Abstract:
An alignment device for assembling a masonry joint includes a main body configured to slidably engage a generally vertical support pole, the main body including a first arm and a second arm projecting away from the main body, the first arm defining a predetermined angle relative to the second arm, and a reel assembly on the main body for supporting a reel of string, the main body further including a string guide between the reel assembly and the first arm for guiding a string from the reel to the first arm. Also a method of building a wall using the alignment device.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of U.S. Provisional Application Ser. No. 60/942,379, filed Jun. 6, 2007, the entire contents of which are hereby incorporated by reference. 
     
    
     BACKGROUND 
       [0002]    1. Field of the Invention 
         [0003]    The present invention is directed toward an alignment device for positioning masonry elements when forming a masonry joint and toward a method of using same, and more, specifically, toward an alignment device having first and second arms for guiding a masonry string away from a first location to define a level line for building a masonry wall and toward a method of using same. 
         [0004]    2. Description of Related Art 
         [0005]    Using traditional methods, building structural joints, such as the corners of a building or similar structure, can be quite time consuming. To create a joint, an experienced or lead mason must use a level to build the corners (inside or outside) on the structure before other masons can build the walls between the corners. An eight block corner typically takes a lead mason about 45 minutes to an hour to build. Thus for a 4-man crew made up of a lead mason and three less senior masons, the less senior masons cannot begin work until at least two corners have been constructed by the lead mason. It would therefore be desirable to provide a method and apparatus that would allow masons of having less skill than a master mason to construct structural joints. 
       SUMMARY OF THE INVENTION 
       [0006]    This and other problems are addressed by embodiments of the present invention, a first aspect of which comprises an alignment device for assembling a masonry joint that includes a main body configured to slidably engage a generally vertical support pole. The main body includes a first arm and a second arm projecting away from the main body, and the first arm defines a predetermined angle relative to the second arm. A reel assembly is mounted on the main body for supporting a reel of string, and the main body has a string guide between the reel assembly and the first arm for guiding a string from the reel to the first arm. 
         [0007]    Another aspect of the invention comprises an alignment system that includes first and second support poles and an alignment device on each of the support poles. Each of the alignment devices includes a main body configured to slidably engage the first or second support pole. Each main body has a first arm and a second arm projecting away from the main body, and the first arm defines a predetermined angle relative to the second arm. A reel assembly is mounted on the main body to support a reel of string. The main body also has a string guide between the reel assembly and the first arm for guiding a string from the reel to the first arm. The string extends from the reel of string of the alignment device on the first support pole over the string guide, along the first arm of the alignment device on the first support pole and connects to the alignment device on the second Support pole. 
         [0008]    A further aspect of the invention comprises a method of building a wall that includes steps of inserting first and second poles vertically into the ground at a first location and placing a first alignment device over the first pole and placing a second alignment device over the second pole. A reel of string is placed on the first alignment device, and the string is pulled from the reel of string along the first arm and to the second alignment device where it is attached. A masonry block corner is then built at each of the first and second poles. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]    Example embodiments of the present invention will be more fully understood from the detailed description given hereinbelow and the accompanying drawings, wherein like elements are represented by like reference numerals, which are given by way of illustration only and are not intended to limit the example embodiments. 
           [0010]      FIG. 1  illustrates a system including a pole and an alignment device for assembling a structural joint in accordance with an embodiment of the present invention. 
           [0011]      FIG. 2  is a perspective view of the alignment device of  FIG. 1 . 
           [0012]      FIG. 3  is a top plan view of the alignment device of  FIG. 2 . 
           [0013]      FIG. 4  is an exploded perspective view of a reel assembly of the alignment device of  FIG. 2 . 
           [0014]      FIG. 5  is a perspective view of the pole the system of  FIG. 1 . 
           [0015]      FIG. 6  is a perspective view of a pole brace collar for the corner pole of  FIG. 5 . 
           [0016]      FIG. 7  is a perspective view of a pole brace for supporting the corner pole of  FIG. 5 . 
           [0017]      FIG. 8  is a perspective view of a second embodiment of an alignment device according to the present invention. 
           [0018]      FIG. 9  is a top plan view of the alignment device of  FIG. 8 . 
           [0019]      FIG. 10  is a perspective view of a building foundation having several types of corner joints and schematically showing different alignment devices that could be used to build each type of corner joint. 
           [0020]      FIG. 11  is a perspective view of a third embodiment of an alignment device usable in the system of  FIG. 1 . 
           [0021]      FIG. 12  is a top plan view of the alignment device of  FIG. 11 . 
       
    
    
     DETAILED DESCRIPTION 
       [0022]      FIG. 1  illustrates a system for assembling a structural joint of a structure in accordance with an example embodiment. System  1000  includes at least two alignment devices  100  (only one is shown) separated by a distance along a structure such as a residential or commercial building. As will be seen in more detail below, each alignment device  100  has an alignment guide with at least one alignment arm attached to a main body  101  of the device. The main body  101  includes a reel assembly  150  for paying out masonry string  75  and a string guide  120  thereon. 
         [0023]    The system  1000  includes a corner pole assembly  200  provided for each device  100 . The corner pole assembly  200  includes a corner pole  21   0  on which the alignment device  100  is movably secured so as to slide up and down the pole  210  to build up the structural joint, and a pair of pole braces  230  attached to a corner pole brace  220  to secure the corner pole  210  in a vertical orientation at the corner of the building structure. The masonry string  75  is payed out from the reel assembly  150  of one alignment device  100  through alignment channels on the main body  100  and alignment arm  111 , then is tightened and secured at the other alignment device  100  so as to provide a level line for building up the structural joint with masonry products  50 , which can be brick or block products, for example. Of note, there is no need to actually build a corner as in the prior art before laying rows of masonry products; the system is installed and the masonry products can be laid immediately 
         [0024]      FIG. 2  is a perspective view of a alignment device for assembling a structural joint of a structure in accordance with an example embodiment that is usable in the system of  FIG. 1 . Referring to  FIGS. 2 and 3 , the alignment device  100 , also called a corner mount assembly, is shown in this embodiment as being applicable to an ‘outside’ corner, i.e., it is used to build up an outside corner of a building structure with masonry product. Accordingly, the device  100  of  FIG. 2  is employed where the structural joint to be built up is an outside corner, such as a 45° or 90° outside corner, for example. 
         [0025]    Device  100  includes a main body  101  to which a string reel assembly  150  is attached thereto for paying out masonry string used in preparing a level line. The main body  101  may be composed of a resilient material such as polyvinyl carbonate (PVC), although other materials may be used, such as a medium or heavy gauge impact plastic like acrylonitrile butadiene styrene (ABS). ABS is an easily machined, tough, low-cost, rigid thermoplastic material with medium to high impact strength, and is a desirable material for turning, drilling, sawing, die-cutting, shearing, etc. PVC and ABS are merely two examples. Alternatively, main body  101  could be composed of other thermoplastic and thermoset materials that have characteristics similar to PVC or ABS, such as, for example, polypropylene, high-strength polycarbonates such as GE Lexan, and/or blended plastics. 
         [0026]    Device  100  includes a masonry alignment guide  110  attached to the main body  101  at an upper end thereof. The masonry alignment guide  110  is provided to keep masonry products  50  such as concrete block and brick level and straight as the device  100  is moved up the corner pole  210  to build up the structural joint. 
         [0027]    The alignment guide  110  comprises alignment arms  111  that extend at an angle from each other to mate to the building corner. Each alignment arm  111  includes one or more string guide alignment supports  112  extending above arm  111  along a top surface thereof. The alignment arm  111  may be composed of PVC plastic of another material such as ABS, polypropylene, GE Lexan, etc. The string guide alignment support  112  includes a groove or alignment channel  113  therein that receives and aligns the masonry string  75  as it is paid out from the reel assembly  150 . Each alignment arm  111  additionally includes one or more viewing notches  114  between string guide alignment supports  112  to enable a user of the device to verify that the masonry product  50  is aligned with the masonry string  75 . 
         [0028]    The alignment guide  110  also includes an offset guide  115  at the intersection of the two arms  111 . The offset guide  115  can be employed when using brick for job such as building a corner accent (sometimes referred to as a “Cowen corner”) and bands that encircle a residential building. Each alignment arm  111  includes a Support brace  116  which has a string keeper  117  therein. The string keeper is embodied as a notch or slot and is designed to hold the masonry string  75  secure; the string  75  is fed through the keeper  117  and a knot is tied such that the knot cannot pass through the slotted string keeper  117 . The string keeper  117  is thus employed when a alignment device  100  is receiving the string  75  from another alignment device  100  at the adjacent corner of the building structure. Further, all of the string guide alignment supports  112  and offset guide include a pair of wear pins  118  on the top corners thereof. The wear pins  118  are formed from metal or a harder plastic material prevent the masonry string  75  from cutting into the PVC material of the alignment arms  111 . 
