Systems, devices, and methods for mounting a lightweight architectural masonry product to a building

The present subject matter relates to systems, devices, and methods for mounting one or more lightweight architectural masonry units to a building support structure. An elongated track includes a web and opposed edge portions that form a pair of slide channels, the elongated track being configured to be mounted to the building support structure. A connecting member includes a base portion configured to retain the connecting member to the channels but is movable within the channels along the track, and a flange portion is configured to connect to a first lightweight architectural masonry unit of the one or more lightweight architectural masonry units. A fixation member includes a first end configured to connect to the elongated track and a second end configured to connect to the lightweight architectural masonry unit, the fixation member being configured to retain the first lightweight architectural masonry unit in place relative to the elongated track.

TECHNICAL FIELD

The subject matter disclosed herein relates generally to systems, devices, and methods for attaching architectural building elements together. More particularly, the subject matter disclosed herein relates to systems, devices, and methods for mounting one or more lightweight architectural masonry units to a building support structure.

BACKGROUND

Architectural cast stone is a class of masonry products that are designed to replicate the look of stone construction when used as an architectural trim, feature, or ornament for buildings and other structures. In many configurations, such products are not designed to support the building structure or load bearing elements, though, and therefore must be mounted to the load-bearing elements of the structure. Traditional cast-stone systems can be very heavy and require significant structural steel connections to the structure using welds, bolts, anchors, diagonal kickers, and the like.

To address some of these issues with traditional cast-stone systems, lightweight architectural masonry units produced using a combination of a lightweight stone or stone-like shell and an expanded polystyrene (EPS) core can provide a similar look and durability with dramatically lower weight. Originally, an adhesive attachment to the structure was considered, but adhesives are not a trusted attachment mechanism for an architectural stone system such as this. Split-tail connectors are frequently used in masonry and cast-stone construction, but such connectors are not sufficient for the varied and complex geometrical constraints of the lightweight architectural masonry products contemplated by the present subject matter. As a result, it is desirable for mounting systems, devices and methods to enable the installation of lightweight architectural masonry products in a more efficient and flexible manner than traditional cast-stone products.

SUMMARY

In accordance with this disclosure, systems, devices, and methods for mounting one or more lightweight architectural masonry units to a building support structure are provided. In one aspect, a connector assembly for mounting one or more lightweight architectural masonry units to a building support structure is provided. The connector assembly includes an elongated track, a connecting member, and a fixation member. The elongated track includes a web and opposed edge portions that extend in a first direction from a first surface of the web and that form a pair of slide channels, the elongated track being configured to be mounted to the building support structure. The connecting member includes a base portion and a flange portion, the base portion being configured to retain the connecting member to the channels but is movable within the channels along the track, and the flange portion being configured to connect to a first lightweight architectural masonry unit of the one or more lightweight architectural masonry units. The fixation member includes a first end configured to connect to the elongated track and a second end configured to connect to the first lightweight architectural masonry unit, the fixation member configured to retain the first lightweight architectural masonry unit in place with respect to the elongated track.

In another aspect, an assembly of one or more lightweight architectural masonry units configured for mounting to a building support structure is provided. The assembly includes an elongated track having a web and opposed edge portions that extend in a first direction from a first surface of the web and that form a pair of slide channels, the elongated track being configured to be mounted to the building support structure. A connecting member includes a base portion and a flange portion, the base portion being configured to retain the connecting member to the channels but is movable within the channels along the track. A first lightweight architectural masonry unit of the one or more lightweight architectural masonry units is attached to the flange portion of the connecting member. A fixation member has a first end connected to the elongated track and a second end connected to the first lightweight architectural masonry unit, the fixation member configured to retain the first lightweight architectural masonry unit in place with respect to the elongated track.

In yet a further aspect, a method for mounting one or more lightweight architectural masonry units to a building support structure is provided. The method includes mounting an elongated track to the building support structure, the elongated track being having a web and opposed edge portions that extend in a first direction from a first surface of the web and that form a pair of slide channels. The method further incudes positioning a connecting member in the slide channels, the connecting member including a base portion and a flange portion, the base portion retaining the connecting member to the channels but being movable within the channels along the track. The method further includes connecting the flange portion of the connecting member to a first lightweight architectural masonry unit of the one or more lightweight architectural masonry units. The method further includes connecting a first end of a fixation member to the elongated track and connecting a second end of the fixation member to the first lightweight architectural masonry unit, the fixation member retaining the first lightweight architectural masonry unit in place with respect to the elongated track.

