Masonry anchor

An axially elongated performed tube having a leading end and a trailing end. The tube is restricted at its leading end and open at its trailing end for the insertion of an adhesive and a ram to extrude the adhesive. The tube is selectively divided along its length into a plurality of porous axial sections, each section having a porosity different from that of its adjacent section, enabling selected distribution of the adhesive in selected areas.

BACKGROUND OF THE INVENTION 
The present invention relates to a method and device for anchoring and/or 
fixing masonry wall elements. 
In much of masonry construction, two or more elements must be anchored or 
"pinned" together to strengthen them, either during initial construction, 
during subsequent repair, or during attachment of ancillary elements to 
the masonry structure. One such typical application, which also 
illustrates the prior art method and the curently used device is shown in 
FIGS. 1 and 2. Here, a concrete block wall construction 10 is faced with a 
brick facade 12, and a void 14 exists either by design or shift due to 
failure of original brick tie elements. Under prior art techniques, a hole 
18 is drilled through both the facade 12 and the concrete block 10 into 
which a tubular hollow screen sleeve 20 is inserted. The sleeve 20 is 
restricted but not fully closed at its leading end 22 by overlapping the 
edge of the screen and is opened at its trailing end 24. Upon insertion, 
or even after insertion, the sleeve 20 is filled with a hardenable 
adhesive or cementatous mass 26. Prior to the hardening of the mass 26, a 
metal rod 28 or anchor is inserted into the sleeve so as to exert ram 
pressure on the adhesive mass forcing the material through the sleeve and 
radially outward. 
It is of course, intended that the sleeve 20 permit the adhesive material 
26 to be extruded radially therefrom into the holes 14 and 15, and to thus 
create an anchor involving the sleeve 20, the adhesive mass 26, the facade 
12 and the concrete block 10. This, however, is only partially effective 
with the prior art devices. As will be seen from FIG. 1, very little 
adhesive material is extruded between the sleeve 20 and the facade 12. 
Therefore, insufficient anchoring is created between sleeve 20 and facade 
12. It can be noted that sufficient material moves into the voids 14 and 
15 and between sleeve 20 and block 10 forming an anchor between sleeve 20 
and block 10. 
The foregoing disadvantage arises from the fact that all of the known prior 
art sleeves are uniformly pervious, i.e., have a uniform mesh or hole 
distribution along their entire length and are at least in part open at 
their leading ends. As a result, as seen in FIG. 2, when the threaded rod 
28 is inserted into the sleeve 20, the distribution of the adhesive, along 
the length of the tube, produces a conical taper indicated generally by 
the numeral 30 wherein the material moves freely and uniformly toward the 
leading edge rather than in a significantly radially direction through the 
sleeve. It is only when the pressure against the slug of adhesive material 
within the sleeve becomes so great, that the material is forced in any 
degree radially from the sleeve. This, occurs only toward the leading end 
of the sleeve. As a consequence of the conical pattern 30, it will be 
noted that very poor contact exists between the sleeve 20 and the facade 
12 although it is precisely in this area, that the maximum adhesion is 
desired. 
Illustrative of the prior art anchoring sleeve, is that shown in HUGEL, 
U.S. Pat. No. 4,620,406, which shows a sleeve formed of a wire screen 
having uniform mesh size along its entire length. This device also 
includes a collar at its trailing end which is adapted to make force-fit 
contact with the bore formed in the masonry so as to prevent overall 
movement of the sleeve during the extrusion of the hardenable mass. 
Uniform mesh or perforated sleeves are also shown in U.S. Pat. No. 
4,528,792; U.S. Pat. No. 1,646,457. In British application No. 2,112,487 
an anchoring sleeve like socket is formed having uniformly disposed open 
slots or perforations therein. The sleeve is filled with a adhesive 
material which is caused to effervesce in situ expanding through the slots 
or holes. This type of anchor is not subject to ram forces created by the 
anchoring rod. 
It is an object of the present invention to provide an anchoring system in 
which better contact of adhesive is provided with the masonry than is 
currently possible, particularly when it is intended to attach or reattach 
the building facade to the base concrete block. This is absolutely 
necessary (see FIG. 1) when it is the object of the fastening to attach or 
reattach the building facade 12 to the base material 10 (brick, pored 
conceret, etc.) where no trailing end attachment is desired, such as a 
nut, roset, or other flange device. 