         [0029]    The main body  101  further includes a string guide alignment support assembly, shown generally at  130 . Assembly  130  includes a string guide alignment support  132  and a string feed guide  135 . The string guide alignment support  132  extends above the top of main body  101  and includes a string holder  134  to prevent the string from shifting out of position. The top ends of the string guide alignment support  132  also include a wear pin  118  thereon. The string feed guide  135  controls the string alignment as it comes off a string reel  155  of the reel assembly  150 . In an example, the string feed guide  135  is configured to hold the string in a 4″ offset for a step out work evolution in shifting from setting an 8″ concrete block to a 12″ block. The string feed guide  135  includes a channel or recess  137  which aligns the string as it comes off the reel  155 , and has a cross-wise string holder  139  to prevent the string  75  from shifting out of position. 
         [0030]    The alignment device  100  includes at least one bottom support guide  140  attached to the main body  101  which provides support for the alignment guide  110  above it. Each bottom support guide  140  has brace supports  142  for additional support. The main body  101  also includes an alignment block  145  that maintains the masonry product (such as a concrete block) in the plumb position, so as to prevent shouldering. The alignment block  145  is provided on two sides of the main body  101 , each below a corresponding alignment arm  111  of the alignment guide  110 . Further, a thumb screw  148  is provided through the main body  101  for securing the alignment device  101  to the corner pole  210  of the system  1000 . 
         [0031]    As shown in  FIG. 3 , the dotted line  146  indicates the path of the string  75  from the reel assembly and out from device  100  so as to provide a level line for building up the structural joint with masonry products  50 . Following dotted line  146 , string  75  rolls off of the string reel  155 , up through the string feed guide  135 , along offset guide  115  and across a viewing notch  114 , along one side of a string guide alignment support  112  (within a channel  113  not shown), across another viewing notch  114  and then along through a channel  113  (not shown) on an opposite side of another string guide alignment support  112 , and then over to a alignment device  100  on an adjacent corner. The string  75  is tightened in a keeper  117  at the other device  100  so as to provide a level line for building up the structural joint with masonry products  50 . 
         [0032]      FIG. 4  is an exploded perspective view of a reel assembly the alignment device of  FIG. 2 . The reel assembly  150  includes a spacer block  151  which provides support for the string reel  155  and also provides additional thread depth for the reel support bolt  153 . A notched locking wheel  152  is provided between spacer block  151  and string reel  155 . The locking wheel  152  is secured to the string reel  155  and holds the reel  155  in the desired position when the masonry string  75  is being tightened. The reel assembly  150  includes a handle  156  to reel-in loose masonry string  75 . 
         [0033]    The tightening of the string  75  should be done by hand-pull, with the slack taken in by actuating handle  156 . The spacer block  151  includes a pawl  158  ( FIG. 2 ) that engages the locking wheel  152  to secure it in the desired position when the string is tightened. The handle  156  includes a handle extension  157  that improves leverage for reeling. 
         [0034]      FIGS. 5-7  describe the corner pole assembly  200  of  FIG. 1  in further detail. As shown in  FIG. 5 , the corner pole  210  supports the alignment device thereon against a building structure. In an example, corner pole  210  may be constructed of 2″ square tubing, 16 gauge steel, although it is evident that other materials could be used, such as an alloy, aluminum, a hard plastic, etc. At the corner pole bottom is provided a pair of different sized flange  212 ,  214 . Flange  212  is employed when the alignment device is employed to lay masonry products  50  and includes a small offset from the corner post to accommodate the alignment device. In an example, flange  212  is welded to the corner pole  210  and may be 4′ long×1½″ wide. Flange  214  is employed when the alignment device is not used to lay masonry products  50 . In an example, flange  214  is welded to the corner pole  210  and may be 2′ long×1½″ wide. Flange  214  does not have an offset from the corner pole and can be used as a corner marker at the location where the corner of the structure will be formed. 
         [0035]    As shown in  FIG. 6 , the corner pole brace collar  220  includes a recess  222  to receive the thumb screw  148  that extends there through and into the main body  101  of the alignment device  101 . The brace collar  220  can be secured to the corner pole  210  via a suitable fastener such as a thumb screw. In an example, brace collar  220  can be made from 2″ flat stock steel. 