Although some of the aspects of the subject matter disclosed herein have been stated hereinabove, and which are achieved in whole or in part by the presently disclosed subject matter, other aspects will become evident as the description proceeds when taken in connection with the accompanying drawings as best described hereinbelow.

DETAILED DESCRIPTION

The present subject matter provides a stone attachment mechanism specifically developed to attach lightweight decorative stone pieces to a structure by the use of formed metal clips. The system includes specific connector configurations that have been designed to accommodate allowable fastener loads used in lightweight architectural masonry products. As used herein, the term “lightweight architectural masonry” refers to products produced using a combination of a lightweight stone or stone-like shell and an expanded polystyrene (EPS) core or extruded polystyrene (XPS) core. In some embodiments, the shell is formed from any of a variety of material compositions, including but not limited to blended marble aggregate, polymers, and/or wet poured in-place concrete, which individually or together in combination are made to look like stone. Such a configuration can produce a shell that is quite strong (6850 psi) and thus yields high fastener attachment shear and tensile values. This in turn enables compact clip connections to carry the load back to the structure.

It is also unique in that by using a combination of a lightweight stone or stone-like shell and an expanded polystyrene (EPS) or extruded polystyrene (XPS) core, the thermal properties (measured in R-value) of the lightweight architectural masonry products are superior to that of traditional stone claddings. It combines the thermal properties of EPS (or XPS) with the structural properties of the architectural masonry and the structural properties of the steel connections to create a lightweight stone cladding system that is superior in terms of weight, structural performance, and thermal performance, and mounting such products exhibits improved assembly simplicity and lower installation cost of labor. Such decorative stone pieces can thus be readily attached on certain building features, such as parapets, soffits, door headers, outside and inside corners, and columns, among others.

In one aspect, the present subject matter provides systems, devices, and methods for mounting one or more lightweight architectural masonry units to a building support structure using a combination of connectors and a framing system adapted from light steel construction for the lightweight stone attachment conditions. In some embodiments, support structure and connectors can range from 54 mil-97 mil thickness and have a 50 ksi minimum yield strength and 65 ksi minimum tensile strength. In some embodiments, the support structure and/or connectors are composed of ASTM A1003/A1003M Structural Grade 50 (340) Type H, ST50H (ST340H) cold-formed structural parts carbon steel sheets with metallic and non-metallic coatings (e.g., ASTM A653/A653M G90 (Z275) hot dipped galvanized coating), although those having ordinary skill in the art will recognize that other material compositions and configurations can likewise be used to produce support and connections of sufficient strength to mount the lightweight architectural masonry units.

As shown inFIGS.1A and1B, in some embodiments, the connector assembly, generally designated100, includes an elongated track110configured to be mounted to a building support structure, generally designated SS, and a connecting member120configured to connect to a first lightweight architectural masonry unit150of the one or more lightweight architectural masonry units. As shown inFIG.1A, in some embodiments, a single elongated track110can be used to support the lightweight architectural masonry unit150. In some embodiments, the specifications of the elongated track110(e.g., metal gauge, tensile strength) can be tailored to support the lightweight architectural masonry unit150having a particular size or configuration. Alternatively, referring toFIG.1B, multiples of the elongated track110can be connected to the building support structure SS to support each lightweight architectural masonry unit150of the one or more lightweight architectural masonry units. Those having ordinary skill in the art will be able to identify the number of the elongated track110that are needed to support the lightweight architectural masonry unit150in a particular installation.

Referring toFIG.2, the elongated track110has a web112and opposed edge portions114that extend in a first direction from a first surface of the web112and that form a pair of slide channels115. In some embodiments, to mount the elongated track110to the building support structure SS, a plurality of holes116through the web112through which a corresponding plurality of fasteners can be received. Compared to conventional track-mounted building products, larger screws (e.g., about 0.225 inch) can be used such that the elongated track110is sufficiently able to transfer the load of the attached lightweight masonry unit150to the building support structure SS. In some embodiments, the elongated track118further includes weep holes118configured to allow for drainage behind the lightweight masonry unit150mounted thereto, which can help to prevent pooling and corrosion. In some embodiments, the weep holes118are offset laterally with respect to the holes116such that drainage passing into the track110is not aligned with the fasteners attaching the track110to the support structure SS. In some embodiments, for example, the weep holes118can be provided in alignment on both a top and an opposing bottom of the edge portions114and offset laterally with respect to the holes116such that a direct path is formed for water to flow through the slide channels115without passing over any attaching fastener secured through the holes116. Such weep holes118can be spaced periodically along the length of the elongated track110(e.g., positioned every 8 inches along the length). In addition, the weep holes118can be approximately the same size as the holes116for ease of manufacture, or the weep holes118can be a different size configured to accommodate the amount of drainage expected for a given configuration.

Referring next toFIGS.3A through3C, the connecting member120includes a base portion122that retains the connecting member to the channels115but is movable within the channels115along the track110and a flange portion124that extends from the base portion122and includes one or more fastener-receiving openings126such that the base portion122is configured to be affixed to the lightweight architectural masonry unit150. To provide the ability for the connecting member120to move along the track110, the connection between the base portion122and the flange portion124can include notches123formed into the base portion122in alignment with a position of fasteners used to mount the elongated track110to the building support structure SS. In this way, the notches123establish intermittent openings between the base portion122and the web112of the elongated track110through which the fasteners can pass as the connecting member120moves along the elongated track110.FIGS.3A through3Cillustrate different configurations for the flange portion124that are designed to be affixed to corresponding configurations of the lightweight architectural masonry unit150. Those having ordinary skill in the art will recognize that the connecting member120can provided any of a variety of further configurations depending on the size and shape of the lightweight architectural masonry unit150to which it is designed to be affixed.

Similar track and clip configurations exist in the area of light steel frame construction, although the present subject matter differs in a number of respects. For example, in some embodiments, the thickness is reduced relative to conventional clip and frame elements to better match the weight of the lightweight stone panels. In some particular examples, the elements have a thickness of between about 54 mils and 97 mils, although those having ordinary skill in the art will recognize that the thickness of the elements can be adjusted (e.g., using any standard gauge of cold-formed steel having thicknesses between about 33 mils and 118 mils) to accommodate different configurations for the lightweight architectural masonry units.

Similarly, as shown inFIGS.3A and3B, in some embodiments, the connecting member120can be provided as a first connecting member configuration120athat is affixed to the lightweight architectural masonry units150using fasteners that attach to the lightweight architectural masonry units through the one or more openings126that are provided as holes formed in the flange portion124, and the size of these holes can be configured specifically to receive the connectors required by the stone material. Alternatively, as shown inFIG.3C, in some other embodiments, the connecting member120can be provided as a second connecting member configuration120bthat is affixed to the lightweight architectural masonry unit150using fasteners that attach to the lightweight architectural masonry unit150through the openings126that are provides as slots that allow for vertical deflection. In some embodiments, for example, the openings126configured as slots are sized to allow for a total vertical displacement of about 2 inches. Again, the size of these slots can be configured specifically to receive the connectors required by the stone material.

In either configuration, the higher strength and lower thickness of the concrete shell used for the present lightweight architectural masonry units leads to smaller concrete failure cones, which in turn allows for tighter groups of fasteners attaching the connecting member120to the lightweight architectural masonry unit150. In this way, the present configurations provide more fastening capacity in a tight space. Specifically, for example, the fasteners can be attached at or near an edge (e.g., within a range of about 0.75″ to 3″ from the edge) of the lightweight architectural masonry unit150without a reduction in the fastener capacity. In addition, the center-to-center distances of the openings126in the connecting member120can be reduced relative to conventional attachment configurations for stone materials (e.g., within a range of about 0.5″ to 4.5″) without a reduction in the fastener capacity. This compactness of the attachment between the connecting member120and the lightweight architectural masonry unit150enables the present connector assemblies100to engage a side-facing surface of the lightweight architectural masonry unit150rather than a rear-facing surface (where there may be no viable way to facilitate attachment) or a forward-facing surface (which is meant to be decorative). Such an arrangement is still able to readily support the weight of the lightweight architectural masonry unit150. For instance, as indicated in an ASTM E488 test of one exemplary configuration of the present connector assemblies, an average ultimate tested load for a 3/16″ concrete screw in tension in 1″ of the present lightweight architectural masonry unit150is 553 lbs, and an average ultimate tested load for a 3/16″ concrete screw in shear in 1″ of the lightweight architectural masonry unit150is 369 lbs.

In either configuration, in some embodiments, the size of the notches123formed in the base portion122are configured to accommodate larger fasteners attaching the track110to the structure SS such that the elongated track110is sufficiently able to transfer the load of the attached stone material to the building support structure SS. For example, where the fasteners attaching the track110to the structure SS are 0.225 inch screws, the notches123can have a size of approximately ½ inch to accommodate the size of the corresponding screw head.

