Cladding installation support

A cladding support device comprises a folded sheet metal body. The folded sheet method body includes a base wall, a top wall portion protruding out relative to the base wall, a side wall protruding from the base wall and having an upper edge adjacent the top wall portion; and a clamp on the top wall portion, the clamp including a substantially planar body with side edges extending between a coupled end to which the clamp is coupled to the sheet metal body and an outboard end and the clamp being positioned on the top wall with one side edge extending along the upper edge of the side wall.

TECHNICAL FIELD

The apparatus and method disclosed herein relates to a support useful for supporting cladding components on a building or building component.

BACKGROUND

In constructing buildings, it is common to attach cladding components (e.g., beams, purlins, panels, roofing, etc.) to supportive building structures (e.g., steel stud wall studs, concrete or masonry walls, floors, roofs, and other back-up supports). In many applications, it is preferable to provide a space between the cladding components and the building structures. This is typically done by attaching cladding components with supports to the building structure.

FIG.1is a perspective view of an exterior wall assembly10that illustrates use of prior art supports to connect cladding components to supporting building structures. Assembly10comprises a wall12formed by interior finish14such as a drywall board, a C-shaped steel stud16, and an exterior wall panel or sheathing18. A moisture barrier20may cover exterior wall sheathing18. A support22is attached to steel stud16by screws22A that pass through barrier20, exterior wall sheathing18and at least a portion of stud16. Support22shown inFIG.1is one of a plurality of like supports attached to wall12in spaced apart, vertically aligned relation. Alternatively, continuous beams are also used to achieve this function. Support22connects cladding components24, which may consist of supporting cladding framework such as elongate vertical steel beam26, and exterior finish30(e.g., stucco, metal panels, etc.), to wall12. Beam26is attached by fasteners, such as screws24A, to support22. Insulation32may be provided in the space between wall12and cladding components (24,26, and30), and an air cavity and/or moisture drainage cavity28may be provided.

In assembly10, support22must have sufficient strength and rigidity to support the cladding under the various loads it faces (gravity, wind, seismic, etc.). Sheet steel supports are known, such as the one illustrated inFIG.1. However, they can be flimsy. This is especially problematic when securing a horizontal beam. Sagging and flexing can occur and if the solution is to add more supports, this increases material and time costs and does not allow for easy adjustment of the cladding component on the numerous supports. Also, because supports extend from the building structure to the cladding, cladding supports can create a thermal loss path from the building structure to the exterior of the building. If the supports are not durable, so many supports are required that a significant and problematic thermal loss occurs through the wall.

To overcome this problem, polymeric, fiberglass or cast metal supports have been introduced for their strength and stiffness characteristics. However, because so many supports are required, more expensive, heavier, complicated and multi-part support structures are difficult to justify in the construction industry.

Accordingly, a support and method is needed that is simple but adaptable for adjustment and a variety of uses.

SUMMARY OF THE INVENTION

Thus, in an exemplary embodiment, a cladding installation support device comprising: a folded sheet metal body including: a base wall; a side wall protruding from the base wall and having an upper edge; a top wall portion protruding out substantially orthogonally relative to the base wall, the top wall portion including a clamp, the clamp including side edges extending between a coupled end to which the clamp is coupled to the folded sheet metal body and an outboard end, and the clamp having one side edge extending along the upper edge of the side wall.

Moreover, according to another exemplary aspect, there is provided method of constructing a cladding support device, the method comprising: bending an L-shaped piece of sheet steel to create a base, a top wall portion extending substantially orthogonal from the base and a side wall extending substantially orthogonal from the base, such that the top wall portion is adjacent and extends along a top edge of the side wall and each of the top wall portion and the side wall have front edges opposite to the base; and bending a portion of the top wall portion into a clamp.

Moreover, according to another exemplary aspect, there is provided a method for installing a cladding component to a building structure at a worksite, the method comprising: securing a hook through a hanging port of a cladding support device to secure the cladding support device to a worker or a fixed structure at the worksite; driving a fastener through a base wall of the cladding support device to secure the cladding support device against the building structure; after driving a fastener, removing the hook from the hanging port; and inserting the cladding component into a clamp on the cladding support device.

