BRIEF DESCRIPTION OF DRAWINGS
For a better understanding of the present invention, reference may be made to the accompanying drawings.
FIG. 1 is a perspective view of an ICF supporting wall structure and a masonry structure, partly cut-away, incorporating the present anchor assemblies made in accordance with the teachings of the present invention.
FIG. 2 is a partial perspective view showing the positioning of the present anchor assemblies on the ICF supporting wall structure relative to the masonry wall structure.
FIG. 3 is a perspective view of one embodiment of the present anchor assembly.
FIG. 4 is an enlarged partial cut-away view of one of the ICF blocks showing the present anchor member attached to a corresponding ICF tie flange member.
FIG. 5 is a partial perspective view showing the tab member associated with the anchor member positioned relative to a corresponding ICF tie flange member for attachment thereto.
FIG. 6 is a partial top plan form view showing the present anchor member being attached to a corresponding ICF tie flange member.
DETAILED DESCRIPTION
Referring to the drawings more particularly by reference numbers wherein like numerals refer to like parts, the number 30 in FIGS. 1-3 identifies one embodiment of an adjustable masonry anchor assembly constructed according to the teachings of the present invention. FIGS. 1 and 2 illustrate a typical use of the present anchor assembly 30 for joining or tying together a masonry structure such as the conventional brick wall structure 28 which is positioned and located in spaced apart relationship in front of a supporting back-wall structure 10 which is formed using a conventional ICF system. As best shown in FIG. 2, the brick wall or other masonry veneer 28 is positioned in front of the back-wall structure 10 so as to form a space or cavity 29 therebetween. As discussed below, this space or cavity 29 is sufficient to receive and accommodate the attachment portion 38 of the present anchor assembly 30 as will be hereinafter further explained.
The supporting back-wall structure 10 is formed by a plurality of individual ICF foam blocks 12 which are aligned horizontally and vertically in an interlocking arrangement to create the form for a specific concrete wall. Each ICF block 12 includes a pair of parallel opposing foam panels 14 retained in spaced apart relationship to each other by a plurality of ICF form ties 16. Each tie 16 includes a pair of opposed flange members 18 which are separated by, and connected to, a web portion which includes opposing truss members connected by a pair of substantially identical transverse bridge members 20, each bridge member 20 having a plurality of rebar retaining seats 22 molded therein. As best illustrated in FIGS. 1, 4 and 6, the plurality of spacing ties 16 extend transversely between the opposing inner surfaces of the opposing panels 14 such that the opposing flange members 18 of each respective tie 16 are substantially retainably encapsulated or embedded within each respective opposed foam panel 14 such that each flange member 18 is seated inwardly from the outer surface of the panel 14 within which it is encapsulated. The tie web portion is designed to provide centralized structural support to the block 12 and to optimize the flow of concrete poured between the opposing panels 14. In a preferred embodiment, the ties 16 are constructed from a plastic material such as polypropylene. In other embodiments, the spacing ties can be constructed from metal, or other suitable materials.
The rebar seats 22 are substantially identical to each other in configuration, and are arranged in a pair of opposing rows along each transverse bridge member 20. Each seat 20 includes a substantially U-shaped well formed by a plurality of adjacent fingers. These adjacent fingers are shaped and configured to create a substantially U-shaped well that is capable of retaining either one or a pair of rebar rods positioned therein.
Both the opposing horizontal top and bottom longitudinal edges of the panels 14 as well as the opposing vertical ends of each panel 14 include cooperatively engageable means typically in the form of an array of alternating teeth and sockets as best illustrated in FIG. 1 for vertically and horizontally interlocking similarly constructed ICF form blocks 12 to one another to create the particular concrete wall desired. At the construction site, the appropriate ICF blocks 12 are engaged in the appropriate manner to form the particular supporting back-wall structure desired; rebar rods may be retainably placed within the rebar seats 22 to provide additional strength and stability to the finished wall structure; and concrete is poured into the center cavity formed between the respective ICF blocks 12 to yield a particular solid, continuous concrete wall structure.
