 1976-12-21 | H. H. Robertson Company | Blow-in/blow-out wall structure |
US4299069A (en) * | 1977-11-28 | 1981-11-10 | Alfred Neumann | Prefabricated wall facing panels |
US4407104A (en) * | 1980-10-02 | 1983-10-04 | Francis Gerald T | Brick panel insulation with load bearing clip |
US4516373A (en) * | 1981-10-26 | 1985-05-14 | Yoshinori Osawa | Apparatus for tile-setting |
US4641473A (en) * | 1985-12-23 | 1987-02-10 | Trezza Ronald F | Clip construction for wall arrangement |
US4765111A (en) * | 1987-06-18 | 1988-08-23 | Yoshinori Osawa | Assembly for mounting plates on wall |
US4956949A (en) * | 1989-05-25 | 1990-09-18 | Gerald T. Francis | Brick panel wall construction |
US5207043A (en) * | 1988-11-07 | 1993-05-04 | Mcgee Brian P | Masonry connector |
US5501050A (en) * | 1993-10-18 | 1996-03-26 | Ruel; Raymond | Shingled tile block siding facade for buildings |
US5526630A (en) * | 1992-09-28 | 1996-06-18 | Francis; Steven R. | Method of producing a thin brick panel assembly |
US5634305A (en) * | 1992-05-18 | 1997-06-03 | Erlanger; Israel | System for stone cladding of buildings |
US5657600A (en) * | 1994-06-20 | 1997-08-19 | Aab Building Systems Inc. | Web member for concrete form walls |
US5802797A (en) * | 1994-12-30 | 1998-09-08 | Jannock Limited | Dry-stackable masonry unit and methods of manufacture and use |
US5845448A (en) * | 1997-04-10 | 1998-12-08 | Potvin; Philip N. | Masonry block assembly |
US5983585A (en) * | 1997-02-04 | 1999-11-16 | Spakousky; John | Building block with insulating center portion |
US20020023398A1 (en) * | 2000-08-09 | 2002-02-28 | Nichiha Co., Ltd. | External wall construction, sealing fixture, external wall panel, and external wall constructing method |
US6460311B1 (en) * | 1999-04-02 | 2002-10-08 | Nichiha Corp. | Fixture for boarding, and horizontal boarding method using the fixture |
US6499261B2 (en) * | 2001-01-24 | 2002-12-31 | Nichiha Co., Ltd. | Fastening sealing member and siding boards attachment structure |
US6550212B2 (en) * | 2001-02-20 | 2003-04-22 | Pactiv Corporation | Protective drainage wraps |
US6564520B1 (en) * | 1999-01-05 | 2003-05-20 | W. R. Grace & Co.-Conn | Sheet-like masonry block drainage system |
US6735913B2 (en) * | 2002-08-01 | 2004-05-18 | Sanders & Associates Geostructural Engineering, Inc. | Block wall system |
US20050138876A1 (en) * | 2003-05-21 | 2005-06-30 | Tom Sourlis | Drainage system for use in masonry block construction |
US6951086B2 (en) * | 2002-05-20 | 2005-10-04 | James Kenneth Passeno | Method and apparatus for making thin brick wall facing |
US6978581B1 (en) * | 1997-02-04 | 2005-12-27 | Pentstar Corporation | Composite building block with connective structure |
US20070151190A1 (en) * | 2005-12-19 | 2007-07-05 | Robert Huff | Thin stone or thin brick veneer wall system and clips therefor |
US7665260B2 (en) * | 2004-07-28 | 2010-02-23 | Nichiha Co., Ltd. | Fastening member, siding boards attachment structure using the same and method of attaching siding boards |
US7918065B2 (en) * | 2006-08-11 | 2011-04-05 | Nichiha Corporation | Fastening member and external wall construction structure using the same |
-
2009
- 2009-12-18 US US12/641,839 patent/US20100095628A1/en not_active Abandoned
Patent Citations (37)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2736188A (en) * | 1956-02-28 | Wilhelm | ||
US904588A (en) * | 1908-02-26 | 1908-11-24 | William T Wightman | Building-block and wall constructed thereof. |
US1052670A (en) * | 1912-01-31 | 1913-02-11 | Walter J La Francis | Building-veneer. |
US1171191A (en) * | 1915-08-21 | 1916-02-08 | William J Gronert | Building-block. |
US1420478A (en) * | 1920-12-11 | 1922-06-20 | Walter R Forbush | Wall construction |
US1588332A (en) * | 1925-03-17 | 1926-06-08 | Frank E Peters | Building wall |
US2106177A (en) * | 1936-12-15 | 1938-01-25 | Victor J Hultquist | Building unit |
US2245785A (en) * | 1939-06-09 | 1941-06-17 | Jr Henry Jentzer | Wall tile |
US2924963A (en) * | 1955-04-07 | 1960-02-16 | Structural Clay Products Res F | Method and means for veneer brick |
US3256657A (en) * | 1963-01-30 | 1966-06-21 | Idaho Invest Corp | Wall of interlocked, adhesively secured building blocks and sealing means therebetween |
US3998016A (en) * | 1975-03-13 | 1976-12-21 | H. H. Robertson Company | Blow-in/blow-out wall structure |
US4299069A (en) * | 1977-11-28 | 1981-11-10 | Alfred Neumann | Prefabricated wall facing panels |
US4407104A (en) * | 1980-10-02 | 1983-10-04 | Francis Gerald T | Brick panel insulation with load bearing clip |
US4516373A (en) * | 1981-10-26 | 1985-05-14 | Yoshinori Osawa | Apparatus for tile-setting |
US4641473A (en) * | 1985-12-23 | 1987-02-10 | Trezza Ronald F | Clip construction for wall arrangement |
US4765111A (en) * | 1987-06-18 | 1988-08-23 | Yoshinori Osawa | Assembly for mounting plates on wall |
US5207043A (en) * | 1988-11-07 | 1993-05-04 | Mcgee Brian P | Masonry connector |
US4956949A (en) * | 1989-05-25 | 1990-09-18 | Gerald T. Francis | Brick panel wall construction |