DETAILED DESCRIPTION

Various aspects of the invention are now described with reference to the drawings, wherein like reference numerals are used to refer to like elements throughout. In the following description, for purposes of explanation, numerous specific details are set forth in order to promote a thorough understanding of one or more aspects of the invention. It may be evident in some or all instances, however, that any aspects described below can be practiced without adopting the specific design details described below. In other instances, well-known structures and devices are shown in block diagram form in order to facilitate description of one or more aspects. The following presents a simplified summary of one or more aspects of the invention in order to provide a basic understanding thereof.

FIGS.2,3and4show different views of a cladding support50according to an example embodiment. The cladding support is sometimes referred to as a “clip”. More particularly:FIG.2is a perspective view of support50from the rear, top and first side thereof;FIG.3is also a top, rear perspective view of support50but from the opposite side compared toFIG.2; andFIG.4is a perspective view of support50showing a beam26supported thereon.

Support50may be used for spacing a cladding component, such as beam26from a building structure.

Support50is constructed of sheet metal such as galvanized sheet steel or stainless steel, which is strong but light weight. The support focuses on the structures that act to secure the cladding components to further reduce the weight. Further, support50is specifically constructed to overcome difficulties of sagging and inadequate support inherent with prior galvanized sheet metal supports, while permitting adjustment to be more generally useful.

Cladding support50comprises a base54through which the support is secured to the building structure. Base54has an upper edge54a, a first side edge54badjacent to and extending away from the upper edge and a second side edge54cextending away from the upper edge opposite the first side edge. Base54is overall substantially planar at least on its rear side. A portion, herein referenced as top wall56, extends out from upper edge54agenerally orthogonally from base54and a side wall58extends out from first side edge54bgenerally orthogonally from base54. The terms top and side are employed for convenience to permit these walls to be readily differentiated herein and because the usual orientation of the support50is with top wall facing up. However, it is to be understood that the support can be employed such that the wall, herein termed as side wall58is facing upwardly.

The top wall and the side wall are on adjacent edges of the base and, as such, a corner is formed between base54, top wall56and side wall58.

In the illustrated embodiment, support50is generally elongate, where side edge54bis longer than top edge54a, though this is not necessary.

Second side edge54cis free of any wall extending therefrom such that access can be readily had to the front side54dof base, the underside of wall56and the inner facing side of wall58. While second side edge54ccould extend parallel to first side edge54b, in one embodiment the second side edge54cof base54extends downwardly and inwardly toward the first side edge. In other words, the side to side width of base54between the side edges tapers toward the lower end of the base. This minimizes the amount of material needed to form base54and also limits the amount of material secured against the building structure, which thereby limits the surface area through which thermal transfer can occur. Second side edge54cmay taper inwardly in various ways. In the illustrated embodiment, the second side edge tapers at its upper end54c′ and then extends parallel to the first side edge at its lower end54c″.

Base54has a plurality of apertures59a,59bfor receiving fasteners for securing to the building structure. Base54may include one or more elongate, for example slot-shaped, apertures59athat permit locational adjustment of the base along the building structure after a fastener is inserted through the aperture and threaded into the building structure. The slot shaped aperture may be positioned on base54with its elongate dimension extending in a substantially vertical direction, for example substantially parallel to the side wall58, such that the location of the support50can be adjusted to move top wall56up and down after the fastener is inserted. That or another slot shaped aperture may be angled off parallel from side wall58, to allow the cladding support50to be installed at various angles (i.e. the side wall58not vertical), if required/desired. Base54may also include one or more circular shaped apertures59bfor accepting further fasteners and securing the cladding support in a fixed position to a building structure.

Top wall56includes a clamp60configured to locate a cladding component, such as a beam26, supported on top wall56. In the illustrated embodiment, clamp60is defined as a planar body coupled at a coupled end60ato the support but is free from any connection to the support along its side edges60band at its outboard end60c. A slot62is formed at the underside of clamp60, in this case between the planar surface of top wall56and the underside of clamp60. Slot62opens towards, and possibly along, the front edge of wall56. In one embodiment, for example, outboard end60cextends along a line substantially parallel with the intersection between base54and wall56. Side edges60bof the clamp extend back from the outboard end towards base54. The underside of clamp60is offset from, for example, spaced above, the plane of top wall56, so that slot62is defined as the gap between the planar expanse of the top wall and the clamp. Clamp60can resiliently flex relative to top wall56so that slot62can be urged further open, but will resiliently return to its neutral position when the force is removed. In operation, an edge of a cladding component can be inserted into slot62and secured under clamp60, for example clamped or pinched between clamp60and the rest of the support, such as top wall56. If the cladding component has a length greater than the side edge60bto side edge60bwidth of the clamp, the cladding component extends out from under clamp60.

