1. Field of the Invention
This invention relates to a reinforcing spacer device for use in the horizontal and vertical mortar of masonry walls. More particularly, this invention relates to a device combining reinforcement and spacing between adjacent masonry units.
2. Description of the Prior Art
Masonry, the building of structures from individual units laid in and bound together by mortar, is commonly used for the construction of buildings. Such widespread use is the result of the high durability, compressive strength, thermal mass and heat resistance of the masonry building materials. Because masonry construction requires extensive manual labor and individual building materials such as brick or block, the quality of the masonry construction is directly dependent on the type of materials used and the workmanship of the mason.
In the past, the construction of structurally sound, high quality wall units constructed of brick, block, stone or similar masonry building units has depended upon the workmanship of masons. The pattern used in setting the building materials strongly effects the durability of the overall construction. Through extensive training, masons develop techniques for evenly applying mortar to bed joints and vertical joints between units so that the units are evenly spaced in each course and the wall face remains vertical.
In recent years attention has been paid to wall reinforcement especially for areas that are routinely subjected to seismic forces. Here both wire reinforcements and ladder and truss reinforcements have been in widespread use. Such reinforcements are embedded in the horizontal mortar joints to reinforce, bond and control shrinkage cracking. Additionally, the reinforcements provide higher resistance to lateral loads, such as wind, by increasing tensile strength.
The inventors' patents and their assignee's product line include masonry accessories, namely, ladder and truss reinforcements, wall anchors, veneer ties, masonry flashing and related items for cavity walls. These products, which are sold under the trademarks of Lox All, DW-10X, X-seal and FlexFlash, are manufactured by Hohmann & Barnard, Inc., Hauppauge, N.Y. 11788 (“H&B”). The products have become widely accepted in the construction industry and the inventors have gained particular insight into the technological needs of this marketplace.
In general, the difficulties with masonry construction lie in two distinct areas. The first is the weakness of the horizontal mortar or bed joints that bond the masonry units together. This weakness is the result of the low tensile strength of the mortar joints and generally requires mortar joint reinforcement for structural stability. The second difficulty is constructing a wall with consistent and uniform mortar joints that keeps the structure vertical and maintains aesthetics. An uneven mortar joint thickness detracts from the overall appearance of the wall and can effect the overall stability and durability of the masonry construction.
The first difficulty is addressed by well-known devices, such as ladder and truss reinforcements for augmenting the tensile strength of the horizontal mortar joints. These devices greatly reduce cracking that can arise from thermal stresses, and increase lateral flexural strength, elasticity and performance of masonry walls under various stresses.
Exemplary of the above, in a patent to Stephen Priest, Jr., U.S. Pat. No. 903,000 issued Nov. 3, 1908, entitled “Wall Tie,” a reinforcing ladder device is taught which is constructed of twisted wires with one side of the ladder device embedded in the outer wythe and the other, in the inner wythe. Similarly, H. Spaight, U.S. Pat. No. 2,300,181 issued Oct. 27, 1942, entitled “Means for Constructing Buildings,” teaches a truss-shaped reinforcement device for embedment in either one wythe or in cavity walls in both wythes. More recently, W. Smith in U.S. Pat. No. 3,183,628 issued May 18, 1965, entitled “Masonry Wall Reinforcing Means,” describes an improvement of the Spaight invention by teaching truss and ladder reinforcements having grooves or bosses on the parallel side wires to increase the mortar bonding therewith. Placing one of the aforementioned devices in the horizontal mortar joints enhances the tensile strength of the horizontal joints.
Several improvements to masonry wall reinforcement have been made by H&B. In 1976, Hala and Schwalberg of H&B, received U.S. Pat. No. 3,964,226 for an adjustable wall-tie reinforcing system which joined reinforcements in inner and outer wythes with an attached eye and pintle structure. During the period when the Uniform Building Code developed joint reinforcement specifications, Hohmann et al., received U.S. Pat. No. 5,454,200 issued Oct. 3, 1995 and U.S. Pat. No. 6,279,283 issued Aug. 28, 2001. These patents provide veneer anchoring systems for masonry walls which include reinforcement for cavity walls. These devices have received widespread usage in the industry. However, none of these devices were designed to aid in the application of uniformly thick mortar joints.