US5634305A (en) * | 1992-05-18 | 1997-06-03 | Erlanger; Israel | System for stone cladding of buildings |
US5526630A (en) * | 1992-09-28 | 1996-06-18 | Francis; Steven R. | Method of producing a thin brick panel assembly |
US5501050A (en) * | 1993-10-18 | 1996-03-26 | Ruel; Raymond | Shingled tile block siding facade for buildings |
US5657600A (en) * | 1994-06-20 | 1997-08-19 | Aab Building Systems Inc. | Web member for concrete form walls |
US5802797A (en) * | 1994-12-30 | 1998-09-08 | Jannock Limited | Dry-stackable masonry unit and methods of manufacture and use |
US5983585A (en) * | 1997-02-04 | 1999-11-16 | Spakousky; John | Building block with insulating center portion |
US6978581B1 (en) * | 1997-02-04 | 2005-12-27 | Pentstar Corporation | Composite building block with connective structure |
US5845448A (en) * | 1997-04-10 | 1998-12-08 | Potvin; Philip N. | Masonry block assembly |
US6564520B1 (en) * | 1999-01-05 | 2003-05-20 | W. R. Grace & Co.-Conn | Sheet-like masonry block drainage system |
US6460311B1 (en) * | 1999-04-02 | 2002-10-08 | Nichiha Corp. | Fixture for boarding, and horizontal boarding method using the fixture |
US20020023398A1 (en) * | 2000-08-09 | 2002-02-28 | Nichiha Co., Ltd. | External wall construction, sealing fixture, external wall panel, and external wall constructing method |
US6499261B2 (en) * | 2001-01-24 | 2002-12-31 | Nichiha Co., Ltd. | Fastening sealing member and siding boards attachment structure |
US6550212B2 (en) * | 2001-02-20 | 2003-04-22 | Pactiv Corporation | Protective drainage wraps |
US6951086B2 (en) * | 2002-05-20 | 2005-10-04 | James Kenneth Passeno | Method and apparatus for making thin brick wall facing |
US6735913B2 (en) * | 2002-08-01 | 2004-05-18 | Sanders & Associates Geostructural Engineering, Inc. | Block wall system |
US20050138876A1 (en) * | 2003-05-21 | 2005-06-30 | Tom Sourlis | Drainage system for use in masonry block construction |
US7665260B2 (en) * | 2004-07-28 | 2010-02-23 | Nichiha Co., Ltd. | Fastening member, siding boards attachment structure using the same and method of attaching siding boards |
US20070151190A1 (en) * | 2005-12-19 | 2007-07-05 | Robert Huff | Thin stone or thin brick veneer wall system and clips therefor |
US7918065B2 (en) * | 2006-08-11 | 2011-04-05 | Nichiha Corporation | Fastening member and external wall construction structure using the same |
Cited By (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20120131870A1 (en) * | 2010-11-29 | 2012-05-31 | Demaere Jean-Louis | Wall form |
US8820024B1 (en) * | 2013-03-11 | 2014-09-02 | Mohammad A. H. S. H. Abdullah | Wall building system and method |
US20150089825A1 (en) * | 2013-10-02 | 2015-04-02 | Jonathan E. Jones | Concrete Block Spacer System |
US9086268B2 (en) * | 2013-10-02 | 2015-07-21 | Jonathan E Jones | Concrete block spacer system |
EP2990558A1 (en) * | 2014-08-28 | 2016-03-02 | Mohammad A.H.S.H. Abdullah | Wall building system and method |
USD997387S1 (en) * | 2021-09-20 | 2023-08-29 | Allan Block, Llc | Modular block system |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
US8769891B2 (en) | Building method using multi-storey panels | |
US9194118B2 (en) | Brick bracket for installation of a ledger on the brick facing or veneer of a structure and associated methods for the installation of the brick bracket on the brick facing | |
US6622452B2 (en) | Insulated concrete wall construction method and apparatus | |
US6698710B1 (en) | System for the construction of insulated concrete structures using vertical planks and tie rails | |
US8347581B2 (en) | Adjustable masonry anchor assembly for use with insulating concrete form systems | |
US3676967A (en) | Forms for concrete wall construction | |
US4885884A (en) | Building panel assembly | |
US6739105B2 (en) | Constructional elements | |
CA2251310C (en) | Bracket for concrete forms | |
US20100107536A1 (en) | Thermo tech mark ii limited | |
US20130047539A1 (en) | Building Structure | |
US20100269439A1 (en) | Insulated panel and system for construction of a modular building and method of fabrication thereof | |
US20160281355A1 (en) | Wall forming system and kit thereof | |
US6314696B2 (en) | Reinforced concrete walls having exposed attachment studs | |
US20100095628A1 (en) | Wall system | |
US9068350B2 (en) | Building module, a method for making same, and a method for using same to construct a building | |
US8522508B1 (en) | Flashing support cant for a wall assembly and associated method | |
CA2673813A1 (en) | Joist hanger for icf wall systems | |
US11859382B2 (en) | Formwork for foundation construction | |
US7530203B1 (en) | Pre-cast concrete wall with truss ledge | |
US20060059846A1 (en) | Bracket for concrete forms | |
MX2011001599A (en) | Apparatus for connecting framing components of a builiding to a foundation. | |
US20090205282A1 (en) | Wall system | |
US20080148661A1 (en) | Masonry block wall system | |
US4444374A (en) | Prefabricated concrete forms assembly |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |