Method of constructing angled brick panels

A method of prejoining a pair of bricks at an angle which are to be later incorporated into a prefabricated brick panel having a pair of outer surfaces at an angle other than 90.degree. relative to each other. Either one or both ends of a pair of bricks are beveled at a total angle substantially in excess of the ultimate surface angle between the surfaces of the two adjacent bricks. The bricks are placed in a jig with the ultimate outer surfaces facing downwardly and the outer corners formed by the bevels in abutment. The V-shaped groove formed by the total angle of the bevels in excess of the ultimate angle is then filled with a cement grout which is then allowed to harden. Usually before the corners are placed in engagement, a bead of unhardened cement grout, usually colored to match the outside color of the bricks, is placed on the abutting corners.

This invention pertains to the art of building construction and, more 
particularly, to a method of constructing a prefabricated brick panel 
wherein the panel has two outer surfaces at an angle other than 90.degree. 
relative to each other and to the article constructed by such method. 
BACKGROUND 
In the art of building construction, it has become conventional to 
construct an internal steel framework of the building and then to hoist 
into position prefabricated panels to form the outer skin of the building, 
such panels normally arranged to provide the window and door openings. 
In recent years, it has become conventional to so form the individual 
panels that the outer surfaces are comprised of two surfaces disposed at 
an angle other than 90.degree. relative to each other. At first such 
panels were made from precast concrete slabs. Because of the architectural 
beauty of bricks, it was desired to make such panels from bricks but the 
formation of the angle between the surfaces had been difficult to achieve 
while still maintaining a structurally sound panel. 
It is possible to order from the brick factory bricks having the angled 
surfaces preformed. However, because such bricks have to be made special, 
there is a substantial additional cost. Furthermore, because these 
specially made bricks are usually fabricated at a time different than the 
regular bricks for the panel, matching of the color and brick texture is 
difficult. 
THE INVENTION 
The present invention contemplates a new and improved method of 
constructing a brick panel wherein the outer surfaces are disposed at a 
predetermined angle other than a right angle which is attractive in 
appearance, structurally sound and economical to manufacture. 
In accordance with the invention, the method includes the steps of: 
providing a pair of bricks having outer surfaces to be disposed at a 
predetermined angle relative to each other; beveling the end of at least 
one of the bricks at an angle such that when said bricks are positioned 
relative to each other at the predetermined angle and with the outer 
corners in contact, the inner corners will be spaced a distance apart of 
approximately 11/2 to 21/2 inches with the maximum bevel angle of either 
brick not exceeding 55.degree.; positioning said bricks with the outer 
surfaces at said predetermined angle with the outer corners in contact and 
the space formed by the bevel(s) preferably facing upwardly and exposed; 
filling the space with cement; and, allowing the cement to harden. For a 
standard brick width of 35/8 inches and with a predetermined outer surface 
angle of 0.degree. (i.e. a flat surface), to produce a 2 inch spacing 
between the inner corners of the bricks requires a total bevel angle of 
30.degree.. This total bevel angle may be provided by beveling the end of 
one brick at the 30.degree. angle and leaving the end of the other brick 
untouched or the total angle may be divided between the two bricks and if 
so, preferably equally, namely 15.degree.. The total bevel angle in 
accordance with the invention will thus equal 30.degree. plus the 
predetermined surface angle between the two bricks. The bevel angle on any 
one brick should not exceed 55.degree.. Thus, if the predetermined angle 
is in excess of about 30.degree., then the ends of both bricks should be 
beveled. 
Standard bricks also include a plurality, e.g. five, transverse openings 
through the large side of the bricks and in accordance with the invention, 
the bevel cut preferably passes through one of such openings, either on 
the diameter or preferably close thereto. 
Further in accordance with the invention, the pair of bricks to be joined 
with the predetermined surface angle are positioned in side-by-side 
relationship with other similar pairs of bricks with a space in between of 
a type to which the hardened cement will not adhere. 
Further in accordance with the invention, the beveled surface(s) is(are) 
coated with a cement bonding material prior to the application of the 
cement. 
Further in accordance with the invention, prior to positioning the outer 
corners of the bricks in engagement with each other, a bead of cement is 
placed on at least one of the corners to be abutted of a color matching 
the color of the brick such that if the corner between the two surfaces is 
damaged or does not exactly fit, the flaw will not be noticeable except 
upon close inspection. 
The invention further comprises the additional step of progressively laying 
bricks including at one point the joined bricks in end-to-end relationship 
on their sides and in a plurality of vertically stacked layers with cement 
between the ends of bricks and between each layer until the panel has 
reached its desired height which will become the width of the panel when 
ultimately installed. 
Further, the invention contemplates inserting rods through vertically 
aligned openings in the bricks of each layer and grouting such rods in 
place so as to provide a structurally sound and strong panel which can be 
easily shipped to the job site and hoisted into its final assembled 
position. Horizontal joint reinforcing is also placed between layers 
bridging the cement between the brick ends. 
OBJECTS 
The principal object of the invention is the provision of a new and 
improved method of joining a pair of bricks with the outer surfaces 
disposed at an angle other than a right angle which provides a 
structurally sound and essentially continuous brick surface through the 
angle. 
Another object of the invention is the provision of a new and improved 
method of joining a pair of bricks so that the outer surfaces will be at 
an angle wherein there will be no apparent joint where the bricks are 
joined and if there are any flaws, they will not be visible or apparent 
except upon a very close inspection. 
Another object of the invention is the provision of a new and improved 
method of constructing a brick panel wherein the outer surfaces are at an 
angle relative to each other which enables the panel to be economically 
constructed at a point remote from the ultimate job site and then 
transported to the job site and hoisted into position.

PREFERRED EMBODIMENT 
Referring now to the drawings wherein the showings are for the purposes of 
illustrating a preferred embodiment of the invention only and not for the 
purposes of limiting same, FIG. 1 shows a side view of a brick panel 
comprised of bricks 10, 11, 12 and 13 disposed essentially in end-to-end 
relationship with cement 15 between bricks 10 and 11, cement 16 between 
bricks 11 and 12 and cement 17 between bricks 12 and 13. While not shown, 
in the finished panel there are additional layers of vertically extending 
rows of bricks with the cement joints staggered relative to the cement in 
the joints shown in FIG. 1. 
The bricks 10, 11, 12, 13 are standard bricks and are normally 21/4 to 4 
inches wide, 35/8 inches thick and 12 inches long and have end surfaces 
20, large side surfaces 22, an outer surface 24 and an inner surface 26. 
Each 12 inch long brick is normally provided with five openings 30 
extending transversely through the sides 22 and in a given panel, the 
openings 30 in adjacent layers of the panel are horizontally aligned. In 
the preferred embodiment, metal rods 33 extend through at least some of 
these openings and are rigidly held in position by grout 34. Bricks 10 and 
13 are identical. Metal reinforcing (not shown) is provided between 
adjacent layers. 
In accordance with the invention, brick 11 has its upper end 40 and brick 
12 has its lower end 42 beveled at an angle with the V-shaped space 
between the beveled end 40, 42 filled with a hardened cement 44. The 
beveled surface 40 generally passes through one of the openings 30 in 
brick 11 and also forms an upper outer corner 50 with outer surface 24 
while the beveled surface 42 passes through one of the transverse openings 
30 in brick 12 and forms a lower outer corner 52 with outer surface 24. 
The outer surface 24 of brick 11 is at an angle A other than 90.degree. 
relative to the outer surface 24 of brick 12, which angle is predetermined 
by the architectural requirements of the building and will hereinafter be 
referred to as the surface angle. In the embodiment shown, the surface 
angle A is 30.degree.. Obviously it can be any angle from 0 up to 
approximately 90.degree.. 
In the embodiment shown, the outer upper corner 50 of brick 11 is in 
physical contact with the outer lower corner 52 of brick 12 and at least 
immediately adjacent the intersection of these corners, the cement 44' is 
preferably colored the same color as that of the bricks 11, 12. 
In accordance with the invention, the inner adjacent corners of bricks 11, 
12 are spaced a distance apart S of between 11/2 to 21/2 inches and 
preferably 2 inches, such that when the bricks 11, 12 are positioned at 
the angle shown and with corners 50, 52 in engagement, there will be ample 
room to force the cement 44 into the V-shaped gap in the cut openings 30' 
provided by the beveling which gap has its apex at the engaging corners 
40, 42. 
FIGS. 2 and 2A show the first step in the method of manufacturing of the 
panel shown in FIG. 1. Thus, a cutting saw 60 is provided to bevel the end 
of either brick 11 or brick 12 or both, depending on the surface angle A 
desired in the ultimate panel. 
To provide a distance S equal to 1.5, 2 or 2.5 inches with a surface angle 
of 0.degree. and with a standard 35/8 inch thick brick, the total bevel 
angle B calculates to be about 22.degree., 28.degree. and 34.degree. 
respectively. This bevel angle B may be taken on either brick 11 or brick 
12 or may be divided in any desired way between bricks 11 and 12 but if it 
is divided, it is divided preferably equally. In order to avoid the 
expense of beveling both ends, when the surface angle A approaches 
30.degree., the distance S is allowed to approach the minimum of 1.5 
inches. For a surface angle A in excess of 30.degree., both bricks should 
be beveled equally. 
For a distance S equal to 2 inches, a total bevel angle B of 28.degree. is 
required which must be increased by the surface angle A of the bricks. If 
the surface angle is to be 10.degree., there must be a total bevel angle 
of 38.degree.. If the surface angle A is 30.degree., there must be a total 
bevel angle B of 58.degree.. It is preferred that the bevel angle of any 
one brick not exceed 55.degree.. If the total bevel angle B between two 
bricks is to exceed 55.degree., then in accordance with the invention, the 
ends of both bricks should be beveled. As indicated, the beveling may be 
divided in any desired way between the two adjacent bricks but preferably 
the bevel angle is equally divided. 
The next step in the method is to coat the beveled end of the bricks 11, 12 
with a cement bonding material 65. A preferred material employed is a 
proprietary formula sold under the trademark "Thorobond". 
After coating the beveled ends of the bricks, they are preferably placed in 
side-by-side abutting relation ship with the sharp corner formed by the 
bevel facing upwardly and by means of an extrusion gun 67 a cement 68, 
preferably colored to match the color of the brick, is deposited on the 
sharp upper corner. 
FIG. 4 shows the next step. In this step a jig is provided which is 
comprised of a pair of parallel extending, upwardly facing supporting 
surfaces disposed at the desired surface angle of the panel. This jig may 
be made adjustable but normally is rigidly constructed for each job and is 
comprised of a pair of end members 70 each having a pair of arms 71, 72 
disposed at an angle relative to each other equal to the desired surface 
angle A and horizontal members 73, 74, 75, 76 extending below and between 
such end members 70 providing supporting surfaces at the desired angle A. 
The bricks 11, 12 are positioned on such surfaces with their outer 
surfaces 24 facing downwardly and with the corners 40, 42 with the cement 
68 thereon in abutting relationship. Pairs of such bricks 11, 12 are 
placed in side-by-side relationship with spacer members 78 therebetween. 
The spacer member 78 has a lower edge cut to the surface angle A and has 
the characteristic that the cement will not rigidly adhere thereto so that 
when the cement hardens or at least partially hardens, the spacer member 
can be broken away leaving the bricks 11, 12 in rigidly joined 
relationship. 
Once the bricks are so placed, a conventional quick setting cement 44 is 
placed in the upwardly diverging opening, preferably in an amount such 
that its upper surface overlaps the inner surface 26 of the bricks 11, 12. 
Normally the cement will be smoothly feathered into the surfaces of the 
bricks generally as is shown. 
The members 73, 74, 75, 76 of the jig may be of any length depending upon 
the member of bricks 11, 12 to be joined at the desired angle. It will 
also be noted that the cement is forced into the openings 30 which have 
been intersected by the beveling of the ends of the bricks 11, 12. 
The cement is then allowed to harden to a strength sufficient for handling. 
The assembled bricks may then be removed from the jig. Any burr of the 
cement extending beyond the corners 40, 42 can be readily brushed away 
leaving a smooth uninterrupted brick surface between bricks 11, 12 around 
the outwardly facing corner. 
Once a plurality of bricks 11, 12 have been joined as above described, the 
brick panel shown in FIG. 1 can be constructed using conventional brick 
laying techniques. In such an operation, it is preferred that the cement 
joints 15 and 17 of adjacent layers be staggered as is conventional in the 
construction of brick panels. Also openings 30 in adjacent layers are 
aligned. Alternatively, the joints are aligned all as required by the 
architect. 
Once the required number of layers of bricks 10, 11, 12, 13 have been laid 
to provide a panel of the desired height or width when ultimately 
installed, metallic rods 33 of a diameter less than the diameter of the 
openings 30 are inserted through the aligned openings and the space 
between the rods and the inner walls of the openings 30 are then grouted 
with grout 34. 
The entire assembled panel is then allowed to rest in place until the 
cement has thoroughly hardened at which time the panels can be transported 
either to storage or to the ultimate job site and hoisted into position. 
For the purposes of simplicity the bonding material placed in the notch or 
between adjacent bricks has been referred to generically as "cement" 
meaning at all times a plastic or flowable mass until hardening. Such a 
cement is otherwise known as "cement grout" or "cement mortar" as such 
terms are used in the art. 
The invention has been described in connection with a preferred embodiment. 
Obviously modifications and alterations will occur to others upon a 
reading and understanding of this specification and it is my intention to 
include all such modifications and alterations insofar as they come within 
the scope of the appended claims.