It is a further object of the present invention, to provide an improved 
anchoring system in which a selective distribution of adhesive along the 
length of the anchoring tube is made. It is the particular object of the 
present invention to provide a screen sleeve for use with a hardenable 
adhesive and an anchoring bolt, for obtaining a brick to brick, block to 
block or brick to block masonry securement. (or any other masonry or stone 
elements). 
The foregoing objects, together with additional objects and advantages will 
appear as the description proceeds. 
SUMMARY OF THE INVENTION 
In accordance with the present invention, a method and device is provided 
for anchoring masonry structures together, comprising the use of 
perforated tubular anchoring elements having a leading end and a trailing 
end. The tubular element is restricted at its leading end to prevent 
passage of adhesive material and open at its trailing end for the 
insertion of a hardenable mass of adhesive material. The adhesive 
material, is compressed by ram means to extrude the same radially from the 
tube. The tube is selectively divided along its length into at least two 
axial sections, in one section of which perforations are provided, in 
total, having a path of less resistance to axial extrusion than in the 
other section, thus enabling selection of relatively different amounts of 
adhesive material to be extruded from the selected lengths. Preferably, 
the section with the least resistance to axial extrusion to be located at 
the trailing end of the tube wherein, the initial ram action occurs. 
Still further, it is preferred that the tube is formed of a cylindrically 
shaped wire screen and the difference in porosity and therefore, 
resistance to axial extrusion of adhesive, be provided by varying the mesh 
size in different axial sections of the tube. 
In certain embodiments, it may be advantageous to separate sections by a 
band of relatively impervious material so that extrusion radially from the 
tube is prevented at such a point along the length of the sleeve. It is 
preferred that the leading end of the tube be closed completely as by 
setting a solid metal slug at the leading end. 
It will be apparent, that the axial sections may be selected in any number 
and manner, particularly to conform to the type and size of the masonry 
structures on which it is used. By such selection, the sleeve can be 
provided so that selected amounts of adhesive material are extruded in 
selected axial sections within the structure so that the most advantageous 
and optimal securement may be obtained. 
Full details of the present invention are set forth in the following 
disclosure and illustrated in the accompanying drawings.

DESCRIPTION OF THE INVENTION 
By turning first to the description of the device for carrying out the 
present invention, as seen in FIG. 4, the method thereof may be more 
easily understood. 
As seen in FIG. 4, the invention is embodied in a wire mesh tube generally 
indicated by the numeral 32, being closed at its leading edge by a solid 
slug 34, preferably soldered or welded into place, and open at its forward 
end 36 for the introduction of the anchoring rod 42 and/or slud element as 
desired. Extending forwardly from the trailing end 36, is a tab 38 which 
enables the tube 32 to be manually held for insertion into the masonry 
hole 18 and which enables the tube to be secured against axial movement 
under the force of the ultimately inserted anchoring ram. In accordance 
with the present invention, the tube 32 is divided into at least two axial 
sections, namely a forward section 32a and a trailing section 32b each of 
different mesh size and therefore of different perviousness or porosity. 
The forward section 32a has a smaller mesh size and thus a smaller open 
area than the trailing section 32b. The two sections 32a and 32b are 
joined, in the embodiment of FIG. 3 by a lapping seam 40 wherein the rear 
end of the smaller mesh section 32a overlaps the leading end of the larger 
mesh section on the exterior surface. The lap seam 40 is preferably 
welded, braised or otherwise joined together. 
Preferably, the trailing section 32b (coarser mesh) does not extend too 
deeply axially along the tube 32. A section, somewhat less than the depth 
of the facade 12 is preferable, although this will actually be left to 
selection depending upon the structure being attached. 
The use of the device as shown in FIG. 3 is illustrated in FIG. 4. The tube 
32 is initially filled, in the normal manner, with adhesive material to 
the extent that no voids or air spaces are found in the filling. The 
filled tube is then inserted through the bore 18 and passed beyond the 
void 14 formed between the concrete block 10 and the brick facade 12 and 
fully through the concrete block 10, as is the prior art devices. A 
rod-like ram 42 and/or stud element is inserted into the trailing end. The 
ram 42 may be smooth or embossed as required for greater adhesion or 
holding power. 