Although it is recognized that a wide variety of different types of ICF systems are available for use, it is important to note that the opposing flange members 18 associated with each respective ICF spacing tie 16 run substantially the full vertical height of each respective ICF block 12 thereby providing strength throughout the height of the respective blocks as well as throughout the height of the entire wall structure as best illustrated in FIGS. 1 and 2. In a preferred embodiment, the flange members 18 are of sufficient height, width and thickness such that the flanges can serve as a stud to which interior and exterior facades can be anchored. The inner and outer surfaces of the respective ICF panels 14 are substantially flat surfaces and each respective panel is of an appropriate thickness such that the flange members 18 are positioned inwardly from the outer surface thereof by a sufficient distance to facilitate use as a stud as best illustrated in FIGS. 4 and 6. This interior positioning of the flange members 18 likewise facilitates attachment of the present anchor assembly 30 to such flange members as will be hereinafter further explained.
In order to facilitate locating the flange members 18 embedded within each respective ICF panel 14 to serve as anchoring studs for the anchor assembly 30, a pair of flange indicators 24 are molded into the outer surface of the respective panels 14 as best illustrated in FIGS. 1 and 2. A plurality of spaced horizontal indicators 26 are likewise molded into the outer surface of each respective panel and are positioned between the pair of indicators 24 to further visually identify the location of the respective flange members 18 embedded therewithin. This ladder tie identification design makes its easy for a worker to quickly and easily identify and locate the flange members 18 associated with each respective spacing tie 16 for both aligning the respective ties when the ICF blocks 12 are vertically stacked one upon another to create a wall structure, and for serving as anchoring studs for the anchor assemblies 30.
In addition, the exterior surface of each ICF block 12 likewise typically includes a mark or indicator 27 in the form of a raised horizontal bead line along its central longitudinal axis to mark the mid-height of each respective block. The indicator 27 is provided in the event that it is necessary or desirable to sever a block 12 laterally into equal halves. As such, the indicator line 27 is positioned between the upper and lower bridge members 20 associated with the plurality of ICF form ties 16 such that severing of the block 12 will not interfere with either bridge member 20. The indicators 26 can also be dimensionally spaced such that they can be used as a measuring guide. For example, the indicators 26 could be spaced at intervals of one inch or some other predetermined distance to facilitate measuring and cutting such blocks at a location offset from the central longitudinal axis 27 of the block.
The supporting back-wall structure 10 and the masonry wall structure 28 are joined or tied together by a plurality of the present anchor assemblies 30 as best illustrated in FIGS. 1 and 2. Each anchor assembly 30 includes a main anchor member 32 and a cooperatively engageable masonry tie member 34 as best illustrated in FIG. 3. The anchor member 32 is substantially planar in form and includes an anchor portion 36 and an attachment portion 38. The terminal end 40 of the anchor portion 36 is preferably triangularly shaped as illustrated for facilitating the penetration of the anchor portion 36 through the ICF foam panel 14 as will be hereinafter explained. Although the anchor portion 36 is illustrated as being substantially triangular in shape, it is recognized and anticipated that other shapes of the anchor portion 36 including a shape yielding a pointed end portion will likewise facilitate insertion and penetration of the anchor portion 36 into the ICF wall system. The anchor portion 36 also includes opening 42 through which concrete will flow when properly positioned within an ICF system wall as will be hereinafter further explained.
The attachment portion 38 of anchor member 32 includes a tab member 44 which is positioned substantially perpendicular to the anchor member 32 as illustrated in FIG. 3. Tab member 44 includes a plurality of openings 46 for cooperatively receiving suitable fastening members such as the fastening members 48 for attaching the anchor member 32 to the opposed ICF tie flange portions 18 as will be explained. The attachment portion 38 of anchor member 32 likewise includes an elongated slot 50 located adjacent the tab member 44 for receiving the tie member 34 which can be adjustably positioned along the length of the slot 50 so as to be positioned in alignment with a particular masonry mortar joint as will be likewise hereinafter explained. The anchor tie member 34 is likewise somewhat triangular in shape and includes an opening or slot 52 which is sized and shaped to receive the terminal end portion 54 of the attachment portion 38 for operatively engaging and positioning the tie member 34 within the elongated slot 50. Although the anchor tie member 34 is shown as being substantially triangular in shape, it is likewise recognized and anticipated that the tie member 34 can take on a wide variety of different sizes and shapes while still accomplishing the present task as will be further explained.
To install any one of the present anchor assemblies 30, the anchor member 32 is inserted through a slot previously formed in the ICF foam panel 14 adjacent one of the opposed ICF tie flange members 18 embedded therein such that when the anchor member 32 is inserted therewithin, the tab member 44 will lie flush with the outer face of the ICF panel 14 and overlay the embedded flange member 18 as best illustrated in FIGS. 1, 2, 5 and 6. Locating the appropriate flange member 18 is easily accomplished by locating the appropriate flange indicator 24 (FIGS. 1 and 2) which identifies one side portion of the flange member 18 and thereafter cutting an appropriate slot through the ICF panel 14 adjacent thereto for inserting the anchor portion 36 of the anchor member 32 therethrough. In this regard, the anchor member 32 is vertically oriented when inserted through the slot formed in the ICF panel 14 as best illustrated in FIGS. 4 and 5. When the anchor member 32 is properly positioned within the pre-formed slot adjacent the ICF tie flange member 18, the anchor tab member 44 will lie flush with the face of the ICF panel 14 and will overlay the embedded flange member 18 as best shown in FIGS. 5 and 6. In this position, the fastening members 48 can be inserted through the tab openings 46 and should be of sufficient length so as to engage the tie flange member 18 as best shown in FIG. 6. Attaching the tab member 44 to the tie flange member 18 through the use of the fastening members 48 is only a temporary attachment so as to hold the anchor member 32 in proper position during pouring of the concrete into the central cavity of the ICF block for permanent joinder thereto. In this regard, any number of tab openings 46 and any number of fastening members 48 may be used in order to accomplish this temporary joinder.
As best illustrated in FIGS. 4-6, when the anchor member 32 is properly positioned and attached to a respective ICF tie flange member 18, the anchor portion 36 of anchor member 32 and, more particularly, the opening 42 associated therewith extends inwardly into the cavity space formed by and between the opposed ICF panels 14. This is further illustrated in FIG. 1. In this regard, the anchor member 32 should be positioned vertically along the height of the ICF block 12 such that the anchor portion 36 extends into the ICF cavity space between the respective upper and lower bridge members 20 associated with the plurality of formed ties 16. This is easily accomplished by locating the mid-height indicator 27 and centering the anchor member 32 on this line next to an adjacent ICF tie flange member 18 as previously explained. This will ensure that the opening 42 associated with the anchor portion 36 lies within the open space formed within the ICF block 12 and is properly positioned so as to receive the concrete as it is poured within the form. When the concrete is poured and has cured and hardened, the concrete anchors the anchor member 32 to the ICF wall being formed as illustrated in FIGS. 1 and 2.
In addition, as best illustrated in FIG. 2, when the anchor member 32 is properly positioned and attached to the ICF tie flange member 18, the elongated slot 50 associated with the attachment portion 38 of anchor member 32 lies in the space or cavity formed by and between the supporting back-wall structure 10 and the masonry wall 28. In this regard, the terminal end portion 54 of the anchor member 32 can be sized and shaped so as to be cooperatively received within the slot or space 52 and its dimensions can be adjusted to accommodate any particular application. Once the anchor member 32 is properly positioned and secured to the ICF system as previously explained, the anchor tie member 34 is cooperatively engaged with the anchor slot 50 as previously explained and such tie member 34 can be adjustably positioned along the length of the slot 50 so as to be in alignment with a masonry mortar joint between two respective courses of brick or other masonry material as the masonry wall 28 is being erected in front of the ICF supporting wall system 10. As best illustrated in FIGS. 1 and 2, because the exact location of the mortar joint between two courses of brick or other masonry material in the vicinity of the anchor assembly 30 is unknown at the time that the anchor member is embedded and secured within the ICF form, the elongated slot 50 provides adjustability and flexibility to the user so as to properly position the tie member 34 at the proper position and location so as to rest on the top surface of one course of brick or other masonry material and extend directly into the mortar joint formed between two courses of masonry material. This adjustability can also accommodate construction tolerances and larger differential movement. Once the masonry tie member 34 is embedded in the mortar between two courses of brick or other masonry material, it is fixedly secured to the masonry wall being erected in front of the ICF formed wall system once the mortar joint hardens. Wall and mortar joint layout will typically be coordinated between the locations of the mortar joints and the positions of the various anchor assemblies 30 associated with the supporting ICF system wall.