In one embodiment, the underside of clamp60is spaced above, but in a parallel plane, to the upper surface of top wall56. In one embodiment, outboard end60cis angled up away from top wall56to create the space. The size of the slot facilitates insertion of a cladding component into the slot. The height of slot62, or in other words the size of the gap between the underside of clamp60and the top wall, is generally selected to be about the same as the thickness of the cladding component to be inserted into the slot.

The length of side edges60bdetermine how far a cladding component can be inserted into the slot, with the coupled end60acreating a stop which may be used to limit the advancement of a cladding component over top wall56. For example, a cladding component may be located on support50by inserting the component into slot62and pushing the component into the slot62to a selected degree up to and until the component butts against coupled end60aof the clamp. In the illustrated embodiment, the stop provided by the coupled end is generally parallel to base54of support50. One or more indicators, such as a hole in clamp60may be used to indicate the minimum amount of insertion.

FIG.4shows a beam26inserted into slot62and held under clamp60. The flex in the clamp pinches the beam between the clamp and top wall56. In one embodiment, the clamp is sized to provide for up to 305 mm depth of penetration. In particular, side edges60bare up to 305 mm long between outboard end60cand coupled end60a. As such, the beam26can be inserted under the clamp and adjusted, arrows A, to any depth of penetration between the minimum and the coupled end.

The distance between clamp60and base wall54may be selected depending on how far the cladding is to be spaced from the building structure. For example inFIG.2, the distance between the clamp's connected end60aand base wall54is smaller than that distance inFIG.5.

The clamp includes a plurality of pre-punched fastener holes60dat different distances from outboard end60cso that regardless of the depth of penetration, a fastener can be inserted through a hole60dto engage in the beam in slot62.

There may also be a pre-punched hole56ain wall56. This may be a fastener hole56aor an indicator hole for guiding the minimum insertion. The hole56amay be near the front edge of the wall, aligned with the clamp so that a beam inserted under clamp66overlies the hole56a.

In one embodiment, to strengthen the support and avoid sagging of wall56under the weight of a connected beam, one side of the clamp60is positioned near or at the corner between top wall56and side wall58. Thus, in the illustrated embodiment, one side edge60bextends directly along the corner between the walls. One side edge60bis therefore above and substantially aligned along the side wall58. In one embodiment, for example, the slot62is defined as the space spanning between top wall56and the clamp on one side and the space between the clamp and the upper limit58aof side wall58on the other side. As such, a portion of the weight of any beam26installed under clamp60is borne by side wall58and that weight is effectively distributed into the plane of the side wall58.

In one embodiment, a wall portion64, which is a part of top wall56or is coplanar or in a close and parallel plane with the top wall56, extends below clamp60. Portion64may extend only near the front of the slot such as shown inFIG.3or, such as shown inFIG.2, may extend across more of the depth of the slot. Wall portion64creates a bottom wall for the slot and creates a floor for the slot against which any beam inserted into slot can be biased by clamp60. As such, any beam26inserted into slot62is clamped between clamp60and wall portion64. Wall portion64may be secured to side wall58, for example at edge58a. Wall portion64may also include pre-punched fastener holes60d′ (FIG.6) that align below fastener holes60don clamp60. These pre-punched fastener holes60d′ may be sized to act as pilot holes. For example, pilot holes60d′ may have a diameter smaller than the fastener holes60don clamp60.

Support50in some embodiments is useful for accepting securement of horizontal cladding components under clamp60or vertical cladding components on side wall58. Of course, support50could simply be turned to orient top wall56with its plane in a vertical orientation to accept vertical components under clamp60. However, side wall58has a length along an edge of base that is longer than top wall56, and thereby is better configured to support the weight of a vertical component.

Side wall58may therefore include pre-punched fastener holes58b,58cfor receiving fasteners for securing a vertical cladding component such as a vertical beam see for example, the vertical orientation of the beam shown inFIG.1. Side wall58may include one or more elongate, for example slot-shaped, apertures58cthat permit locational adjustment of the component on the support after a fastener is inserted through the aperture and threaded into the side wall. The slot shaped aperture may be positioned on the side wall with its elongate dimension extending parallel to the depth of the side wall, such that the space between the cladding component and the base54, and thereby the building structure, can be adjusted after the fastener is inserted. One or more circular shaped apertures58bare also provided for accepting further fasteners and securing the cladding support in a fixed position to support50.

Side wall58in some embodiments such as that ofFIG.2-4, also includes a clamp66configured to receive a cladding component, such as a vertical beam. In the illustrated embodiment, clamp66is similar in construction to clamp60, as described above. In particular, clamp66is a generally planar body coupled at a coupled end66ato side wall58but is free from any connection to the support and the side wall along its side edges66band at its outboard end66c. A slot is formed between the planar surface of side wall58and the underside of clamp66. The slot opens towards, and possibly along, the front edge of wall58. In one embodiment, for example, outboard end66cextends along a line substantially parallel with the front edge of wall58and side edges66bof the clamp extend back from the outboard end towards base54. The underside of clamp66is offset from, for example, spaced above, the plane of side wall58, so that the slot is defined as the gap between the side wall and the clamp. Clamp66can resiliently flex relative to side wall58so the slot can be urged further open, but will resiliently return to its neutral position when the force is removed. In operation, an edge of a cladding component can be inserted into slot62and secured between side wall58and clamp66. If the cladding component has a length greater than the side edge66bto side edge66bwidth of the clamp, the cladding component extends out from under clamp66alongside wall58.

In one embodiment, the underside of clamp66is spaced above, but in a parallel plane, to the planar surface of side wall58. In one embodiment, outboard end66cis angled up away from side wall58to create the space. The size of the slot facilitates insertion of a cladding component into the slot. The size of the space between the underside of clamp66and the side wall is generally selected to be about the same as the thickness of the cladding component to be inserted into the slot.

The length of side edges66bdetermine how far a cladding component can be inserted into the slot, with the coupled end66acreating a stop which may be used to limit the advancement of a cladding component over side wall58. For example, a cladding component may be located on support50by inserting the component between outboard end66cand side wall58and pushing it into the slot62to a selected degree up to and until the component butts against coupled end66aof the clamp. In the illustrated embodiment, the stop provided by the coupled end is generally parallel to base54of support50.

The distance between clamp66and base wall54may be selected depending on how far the cladding is to be spaced from the building structure.

The side wall clamp includes a plurality of pre-punched holes66dat different distances from outboard end66c. These holes are warning holes and act as an indicator for minimum insertion.

Clamp66can be positioned anywhere on wall58, but in one embodiment is positioned at a lower edge58dof wall58away from the corner between the side wall and the top wall. For example, the side wall's clamp may have one of its edges66bextending in line with lower edge58d, there being no portion of wall58extending down below the clamp.

Support50may include a hanging port70for storing on a hook such as a clip, pin, lanyard or carabineer. For example, support50may be carried and stored by hanging on a hook or a plurality of supports may be carried together on a hook such as a carabineer or cable by passing the hook through the hanging port. Hanging port70has a diameter much larger than any hole for indicating or receiving a fastener (i.e. the small diameter on a slot or the diameter on a regular fastener hole). For example, hanging port70has a diameter about three or four times larger than any fastener, pilot or indicator hole on the support. The hanging port may be positioned near the unconnected edge of base54, top wall56or side wall58. As such, a plurality of supports50can be hung together with a common hook, such as on a carabineer off a worker's belt, inserted through their ports70and with their corners (i.e. the intersection between walls54,56,58) nested together. In one embodiment, hanging port70is positioned on side wall58near its bottom edge. In other words, hanging port70may extent through the side wall and be positioned close to edge58d, closer to edge58dthan edge58a, which is where the top portion intersects the side wall. InFIG.2, hanging port70is positioned between base54and connected end66. This position near lower edge58dallows the supports50to be hung from the hook in a convenient manner and the hook can remain attached even while the support is being secured to a building structure. This, therefore, avoids the support from being dropped accidentally during installation.

To avoid heat transfer through the support, base54may include a layer of thermal insulation72such as a layer of one or more of wool, felt, fiberglass, aluminum or wall sheeting such as plywood, gypsum board or the like.

