Brick supporting structures

A method and apparatus for assembling modular tooled masonry structures, the method comprising the steps of: providing a pre-fabricated wire support structure having a shape generally corresponding to the shape of the completed masonry structure; assembling a first row of bricks in a pre-determined pattern onto the support structure using the support structure as a support and spacing guide for the bricks; masking selected areas of the bricks by partially surrounding the bricks with an open top removable mortar molding form; applying a pre-determined quantity of mortar into the mortar molding form covering accessible unmasked areas of the bricks with a pre-determined thickness of mortar; leveling the mortar; allowing the mortar to partially set; removing the mortar molding form from the bricks thereby revealing a tooled row of bricks; and repeating the above steps to provide additional tooled rows of bricks as needed to complete the masonry structure.

FIELD OF THE INVENTION 
This invention relates to pre-fabricated masonry forms for supporting brick 
work in pre-determined specified arrangements in order to greatly simplify 
the fabrication of various masonry structures. 
BACKGROUND OF THE INVENTION 
Various masonry forms and spacers for supporting and spacing brick work 
have been developed over the years. Examples of masonry forms and spacers 
are disclosed by Castelli, U.S. Pat. No. 3,196,581; Castelli, U.S. Pat. 
No. 3,420,031; Mundy, U.S. Pat. No. 3,426,497; Wargoe, U.S. Pat. No. 
3,584,426; Eberhardt, U.S. Pat. No. 3,142,938; Zack, U.S. Pat. No. 
1,947,239; Reintjes, U.S. Pat. No. 2,847,849; Jones, U.S. Pat. No. 
3,181,278. 
The references to Castelli, Mundy and Wargoe generally teach devices for 
providing spacing between successive vertical rows of bricks. Each of 
these references relies primarily upon the lowermost row of bricks for 
providing the required support. 
Eberhardt teaches the use of a supporting planar vertical grid with 
horizontal support wires together with cantilevered wire support pieces 
which project outwardly to support pin elements extending normally from 
the rear faces of the facing slabs or bricks. * 
Reintjes discloses a series of spaced apart horizontal stringers for 
supporting clips which in turn engage selective specially formed bricks 
for positioned the same. All of the bricks are of special configuration in 
order to allow interlocking thereof. 
Zack discloses a planar board construction in which successive wire block 
or brick supporting members are integrally connected with the block and 
subsequently driven into the backing panel. 
Jones discloses a vertical panel with attached support clips. The clips 
engage the bricks to hold them in the desired position. This structure 
requires an interlocking configuration between the individual bricks. 
Each of the supporting devices taught by Eberhart, Reintjes, Zack and Jones 
have limited use in that each requires the use of bricks or facing slabs 
having specialized construction or specialized modifications. This aspect 
severely limits the usefulness of these devices since they cannot be used 
in conjunction with standard masonry brick. Since the bricks or facing 
slabs must be individually designed or modified, the overall cost 
associated with masonry structures produced using supports taught by the 
prior art becomes prohibitive. 
SUMMARY AND OBJECTS OF THE INVENTION 
The present invention provides versatile, uncomplicated and easily used 
brick laying supports or forms especially developed as an aid for those 
people lacking professional skill in the field of masonry. 
One embodiment of the present invention concerns a modular unit used in 
constructing brick walls comprising a vertically oriented and supported 
planar wire support structure or grid consisting of a number of evenly 
spaced-apart vertical wires and a number of unevenly or staggered 
horizontal wires. The horizontal wires may be in pre-arranged patterns 
beginning with a lowermost horizontal wire intersecting the lowermost ends 
of the vertical wires. The second lowermost horizontal wire may be spaced 
from the lowermost horizontal wire by a first set distance, for example 
11/8 inches. The third lowermost horizontal wire is set from the second 
lowermost horizontal wire by a second set distance, for example 13/4 
inches. The patterns is repeated with the next lowermost wires 
alternatingly spaced from the previous wires by distances of 11/8 inches, 
13/4 inches, etc. 
The vertically oriented and supported grid is used to receive specially 
shaped hangers or clips which in turn support the bricks. 
The hangers or clips come in a variety of sizes and shapes, however, all of 
the hangers have common characteristics, namely, a generally U-shaped 
horizontal body portion and a pair of spaced-apart legs extending 
vertically from opposite ends of the horizontal U-shaped body portion, the 
distal ends of the vertical legs being hook-shaped. 
The hooked end portions of the vertical legs are used for attaching the 
hangers onto selected horizontal wires of the support structure or grid. 