In any event, the ram 42 is inserted from the trailing end 36 toward the 
leading end 34 forcing the adhesive material 26 within the sleeve toward 
the forward end 34. Because the mesh at the trailing section 32b is 
substantially more coarse than that at the leading section 32a, the 
gel-like adhesive material is more easily extruded radially in the area of 
the facade 12, as at 46 even though the ram force and pressure duration is 
relatively small. 
The larger holes in the coarse mesh section 32b at the trailing end 36 
compensates for the short period of time and pressure duration, effected 
by the ram 42 in moving through the trailing end, as opposed to the larger 
period of time and pressure duration effected by the ram 42 at the leading 
end 32a of the sleeve. As a result, a less cone shaped and more uniform 
volume of the adhesive mass is extruded than otherwise possible with the 
conventional sleeve. As the ram 42 continues its movement, the adhesive 
material is pushed toward the leading end 34. Because of the more 
restricted wall 34 at the leading end of the tube, the axial flow of the 
material is inhibited thereby, the adhesive material backs up within the 
tube 32 causing it to flow readily in a radial direction rather than in 
the axial direction. This provides a significant radial flow of adhesive 
between the outer surface of the tube 32 and the solid surface of the 
concrete block 10, as seen at points 48 and 50 as well as within the 
hollow chambers 15 of the concrete block. 
Consequently, greater adhesive contact is obtained between the brick facade 
12 and the anchoring tube 32, as seen in FIG. 4. Compare this with the 
substantially lesser contact made in the prior art as seen in FIG. 1. This 
increased contact is effected without any waste of the adhesive material. 
If one wants to insure against waste of adhesive material, and provide 
selected extrusion along the length of the tube 32, an impervious band 44, 
of metal, plastic tape or other means is wrapped about the sleeve. The 
band 44, as shown in FIG. 4 as being aligned at 41 with the void 14 
between facade 12 and block 10, acts to blank out certain areas from 
receipt of adhesive, the position of the band or bands are selected, 
depending upon the nature of the structure to be anchored. 
In a typical application such as a brick-tie repair, the tube of the 
present invention will be approximately 8 inches long having 61/2 inches 
at its leading end constructed by a 20.times.20 inch mesh weave of 0.014 
inches diameter stainless steel wire. The remaining 11/2 inches at the 
trailing end is constructed by a 14.times.14 mesh weave of 0.017 inches 
diameter stainless steel wire. The lap seam is welded to join the two 
sections with the 20 mesh material lying exterially of the 14 mesh 
material. The tube, in order to accept a 3/8 inch ram and for insertion in 
a 1/2 inch hole, is formed using a 0.390 inch diameter welding mandrel. 
The tab at the trailing end can be made of any material, mesh or solid, 
being dimensioned in size to enable the user to hold on to the sleeve 
while it is being filled, and to secure the sleeve flush with the outside 
of the facade so that it is not axially movable during the ram extrusion 
process. Once the anchor is completed, the tab can be bent and stuffed 
into the hole. 
The dimensions illustrated herein may of course, be varied depending upon 
the need for each particular application. Mesh sizes specified are for a 
thixotropic adhesive paste, common to most epoxies and polyester resins. 
Mesh sizes may also be varied depending upon the viscosity and/or 
thixotropy of the adhesive. Further, rather than using a wire mesh screen, 
a cylindrical tube formed of sheet material may be employed which is 
provided with holes, perforations, slots or foraminous openings in 
different discrete axial sections, having different open area sizes, 
rather than mesh. The tube may be formed of metal or plastic materials. 
The concept of the present invention is the use of a multi-mesh or 
multi-pervious sectioned tube in which discrete, axial sections have 
differently distributed openings or mesh sizes, which will achieve by a 
non-uniform axial distribution of hole sizes, mesh, etc., a uniform or 
selectively non-uniform axial distribution of adhesive so as to obtain 
more desirable and selective contact in the process of structural pinning 
and/or anchoring. 
A further advantage of the present invention arises in combination with the 
ram, in that the ram more beneficially combines with the adhesive and 
forms a more integral part of the anchor, capable of absorbing and 
carrying loads placed on it by the brick and facade structure and/or other 
exterior facade attachments. In addition, the added adhesive at the 
trailing end increase contact with the ram minimizing any loosening effect 
that may be created by the load conditions. 
Various modification, changes and embodiments have been disclosed herein, 
other such will be obvious to those skilled in the art. Accordingly, it is 
intended that the present disclosure be taken an illustrative only and not 
limiting of the invention.