In addition, as illustrated inFIG.4, in some embodiments, the connecting member120can be configured to have an extra bend to allow an interior corner attachment. In this regard, the flange portion124of the connecting member120can be arranged at an oblique angle with respect to the base portion122. In some embodiments, for example, the flange portion124can be configured to extend away from the track110at an angle of approximately 45° for connection with a correspondingly-angled side of a lightweight architectural masonry unit150used at an inside corner of a structure. In this way, the formed metal connectors can be designed specifically to optimize manufacturing needs and attachment to the structure through the use of novel shapes.

In any configuration, once the lightweight architectural masonry unit150is moved to a desired position with respect to the elongated track110and the building support structure SS (e.g., by sliding the assembly of one or more connecting member120attached to the lightweight architectural masonry unit150along the track110), as illustrated inFIG.5, in some embodiments, the connector assembly100further includes a fixation member140having a first end141configured to connect to the elongated track110and a second end142configured to connect to the connecting member120and/or to the lightweight architectural masonry unit150. The fixation member140is configured to retain the first lightweight architectural masonry unit150in place with respect to the elongated track110. In some embodiments, the first end141extends a length selected to correspond to a desired joint spacing between adjacent lightweight architectural masonry unit150. For example, in some embodiments, the first end141extends approximately ½ inches to correspond to a joint spacing of approximately ⅝ inches between lightweight architectural masonry units150, although those having ordinary skill in the art will recognize that the size, shape, and/or configuration of these elements is adjustable to accommodate different configurations of lightweight architectural masonry units150.

In a further aspect, additional connector configurations can be used in place of or in addition to those discussed above to mount the one or more lightweight architectural masonry units150to the building support structure SS. As shown inFIGS.6A and6B, in some embodiments, some of the one or more lightweight architectural masonry units150can be attached to the elongated track110using one or more web clips130that include a heel portion131configured to attach within the web112of the elongated track110and a flange portion132that is configured to attach to the lightweight architectural masonry units150. These clips have a slim profile that allows adjacent lightweight architectural masonry units150to be separated by only a narrow gap g (e.g., about ⅝ inch) that is sufficient to enable the fasteners which attach to the structure of the building to be installed through the gap g. For example, this condition can occur when the last lightweight architectural masonry unit150is being installed and there is no sideways access to a side of the stone. Alternatively, if a stone has broken in transportation and the installer wishes to put the rest of the stone panels in place while waiting, the web clip130provides the flexibility needed. The web clip130is pre-installed an edge of the lightweight architectural masonry unit150as shown inFIG.7A, and then after the stone is lifted into place the structure fasteners are attached through the gap g as shown inFIG.7B. Depending on the size of the lightweight architectural masonry unit150, this attachment can require the use of a screwgun extension to position the fasteners. This coupling configuration can thus be specifically valuable in arrangements in which only a narrow space can be used. In a similar arrangement, in an embodiment shown inFIG.8, the modified web clip130includes an additional spacer flange133to positively establish the joint spacing between the adjacent lightweight architectural masonry units150as shown inFIG.9.

In a further embodiment shown inFIGS.10A and10B, the connector assembly100includes cuff members135that present alternative points of connection between the one or more lightweight architectural masonry units150to a building support structure SS. As illustrated inFIG.11, for example, one or more cuff member135can be attached to one of the one or more lightweight architectural masonry units150that is already in position with respect to the elongated track110and the building support structure SS. One or more complementary hook clips136shown inFIGS.12A and12Bcan then be attached to an adjacent one of the one or more lightweight architectural masonry units150, and the hook clips136can be configured to matingly engage with the cuff members135to hold the lightweight architectural masonry units150together. These two clips used together form a hook-and-cuff type of attachment option, such as is shown inFIG.13. In this condition, the cuff member135is attached to the stone face while the hook clip136would be connected to the mating face of the piece which comes from the right side of the building corner shown. In some particular arrangements, this combination of connectors can be used to enable a lightweight architectural masonry unit150to be slid into a locking position. Depending on the arrangement of the cuff member135and hook clip136, such installation can allow the lightweight architectural masonry units150to slide horizontally towards the elongated track110, vertically from above the track110, or in any desired orientation such that each hook clip136aligns with and engages the a corresponding cuff member135. Those having ordinary skill in the art will recognize that the size and arrangement of these elements can be adjusted based on the size and configuration of the lightweight architectural masonry units150to be mounted.