Once attached, the U-shaped body portion of the hangers extending 
outwardly in a horizontal direction generally perpendicular to the plane 
of the support structure or grid. 
The U-shaped body portion of the hangers is of sufficient size and 
construction to independently support a brick position thereon. The 
hangers are distributed upon the support structure or grid in such a 
manner as to allow sufficient spacing for mortar to be placed between 
adjacent bricks once a horizontal row of bricks has been set in place. 
Other embodiments cover by the present invention include modular systems 
for constructing various other masonry forms including archways, columns, 
lamp posts, etc. 
It is therefore an object of the present invention to provide modular brick 
structures which are uncomplicated and easy to assemble. 
Another object of the present invention is to provide modular brick 
structures which may be fabricated from standard size and shape masonry 
brick. 
A further object of the present invention is to provide modular brick 
structures which are inexpensive compared with known brick structures. 
Still another object of the present invention is to provide modular brick 
structures of a variety of shapes including walls, columns, archways, lamp 
posts and fireplaces. 
The foregoing and other objects and advantages of this invention will 
appear from the following detailed description, taken in connection with 
the accompanying drawings.

FIG. 1 
The modular wall assembly of FIG. 1 is comprised of a vertically oriented 
support structure or grid A which is formed from a plurality of equally 
spaced-apart vertical wires 2 and a number of unequally spaced-apart 
horizontal wires 4. 
Support structure or grid A is preferably fastened to a backing structure 
such as board 6. While not shown in FIG. 1, any suitable fastening means 
may be used to secure grid A to backing board 6. 
Horizontal wires 4 of support structure or grid A are arranged in a 
pre-determined pattern. The lowermost horizontal wire intersects and is 
connected to the lowermost ends of vertical wires 2. The second lowermost 
horizontal wire is spaced a first set distance, for example 11/8 inches 
from the lowermost horizontal wire. The third lowermost horizontal wire is 
positioned at a second set distance, for example 13/4 inches from the 
second lowermost horizontal wire. The pattern is repeated with each 
successive horizontal wire being alternatingly spaced from the preceding 
wire by distances of 11/8 inches, 13/4 inches, etc. The vertically 
oriented wires 2 are preferably spaced apart at 41/4 inch intervals. 
Wire hangers or clips 8 are attached to grid A in a pre-determined pattern 
as shown in FIG. 1. Each hanger 8 is of one piece construction and 
includes a generally U-shaped horizontal body portion and a pair of legs 
10 extending vertically from opposite ends of the generally horizontal 
U-shaped portion. The distal end of each vertical leg 10 comprises a 
hooked portion 12. Hooked portion 12 is adapted for engagement of selected 
horizontal wires 4 of grid A. The proximal end portions of vertical legs 
10 are situated in a manner so that they rest against the horizontal wire 
directly beneath the hook engaged horizontal wire in order to provide 
additional support and to ensure that the horizontal main body portion 
extends perpendicular to grid A. Hangers 8 may include vertical 
projections 14 for the purpose to be explained later. 
When hangers 8 are positioned on grid A in the manner shown in FIG. 1, with 
each hanger supporting an individual brick 16, a pre-determined spacing 16 
is formed between adjacent bricks, spacing 18 being filled with mortar. 
When bricks 16 are provided with openings 20, projections 14 will engage 
openings 20 from the bottom face of the brick thereby providing additional 
stability. 
FIGS. 2 through 5 
Referring to FIGS. 2 through 5, it may be seen that hangers or clips 8 may 
assume a variety of shapes, each of which provides suitable support for 
the individual bricks 16 resting thereon. 
Each of the hangers shown in FIGS. 3, 4 and 5 vary from the hanger of FIGS. 
1 and 2 by the inclusion of laterally extending wings 22. The distal 
portion of each wing 22 may terminate in the form of a vertical projection 
24 as depicted in FIGS. 3 and 4. Vertical projections 24 will engage the 
side faces of bricks 16. 
FIGS. 6 and 7 
FIGS. 6 and 7 show a modular suspension unit in the shape of an archway. 
The modular unit includes a pre-shaped wire support structure B. Wire 
support structure B is reinforced by means for cross ties 26. The cross 
ties 26 may be arranged in a pre-determined pattern to provide a gauge for 
spacing the individual bricks 16 allowing room for mortar to be placed 
between adjacent bricks 16. 
Two hangers 8 having identical structure as the hangers shown in FIGS. 1 
and 2 are used to support each brick 16. 