In the past, builders inserted devices between the block, stone or similar masonry building material to align and space the mortar joints. Representative patents include: U.S. Pat. No. 2,172,816—A. Douglas and V. Lefebure—Issued Sep. 12, 1939, entitled “Construction of Walls, Partitions, and the Like,” which describes a method of aligning specially-slotted or grooved building blocks using T-shaped dowel plates to tie three adjacent blocks; U.S. Pat. No. 4,334,397—G. Hitz—Issued Jun. 15, 1982, entitled “Masonry Structure and Apparatus and Process for Spacing Block in the Structure,” which describes a plastic-pronged spacer that separates the blocks; and U.S. Pat. No. 5,351,457—W. Colen—Issued Oct. 4, 1994, entitled “Wall Construction and Spacer for Use Therewith,” which describes wall construction spacers for use in various blocks that tie two adjacent blocks together.
Each of the aforementioned devices addresses either reinforcement or spacing. Additionally, more recent technical advances have resulted in several combination reinforcing and spacing devices, described below. However, these devices do not provide a combination unit for both the reinforcing of the horizontal mortar joints and the spacing of the horizontal and vertical mortar joints.
In preparing for this application the below-mentioned patents have become known to the inventors hereof.
PatentInventorIssue Date6,629,393PignataroOct. 7, 20036,553,737BergApr. 29, 20036,279,283Hohmann et al.Aug. 28, 20015,454,200Hohmann et al.Oct. 3, 19955,351,457ColenOct. 4, 19945,259,161CarterNov. 9, 19914,689,931HodgesSep. 1, 19874,334,397HitzJun. 15, 19823,964,226Hala et al.Jun. 22, 19763,183,628SmithMay 18, 19652,300,181SpaightOct. 27, 19422,172,816Douglas et al.Sep. 3, 1939903,000PriestNov. 3, 1908
Of these patents, those not previously discussed, are discussed hereinbelow.
Inventions to properly space masonry building materials are described in patents such as P. Hodges in U.S. Pat. No. 4,689,931 issued Sep. 1, 1987, entitled “Masonry Construction Device,” and T. Berg in U.S. Pat. No. 6,553,737 issued Apr. 29, 2003, entitled “Method and apparatus to achieve consistent spacing between layers of modular construction material.”
Hodges describes a squared “U” shaped device with a straight bridging member connected between parallel sawtooth shaped members. Upon connecting adjacent ones of Hodges devices, the bridging members thereof form supports for the next course of masonry materials and thereby spaces consecutive courses. The “U” shaped devices are short and manually chained together to cover horizontally adjacent bricks. Berg teaches a device with spacer studs connected to the parallel and transverse rails of a ladder-type reinforcement. The device is placed on the top surface of a brick or block to space the horizontal mortar joint. Along a similar path, F. Carter in U.S. Pat. No. 5,259,161 issued Nov. 9, 1991, entitled “Vertical and horizontal reinforcement and spacing guide for panels constructed of blocks,” teaches, specifically for glass block installation, a grid formed by detailed thick elongate reinforcement members of uniform thickness with both horizontal and vertical components.
Horizontal reinforcement and spacing is further taught in J. Pignataro in U.S. Pat. No. 6,629,393 issued Oct. 7, 2003, entitled “Masonry reinforcing tie.” Pignataro describes a ladder-type device formed of wire or rod with the parallel elongate members containing integrally formed, spacing elements. The patent describes providing lateral reinforcement and teaches only consistent horizontal mortar joint thickness in a masonry wall. Pignataro further teaches the use of roller dies to form the spacing elements.
Accordingly, while several distinct devices were developed to assist in properly constructing a masonry wall unit, the current state of the art does not fulfill the need for a single efficient and economical combination device that simultaneously reinforces and spaces brick, block, stone or similar masonry building materials. As described hereinbelow, the present invention utilizes a combination reinforcing spacer device to horizontally reinforce and dually space both horizontally and vertically, thereby providing a useful and novel solution to the aforementioned difficulties.