Alternatively or in addition, referring toFIGS.14and15, in some embodiments, a track clip119can enable attachment in a few unique situations where a connection is required in a certain configuration on the outside face of the track110. This is an example of how the design of the connector assembly100can be configured to remain hidden behind the architectural masonry unit150. In some embodiments, a lightweight architectural masonry unit150can be attached to the track clip141, and the track clip121can be attached to the elongated track110to effectively affix the lightweight architectural masonry unit150to the elongated track110by capping the channels115. By capping the track110with the track clip121in this way, the portion of the elongated track110aligned with the edge of the lightweight architectural masonry unit150is unoccupied, and thus the installer has a larger and simpler surface into which to drive the structure fasteners for further fixation members as discussed herein.

In yet further embodiments, the connector assemblies100discussed herein can include further specialty connectors that are adapted for use with the elongated track110as discussed above or individually to secure a lightweight architectural masonry unit150to the exterior of structures, such as in configurations for mounting arches or curved elements or where the elongated track110is a non-ideal fit. Alternatively or in addition, such specialty connectors can be used to hold a lightweight architectural masonry unit150in place while installing it using the connector assemblies100discussed above and/or to provide supplementary support for a lightweight architectural masonry unit150in non-standard configurations (e.g., where standing off of the structural support is greater than 30 inches). Such connectors can include the trim clips shown inFIGS.16A through16H. For example, various embodiments of an angle trim clip161are shown inFIGS.16A and16B, such connectors being usable to facilitate a number of different attachment options for special trim pieces. The configurations of the angle trim clip161can function to attach a lightweight architectural masonry unit150directly to a support structure SS, attach a lightweight architectural masonry unit150to another lightweight architectural masonry unit150, or it can be used as a dowel, allowing the vertical tab to help keep the panel piece in place without the use of fasteners. A straight trim clip162is shown inFIG.16Cand can be used to connect elements that have surfaces that are aligned substantially flush to one another, such as in the arrangement shown inFIG.17. A tabbed trim clip163shown inFIG.16Dcan be used in various places where the lightweight architectural masonry unit150needs to be held in place. A hole can be formed into the stone shell of the lightweight architectural masonry unit150, and the tab sticking up out of the tabbed trim clip163slips into the stone shell and holds it in place.

Further connector elements can also be provided, individually or in paired combinations, for other special circumstances. For example, a “left-hand” trim clip164aor a “right-hand” trim clip164bshown inFIG.16Ecan be used together with each other and/or in combination with other elements in a variety of orientations to interlace with each other or with other clips to resolve challenges associated with mounting stone pieces in locations with limited access. For example, either of the “left-hand” trim clip164aor the “right-hand” trim clip164bcan be used with a panel trim clip165shown inFIG.16Fto complementarily mount adjacent stone structures to the building support structure, such as is shown inFIG.18. Similarly, a first interlock trim clip166shown inFIG.16Gand a second interlock trim clip167shown inFIG.16Hcan be arranged to interlace with each other to complementarily mount adjacent stone structures to the building support structure. In some embodiments of such interlacing configurations, the clips can be positioned such that the attachment to the structural support SS of the first-installed of the clips (e.g., panel trim clip165in FIG.18) is oriented vertically below the complementary clip (e.g. the “left-hand” trim clip164ainFIG.18) so that the dead load of the second-installed complementary clip is supported by the first-installed clip. In such arrangements, the second-installed clip need not be secured to the structural support SS separately by fasteners but can instead be held in place by a combination of this vertical dead load support and a friction fit of the second-installed clip behind the first-installed clip.

Such configurations for the present connector assembly can thus be selected for mounting lightweight architectural masonry units such as lightweight masonry column elements151, lightweight outside corner elements152, and lightweight masonry soffits153as shown inFIGS.19through23. In one particular configuration shown inFIG.19, for example, different configurations of trim clips are used to assist in the attachment of a round lightweight masonry column elements151to an underlying structural column. In addition, a first interlock trim clip166and a second interlock trim clip167shown inFIGS.16G and16H, respectively, can be used in conjunction to connect lightweight masonry column elements151(e.g., filled with an EPS core) to the structural column. The notched design enables the clips to lock into each other for fast installation. In further example implementations,FIG.20shows an installation of a parapet cap, andFIGS.21through24shows aspects of an installation of a suspended soffit and/or ceiling. As shown inFIG.21, in some embodiments, an edge support111shown inFIG.25can be secured to a wall perimeter to support the lightweight masonry soffits153.

The present subject matter can be embodied in other forms without departure from the spirit and essential characteristics thereof. The embodiments described therefore are to be considered in all respects as illustrative and not restrictive. Although the present subject matter has been described in terms of certain preferred embodiments, other embodiments that are apparent to those of ordinary skill in the art are also within the scope of the present subject matter.