FIGS.7to12show views of another cladding support150. While the parts may not be identical to those described above, similar reference numbers are employed for similar parts. Support150may also be used for spacing a cladding component, such as beam26from a building structure. It has many features in common with support50ofFIGS.2to5and that description applies for support150, but some changes and improvements have been made, which are described below.

Support150is constructed of sheet metal such as galvanized sheet steel or stainless steel.

As with cladding support50, cladding support150comprises a base54through which the support is secured to the building structure. Base54has an upper edge54a, a first side edge54badjacent to and extending away from the upper edge and a second side edge54cextending away from the upper edge opposite the first side edge. Base54is overall substantially planar at least on its rear side. A portion, herein referenced as top wall portion56, extends out from upper edge54agenerally orthogonally from base54and a side wall58extends out from first side edge54bgenerally orthogonally from base54. The terms top and side are employed for convenience to permit these walls to be readily differentiated herein and because the usual installed orientation of the support150is with top wall portion on the top and side wall58substantially vertically oriented and extending below the top wall portion. However, it is to be understood that the support can be employed such that the wall, herein termed as side wall58is on top, which is still vertically extending but oriented above the portion56.

The top wall portion and the side wall are on adjacent edges of the base and, as such, a corner is formed between base54, top wall portion56and side wall58.

In the illustrated embodiment, support150is generally elongate, where side edge54bis longer than top edge54a, though this is not necessary.

Second side edge54cis free of any wall extending therefrom such that access can be readily had to the front side54dof base (visible inFIG.8), the underside of wall56and the inner facing side of wall58, which is the side of the side wall visible inFIG.8.

As withFIGS.1to4, base54has a plurality of apertures59a,59bfor receiving fasteners for securing to the building structure. Herein, the apertures are all limited to a position near the corner between base54and side wall58, for example closer to side edge54bthan to side edge54c. For example, apertures59a,59bmay be lined up in a substantially straight line that is parallel to side edge54b. There are no other apertures on the base54apart from those aligned close to the corner, which ensures that the apertures can be readily aligned along a stud and all fasteners are installed into a wall stud. Because there are no base apertures apart from those aligned along the corner, this avoids the wasteful and less effective installation of fasteners through base54into wall structures apart from the studs.

Top wall portion56includes a clamp60configured to locate a cladding component, such as a beam26, supported by top wall portion56. In the illustrated embodiment, clamp60extends the full width of the top wall portion. As above, clamp60has a body coupled at a coupled end60ato the support but is free from any connection to the support along its side edges60band at its outboard end60c. In this illustrated support150, coupled end60ais close to or at the base54. In particular side edges60b, extend the full side lengths of upper wall portion from outboard end60call the way back to base54. Therefore, in effect, clamp60defines the full uppermost surface of top wall portion56and of support150.

A wall portion64of top wall portion56underlies the clamp60. Wall64creates a bottom wall for a slot62. Wall portion64, as noted above, creates a floor for the slot against which any beam inserted into the slot can be biased by clamp60. As such, any beam26inserted into slot62is clamped between clamp60and wall portion64. Wall portion64may be secured to side wall58, for example at edge58aand in this illustration wall portion64extends below substantially the full width from side60bto side60bof the clamp.

Clamp60is configured to have a greater degree of bias downwardly, towards wall portion64, than the clamp of support50. In particular, clamp60is biased downwardly in its neutral position so that a portion adjacent outboard end60cis closely positioned, or actually pressing against, wall portion64. A portion of the underside of clamp60is offset from, for example, spaced above, the overall plane of top wall portion56, such as that plane defined by wall portion64, but the clamp slopes down such that outboard end60cpinches close to the plane of the wall portion64. Clamp60can resiliently flex relative to the part of the support to which it is connected so that slot62can be urged further open, but will resiliently return to its neutral position when the force is removed. In operation, an edge of a cladding component26can be inserted into slot62(FIGS.11and12) and secured under clamp60, for example clamped or pinched between clamp60and the rest of the support, such as wall portion64.