As shown in FIG. 7, the hangers 8 engage brick 16 from either side with 
hanqer projections 14 likewise engaging openings 20 from either side of 
the brick. This arrangement results in two pairs of opposed hook ends 12 
being directed at each other adjacent one face of the brick. 
The brick with the assembled hangers 8 are positioned adjacent the base of 
support structure B with hook ends 12 extending above support structure B. 
The brick is locked in place by applying an S-shaped spring clamp 28 on 
top of support structure B and in engagement with hook ends 12. 
Using cross ties 26 of support structure B as gauging elements, the 
remaining bricks are assembled onto support structure B with the required 
spacing between adjacent bricks for receiving mortar. 
FIG. 8 
FIG. 8 shows a modular form used in fabricating a brick column. The form 
includes a rectangular shaped wood core 30. Identical shaped wire support 
structures or grids 32 are fastened to each side face of wood core 30. 
Each wire support structure 32 includes lateral extensions 34 
alternatingly extending from either side thereof. Each support structure 
32 has a ladder-like configuration including rungs 36. Rungs 36 are spaced 
apart in the same manner as horizontal wires 4 of grid A as shown in FIG. 
1. Support structures 32 may be attached to wood core 30 by any suitable 
fastening means. 
The wire support structures or grids 32 act as gauges for placement of the 
individual bricks during assembly of the column structure. The lateral 
extensions 34 provide end stops for end faces of the brick, thereby 
ensuring regularity and flushness of the completed column faces. In 
addition, extensions 34 serve as spacers between adjacent bricks providing 
the proper amount of clearance for subsequent reception of mortar. 
FIG. 9 
FIG. 9 depicts the modular assembly and form used in fabricating a mail box 
or lamp post. 
The assembly includes a vertically oriented central rod or bar 38. Pairs of 
rectangular shaped wire frames 40 are attached by welding or other 
suitable means to opposite sides of rod 38 in order to form a first 
spacing unit 42. An additional pair of rectangular wire frames 40 are 
fastened to opposite sides of rod 38 to form a second spacing unit 44. 
Spacing unit 44 is located at a set distance vertically beneath spacing 
unit 42 and oriented at a right angle thereto. 
The pattern of the spacing units continues as shown in FIG. 9. 
The spacing units serve as a guide for placement of the brick layers 
providing proper clearance between adjacent bricks in each Iayer for the 
subsequent reception for mortar. 
FIGS. 10 through 13 
FIG. 10 shows a mortar applicator C which is used when assembling a wall 
unit as depicted in FIG. 1. Mortar applicator C includes vertical side 
walls 46, 48 and 50, an inwardly directed horizontal flange 52 and a 
vertical flange 54. 
A plurality of spaced apart spacing elements 56 extend inwardly from wall 
48. Spacing elements 56 project a short distance into the spaces formed 
between adjacent bricks in order to cause the mortar to be recessed or 
tooled during application of the mortar into the spaces between adjacent 
bricks. The distance between adjacent spacing elements 56 corresponds to 
the overall length of the individual bricks. The height of vertical walls 
46, 48 and 50 correspond to the overall height of the individual bricks. 
The width of side walls 46 and 50 generally corresponds to the width of 
the individual bricks. 
When Mortar applicator C is placed around a corresponding number of bricks, 
the bricks are nested between vertical walls 46, 48 and 50, with spacing 
elements 56 projecting slightly into the spaces between adjacent bricks. 
Horizontal flange 52 covers a marginal portion of the bricks. Horizontal 
flange 52 in conjunction with spacing elements 56 cause the bricks to be 
automatically tooled during application of the mortar. 
FIGS. 11 through 13 show the sequence of brick laying and mortar 
application during preparation of a wall structure such as the wall 
structure of FIG. 1. For illustrative purposes, the backing structure 6, 
grid A and hangers 8 have been omitted from FIGS. 11 through 13. 
As shown in FIG. 11, a completed horizontal row 58 of bricks has already 
been layed, and mortar 60 has been applied to the surface of row 58 as 
well as within the spaces left between adjacent bricks. Mortar 60 is 
recessed leaving an uncovered marginal region 62 along the upper 
peripheral surface of the bricks. In addition, the mortar is recessed 
within spaces 64 between adjacent bricks. 
After a completed horizontal row 58 of bricks has been layed and mortar 
applied, a new row of bricks 66 may be started. Before placement of a new 
row 66 of bricks, a row of hangers (not shown) are assembled onto the 
vertical grid (not shown) with the horizontal portion of the hangers 
resting upon the upper surface of the mortar 60. 