As illustrated in FIGS. 1 and 2, it is recognized that any plurality of the present masonry anchor assemblies 30 can be utilized in association with a particular supporting ICF back-up wall such as the supporting wall 10 and a front facing masonry wall such as the brick wall structure 28 to join, tie or otherwise permanently fix the outer masonry wall to the supporting ICF back-up wall. As a result, the anchor assemblies 30 join the supporting back-up wall and the masonry wall at spaced locations to produce an effective tying arrangement between the two wall systems capable of resisting lateral loads including the negative and positive lateral loads imposed by seismic and wind occurrences.
As best illustrated in FIG. 3, the anchor member 32 may include additional openings such as the opening 56 which may be incorporated into the anchor member 32 for manufacturing purposes and/or for weight considerations. For example, the anchor member 32 can be fabricated from a substantially planar plate-like member wherein the terminal end portion 40, the opening 42, and the slot 50 can be easily formed during a stamping operation. In addition, the tab member 44 can be cut from the base plate-like member and folded or otherwise bent to its proper position as shown in FIG. 3, thereby forming opening 56. Tab openings 46 can likewise be easily stamped or otherwise formed during a conventional stamping operation. Opening 56, or other openings can likewise be formed in order to reduce the overall weight of the anchor member 32; to provide more open space for capturing concrete as it is poured into the ICF form system; or for other reasons. Other manufacturing processes and variations are likewise recognized and anticipated.
The present anchor assembly 30 can also be fabricated so as to meet the particular design requirements for project specific design loads. Once these parameters are known, the present anchor assemblies 30 can be specifically designed and engineered to meet such requirements particularly if seismic and wind applications are involved. Some building codes may dictate a maximum horizontal and vertical spacing for positioning the present anchor assemblies along with a maximum area of wall to which an anchor assembly must be located. Positioning and locating the present anchor assemblies 30 in accordance with any specific building code requirements or other requirements can be accomplished as discussed above. In addition, the present anchor assemblies can be made from any suitable material such as from stainless steel or hot-dipped galvanized steel. Other materials are likewise available for use depending upon the particular application. In addition, the present assemblies can be made so as to be corrosion resistant.
Although a particular ICF system has been illustrated and disclosed herein, it is recognized that a wide variety of different ICF systems are available in the marketplace and that the present anchor assembly 30 is adaptable for use with any ICF system so long as such system includes a flange member similar to flange member 18 to which the anchor member 32 can be attached. In this regard, it is recognized and anticipated that any ICF block and/or panel construction other than the blocks 12 and panels 14 illustrated in FIGS. 1 and 2 can be utilized with the present anchor assemblies 30 including angularly oriented ICF block forms. In addition, any type of ICF spacing tie other than the ICF tie 16 illustrated in FIG. 1 can be used in conjunction with a particular ICF system so long as flange members 18 or equivalent structure is available for attaching the anchor member 32 thereto.
In addition, while a particular embodiment of the present anchor assembly 30 has been described herein, it is likewise recognized and anticipated that other embodiments are possible within the scope of the present invention. For example, the shape and dimensions of the anchor member 32 may vary widely according to the strength, wall dimensions and other physical characteristics of the particular application. In addition, the anchor tie member 34 may also vary in shape and form, provided only that the key to the mortar joint between two courses of masonry material is adequate to accomplish the desired joinder or tie between the ICF supporting structure and the masonry structure positioned adjacent thereto. As indicated above, other modifications and variations to the particular ICF system being utilized, and to the present anchor member 32 and anchor tie member 34 are envisioned and anticipated.
As is evident from the foregoing description, certain aspects of the present invention are not limited by the particular details of the examples illustrated herein and it is therefore contemplated that other modifications and applications, or equivalents thereof, will occur to those skilled in the art. It is accordingly intended that the claims shall cover all such modifications and applications that do not depart from the spirit and scope of the present invention.
Other aspects, objects and advantages of the present invention can be obtained from a study of the drawings and this disclosure.
Patent Application
20080092472