The enhanced bias in clamp60is provided by an angled section of the clamp. In this embodiment, the angled section includes an upwardly angled side60fbetween two creases60f,60rand a downwardly angled side60gthat extends down from crease60rto another crease60g′. Together angled sides60f,60gcreate an upwardly protruding ridge section that extends from side to side on the clamp. The downwardly angled side60gis bent to angle, bias the clamp down towards underlying wall portion64. In section, the two angled sides60f,60ghave an angle between them of 70-110°. In one embodiment, the angled ridge is between planar portions of the clamp. In the neutral position, the planar portions are each substantially in a parallel plane or angled towards that plane defined by wall portion64. For example, downwardly angled side60gis adjoining, coupled to, a planar section60hon which outboard end60cis defined. Of course, outboard end60cmay include a raised, upwardly angled lip such that the planar portion is positioned between the lip and the angled side60g.

FIGS.11and12show a beam26inserted into slot62and held under clamp60. The bias in the clamp pinches the beam securely against wall64and the angled section, specifically the ridge and angled side60gensures that the planar section lies close against the surface of the beam to encourage frictional engagement between the interfacing surfaces of clamp60, beam26and wall64. In one embodiment, the clamp is sized to provide for up to 305 mm depth of penetration. In particular, side edges60bare up to 305 mm long between outboard end60cand coupled end60a. As such, the beam26can be inserted under the clamp and adjusted to any depth of penetration between the minimum and the coupled end60a.

In this embodiment, a marking60mon the clamp60indicates the minimum amount of insertion. The marking is used instead of an indicator hole, thereby to avoid fasteners being inadvertently inserted into an indicator hole.

Clamp60includes a plurality of pre-punched fastener holes60d,60ddat different distances from outboard end60cso that regardless of the depth of penetration, a fastener can be inserted through holes60d,60ddto engage in the beam in slot62. Wall portion64also includes pre-punched fastener holes60d′,60dd′ that align below the fastener holes on clamp60.

To permit the cladding support150to be useful installed with clamp60on the upper end and, alternatively upside down, with clamp60on the lower end, there are two aligned sets of fastener holes: (i) one set with the pre-punched, regular holes60don the clamp that are aligned with the pre-punched, smaller diameter pilot holes60dd′ on the wall64; and (ii) a second set with the regular holes60d′ on the wall, that are aligned with pre-punched, smaller diameter pilot holes60ddon the clamp. As such, fasteners can be readily inserted from either the top surface of the clamp or from the underside surface of wall portion64by driving the fastener first into the selected regular hole60d,60d′.

Support150also includes pre-punched fastener holes58bin side wall58for securing a vertical cladding component. Holes58bare located only near the front edge, as other fastener hole locations are less useful.

Side wall58also includes a clamp66configured to receive a cladding component, such as a vertical beam. Clamp66has been configured to create a significant clamping force for any vertical beam inserted thereunder, for example, between wall58and clamp66. In particular, connected end66ahas been bent to create a first crease that causes a surface66fto protrude laterally outwardly beyond the outer surface plane of side wall58and a second crease66gthat angles a major planar portion66hof the clamp to protrude laterally inwardly through the plane of wall58and out on the other side of the side wall. In other words, clamp66is biased to protrude from its connected end66alaterally out first and then to project through the plane defined by the surface of side wall58to a position below top wall portion56. Outboard end66cof the clamp is therefore, in the neutral position, biased to a position on the opposite side of the side wall from the surface66fat the connected end.

In operation, clamp66can be resiliently flexed relative to side wall58so outboard end66ccan be urged back to open a gap between the outboard end and the plane of the side wall outer surface and an edge of a cladding component can be inserted into the gap and secured between side wall58and clamp66.

Side wall clamp66contains no pre-punched fastener holes or indicator holes. All fastener and indicator holes are eliminated from clamp66, in an effort to prevent any cladding structures from being fastened thereto. Instead, fastener holes are only pre-punched on wall58and a non-apertured marking acts as the indicator for minimum insertion.

Support150may include a hanging port70for storing on a hook such as a clip, pin, lanyard or carabineer. In this embodiment, hanging port70is located on clamp66. This position on clamp66facilitates storage on a hook, since the location on the side wall at its front bottom corner and flex in clamp facilitates the nesting of multiple parts together. In addition, locating the hanging port70on the clamp66, which is at the front bottom corner of the side wall, ensures that the hook/lanyard is accessible near the front and lower edge58dof side wall. The hook can remain attached to support150through hanging port70even while the support is being secured to a building structure.