After the hangers have been positioned as deecribed above, a partial new 
row of bricks 66 are assembled onto the hangers to rest thereon. 
As shown in FIG. 12, mortar applicator C is then positioned around the 
partial row of bricks 66 with horizontal flange 52 covering a marginal 
portion along the upper periphery of the bricks. In addition, spacing 
elements 56 (FIG. 10) project a slight distance into the spaces between 
the individual bricks. 
Mortar is then applied on top of the partial new row 66 of bricks to a 
height equivalent to the height of vertical flange 54 of applicator A. In 
addition to covering the upper surfaces of the new row of bricks, the 
mortar will be caused to flow into the unrestricted spaces between the 
individual bricks. The mortar may be smoothed out by traversing the upper 
surface of vertical flange 54 with a suitable wiping element. Applicator C 
is removed once the mortar has partially set to a point where it will 
retain its shape. 
The process of applying additional hangers and bricks is repeated and the 
mortar applicator applied around a new partial row of bricks as shown in 
FIG. 13. The sequence of steps is repeated until a new row of bricks has 
been completely assembled. 
As shown in FIG. 13, the mortar applicator C is identical with the mortar 
applicator shown in FIGS. 10 and 12 with the exception that one side has 
been omitted. The two sided applicator of FIG. 13 is used to complete the 
row of bricks once the initial bricks have been laid. 
The masonry structures shown in FIGS. 8 and 9 are assembled in a manner 
similar to the manner of fabricating the masonry wall shown in FIGS. 11 
through 13. In each case, the structures are built up row by row until the 
entire structure has been completed. 
Mortar applicators having the same features as the applicators previously 
described are used during construction of the structures of FIGS. 8 and 9. 
It is apparent that the applicators would be modified slightly in order to 
conform to the shape of the structures being fabricated. 
It should be further noted that for purposes of illustration, the mortar 
has been omitted from FIGS. 1, 8 and 9. 
FIGS. 14 through 17 
FIG. 14 discloses the manner in which the grid structure is maintained at a 
horizontal elevation to insure that bricks are placed in a level course. 
The grid structure is generally indicated at B as horizontal wire elements 
72 and vertical elements 74 which are connected at their cross points 78 
by welding or other means. A plurality of levels generally indicated at 80 
are fastened at an end of the horizontal wires 72. 
As illustrated in FIG. 15, the level element 80 has a fluid containing 
capsule 82 and a level bubble 84. The capsule is fastened by means of 
hooks 86 to the horizontal wire 72. 
FIG. 16 shows a simplified hanger element generally indicated at 90 which 
has top outwardly extending wire engaging arms 92, downwardly extending 
legs 94, and a central brick supporting U-shaped wire brick support 
element having outwardly extending horizontal legs 96 which are joined by 
a central horizontal wire element 98. 
The manner in which the hanger 90 supports a brick which fits between the 
elements 92 and 96, is shown in FIG. 17. 
The manner in which the hanger 90 is fastened to the grid is illustrated in 
central portion of FIG. 14. It will be noted that the hanger is tilted so 
that the outwardly extending legs 92 can be fitted behind and then rotated 
into position over one of the horizontal wires 72. 
The method of constructing a modular tooled masonry structure according to 
the present invention includes the steps of providing a pre-fabricated 
wire support structure having a shape generally corresponding to the shape 
of the completed masonry structure; assembling a first row of bricks in a 
predetermined pattern onto the support structure using the support 
structure as a support and spacing guide for the bricks; masking selected 
areas of the bricks by partially surrounding the bricks with an open top 
removable mortar molding form; applying a pre-determined amount of mortar 
into the mortar molding form covering accessible unmasked areas of the 
bricks with a pre-determined thickness of mortar; allowing the mortar to 
partially set; removing the mortar molding form from the bricks thereby 
revealing a tooled row of bricks; and repeating the preceding steps as 
needed to complete the structure. 
In addition to determining the quantity of mortar used, the mortar molding 
form also serves to protect the face of the bricks to prevent mortar 
staining. 
While this invention has been described as having preferred design, it is 
understood that it is capable of further modification, uses and/or 
adaptations of the invention following in general the principal of the 
invention and including such departures from the present disclosure as 
come within known or customary practice in the art to which the invention 
pertains, and as may be applied to the essential features set forth, and 
fall within the scope of the invention of the limits of the appended 
claims.