         [0036]    The brace collar  220  includes a pair of flange brace supports  224  that may be composed of 1½″ flat stock steel. Each flange brace support  224  includes a drilled hole  226  for receiving the corner braces  230 . As shown in  FIG. 7 , each brace  230  may be composed of two brace arms of different width and thickness such that the lower arm  231  fits within the upper arm  232  and is secured by a suitable fastener  233  to form the brace  230 . The end of the upper arm  232  includes a flat bar  234  welded thereto which includes a drilled hole  236  that mates which the drilled hole  226  of the flange brace support  224  so that the brace  230  can be secured to the brace collar  220  with a suitable fastener. At the lower end of brace  230 , the lower arm  231  includes a flat bar  235  with a drilled hole  237  to receive a threaded fastener (bolt) end  239  from a piece of steel pipe  238 . The pipe  238  has a hollow interior configured to receive a piece of rebar  240  ( FIG. 1 ) for securing the brace  230  into the ground. The bolt end  239  of pipe  238  may be secured to the flat bar  235  via a suitable fastener such as a wing nut  241 . 
         [0037]    Installation of the system  1000  is explained as follows. Initially the corner pole  210  is set up and braced with braces  230  to hold the corner pole  210  in a vertical position. Then the corner pole  210  is scored every 8″ or brick, or every 12′ for block. The alignment device  100  is then installed on the corner pole  210  via the thumb screw  148 , noting that the device  100  is slid down the corner pole  210  to the proper elevation for laying the first row of bricks, and then secured. 
         [0038]    To create the level line, the reel  155  is release by unlocking pawl  158 , and string  75  is paid out from the reel assembly  150  through alignment channels on the main body and alignment arms (i.e., as described in  FIG. 3 , through the string feed guide  135 , along offset guide  115 , across viewing notch  114  and along one side of a first string guide alignment support  112 , across another viewing notch  114  and along an opposite side of a second string guide alignment support  112 , and then out to be pulled over to another alignment device  100  on an adjacent corner. The payed-out string  75  is tightened and secured in a string keeper  117  at the other alignment device  100 , and then the string reel  115  is locked at the first device  100  via pawl  158 . Accordingly, a level line has been created for building up the structural joint with masonry products  50  at a fraction of the time it would take a lead mason using conventional level line techniques. 
         [0039]    The lead mason can then begin building the first row of masonry products  50  along the level line formed between the alignment devices  100 . Once complete, the alignment devices  100  are raised to the next score line on the corner pole  210  and secured to building the next row off of the structural joint. The corner pole  210  is typically about eight (8) feet in length. In building structures above 8′, the pole  210  can be eliminated as the level line has already been achieved and the top length of the structure is plumb. 
         [0040]      FIG. 8  is a perspective view of a alignment device for assembling a structural joint of a structure in accordance with another example embodiment that is usable in the system of  FIG. 1 . As many of the components of device  100 ′ have already been described with regard to alignment device  100  in  FIGS. 2-7 , only the differences are discussed in detail. Like reference numerals are used for like elements where applicable. 
         [0041]    Referring to  FIGS. 8 and 9 , alignment device  100 ′, also called a corner mount assembly, is shown in this embodiment as being applicable to an “inside corner,” i.e., it is used to build up an inside corner of a building structure with masonry product  50 . Accordingly, the device  100 ′ is employed where the structural joint to be built up is an inside corner, such as a 45° inside corner, for example. 
         [0042]    Like the alignment device  100  of  FIG. 1 , alignment device includes a main body  101  with an alignment guide  110  attached thereto. The alignment guide  110  includes a pair of alignment arms  111  with a viewing notch provided  114  between a pair of string guide alignment supports  112  extending above the alignment  111  along a top surface thereof. The abutting ends of the interior string guide alignment supports  112  each include a wear pin  118  thereon. The wear pins  118  prevent the masonry string  75  from cutting into the PVC material of the alignment arms  111 . 
         [0043]    Each alignment arm  111  of alignment guide  110  is supported by a support brace  116  having a string keeper  117  to hold the masonry string  75  secure when alignment device  100 ′ receives the string  75  from another alignment device  100  or  100 ′ at the adjacent corner of the building structure. The support brace  116  also includes a string feed hole  119  to maintain the masonry string  75  aligned with the string reel  155 . The support brace  116  includes wear pins  118  that extend out the rear facing to prevent the masonry string  75  from cutting into the PVC material of the support brace  116 . 