To construct a cladding support50,150a piece of galvanized sheet steel is cut, as by laser cutting and/or punching into a generally L-shaped member.FIG.6shows one example of a blank useful for constructing a cladding support. A corner C of the L-shaped piece of sheet metal forms base54and the two extensions of the “L” form the top portion including clip60and side wall58. If there is a wall portion64, it can be formed as a tab that extends from the extension that is to become the side wall58. The tab can extend upwardly in a direction parallel to the leg that is to become the top wall.

The plate can be punched with the fastener holes54a,54b,56a,60d, etc. and a hanging port70.

If necessary, cuts may be made to create the side edges60bof clamp60. As described above, one side edge60bof the clamp may actually be the side edge of the top wall, so only one cut may be required. If the support is to include a side wall clamp66, cuts may be made to create the side edges66bof that clamp. As described above, one side edge66bof the clamp may actually be the lower edge of the side wall, so only one cut may be required to form the clamp.

Bends may made to create the live hinges in clamps60,66to open the slots and to impart a clamping bias therein, as described above.

Support50may then be formed by permanently bending the metal. For example, the connected and outboard ends of clamp60and clamp66, if it is included, to create slots62and ramped outboard ends60c,66c. If there is a tab for slot floor wall portion64, that tab can be folded at line L1up orthogonal to the planar surface of the extension that becomes side wall. In addition, the walls56,58are formed by folding at lines L2, L3to bend the “L” extensions upwardly, orthogonal to the planar surface of the corner, which becomes the base54. If there is a tab for slot bottom wall64, that tab can be inserted under clamp60during the wall folding operation. The insulation layer72can be connected, such as by adhesive coupling, to base54on the side opposite the protruding walls. Being galvanized steel, the bends, once formed, are substantially permanent. While there is some flex in the material, the support tends to hold its form.

To achieve the permanent folded shape and durability, 16 to 18 gauge galvanized sheet steel has been used.

The resulting support50is then ready for use. Support50offers a lightweight but strong, one-piece product that is easy to handle and use.

The type of support to be used can be selected with consideration as to whether only a top clamp or both a top and side clamp are required and/or the desired spacing between the clamp and the base. For example a selection can be made between that support ofFIG.1and that ofFIG.5. The support ofFIG.1work well in either for receiving either vertical or horizontal cladding installations, and therefore, have inventory benefits.

The base can be connected against a building structure by driving a fastener through slot59a, which permits the base to be adjusted vertically. Then fasteners are driven through one or more apertures59bto secure the base in place against the building structure. The support may be secured via a hook through a hanging port70to a worker, such as to a worker's work belt, or to a fixed structure at the worksite. The support may remain secured with a hook through port70until at least one fastener secures base54to the building structure. As such, accidents by dropping a support from a large height are avoided.

A plurality of supports can be releasably carried via port70on a hook, such as a carabineer, to a site at which they are to be employed.

The insulative layer72becomes positioned between the base wall54and the building structure and reduces thermal transfer through the support.

If the support is intended to hold a horizontal beam26, further supports are installed along a horizontal line spaced from the first-installed support. Care is taken to adjust the supports such that their slots62substantially line up horizontally. The beam is then inserted into slots62on the horizontally aligned supports. The depth of penetration of the beam beneath clamp60can be slid back and forth,FIG.4, arrow A, to adjust for how far the cladding is to be offset from the wall and how true the wall is. Fasteners can then be secured through fastener holes60dand56ato couple the beam to the support.

If the support is intended to hold a vertical beam26, as shown inFIG.1, further supports are installed along a vertical line spaced from the first-installed support. Care is taken to adjust the supports such that their clamps66substantially line up vertically. The beam is then inserted into slots of clamps66. The depth of penetration of the beam beneath clamp66can be adjusted to select how far the cladding is to be offset from the building structure and to accommodate deviation in the planar surface of the building structure. Initially, fasteners can be secured through fastener slots58cto hold the vertical beam, while the depth adjustments are made. Then, further fasteners can then be secured through fastener holes58band66dto couple the beam to the support.

The above detailed description of example embodiments is not intended to be exhaustive or to limit this disclosure and claims to the precise forms disclosed above. While specific examples of, and examples for, embodiments are described above for illustrative purposes, various equivalent modifications are possible within the scope of the technology, as those skilled in the relevant art will recognize.