         [0044]    Unlike device  100  of  FIGS. 2 and 3 , device  100 ′ has no guide alignment support assembly  130 . Instead, as string  75  comes off the string reel  155 , it travels over a wear pin  118  and up through feed hole  119 , which serves as a string guide. From there, the string passes around a wear pin  118  on an interior string guide alignment support  112  of one alignment arm  111 , across viewing notch  114  and through an alignment channel  113  of the exterior string guide alignment support  112  on arm  111 , to be received at an alignment arm  111  of another alignment device  100 / 100 ′ at an adjacent corner. 
         [0045]    The components and functions of the reel assembly  150  are the same as described in  FIG. 4 , thus a detailed explanation is omitted for purposes of brevity. The alignment device  100 ′ is attached to the corner pole  210  as previously described. The method for assembling a structural joint of a structure using system  1000  configured with alignment device  100 ′ is also similar to as previously described, with the exception of the different string alignment off of reel  155  as described above. 
         [0046]      FIG. 10  illustrates locations on a building structure where different alignment devices can be employed to build Lip structural joints. As shown in  FIG. 10 , a masonry structure (footwall) on the outside of a building  170  has several structural joints that need to built up to lay the masonry products in building up the structure  170 . Accordingly, different alignment devices  100 ,  100 ′ can be used depending on the corner angle. As shown alignment device  100 A is used for building up a 90° inside corner joint, device  100 B for a 45° inside corner joint (for structures below one side of a bay window) and device  100 C for a 45° outside corner joint can be employed in system  1000 . 
         [0047]      FIG. 11  is a perspective view of a alignment device for assembling a structural joint of a structure in accordance with another example embodiment that is usable in the system of  FIG. 1 . As many of the components of device  100 ″ have already been described with regard to alignment devices  100  and  100 ′, certain differences are discussed in detail. Like reference numerals are used for like elements where applicable. 
         [0048]    Referring to  FIGS. 11 and 12 , alignment device  100 ″ is applicable to expansion or control joints for long expanses of a structure. For example, in building a 400 foot wall, a control joint is employed at 50 foot intervals for structural strength and to maintain the level-line so as to have a plumb, level structure. Thus, control joints can be built between two alignment devices  100 ″ at a distance of 50 feet apart. Pulling the masonry string  75  at 50 foot intervals reduces string bow; building up sectional parts of the wall between control joints maintains the top of the wall level and flat. 
         [0049]    Referring to  FIGS. 11 and 12 , the alignment guide  110  is flat so as to be flush across the control joint. The alignment guide  110  includes three viewing notches  114  provided between four string guide alignment supports  112  extending above the alignment guide  110  along a top surface thereof. Each string guide alignment support  112  has an alignment channel (not shown) grooved therein along its length. 
         [0050]    Unlike the alignment device  100  of  FIGS. 2 and 3 , alignment device  100 ″ has no guide alignment support assembly  130 . Instead, as string  75  comes off the string reel  155 , it is pulled over a wear pin  118  on brace support  116  and up through feed hole  119  that serves as a string guide. The string passes along the channels in the guide alignment supports  112  and viewing notches  114 , to be received at an alignment guide  110  of another device  100 ″ (another control joint) or at an alignment arm  111  of another alignment device  100 / 100 ′ at a corner, for example. 
         [0051]    The components and functions of the reel assembly  150  are the same as described in  FIG. 4 , thus a detailed explanation is omitted for purposes of brevity. The alignment device  100 ″ is attached to the pole similar to corner pole  210 , but without flanges  212  and  214 . The method for assembling a structural joint of a structure using system  1000  configured with alignment device  100 ″ is similar to as previously described in  FIG. 3 , with the exception of the different string alignment off of reel  155  as described above. 
         [0052]    The example alignment device, system and method for assembling structural joints can enable less-skilled masons to perform the level-line evolution. There is no need to actually build a corner before laying rows of masonry products; the system can be installed and the masonry products can be laid immediately. The use of the alignment devices removes the human error from manual sighting so as to build plumb structural joints for both residential and commercial structures. Additionally, the system facilitates the ability of the mason to check the job for squareness. Building up masonry products around bay windows becomes much simpler with the example system and device, and cowan corners may be built only with trig pins and other tools. 
         [0053]    The example embodiments being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as departure from the exemplary embodiments of the present invention. All such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.