Abstract:
A masonry lintel having a concealed spine which spans between piers to either side of an area to be arched and supports masonry bricks through means of horseshoe shaped plates which ride on the spine. The bricks are supported on the spine by stitching rods which extend through apertures in the plates and the bricks. The plates are received in the grouting space between the bricks and, in the finished lintel, are grouted over to be completely hidden from view. Variations in the relative positions of the piers and the width of bricks used to construct the lintel are accommodated by adjustable supports between the spine and the piers which enable the position of the spine relative to the piers to be selectively adjusted. In the embodiments employing multiple generally parallel spines, these supports provide for adjustable spacing of the spines. Center supports for the spines are adjustable both vertically and horizontally to accommodate various structural design parameters.

Description:
BACKGROUND OF THE INVENTION 
   The present invention relates to an improved apparatus and method for use in supporting masonry lintels and, more particularly it is directed to a system for adjustably supporting a spine to be concealed within the lintel. In its more specific aspects, the invention is concerned with such a support system which enables the use of a concealed support, maintains the standard grout width and accommodates various widths of masonry and various tolerances, without requiring a precisely pre-constructed lintel support for each job. 
   It is well known in the art to use supports for masonry lintels. Most of these supports, however, are disposed beneath the lintel and, accordingly, exposed to view. See, e.g., U.S. Pat. Nos. 4,020,612, 4,202,143, 4,757,656, 5,465,558 and the exposed roof truss of U.S. Pat. No. 5,218,801. It is also known to reinforce brick walls supported on piers through means of internal reinforcing elements which extend longitudinally through a passage therefor in the wall so that the elements are concealed, as may be seen from U.S. Pat. No. 5,893,254. 
   The prior art concealed lintel system of HALFEN Anchoring Systems employs a steel spine that spans the opening being arched and rests on bearing plates at each end. Cored bricks are suspended from the spine through means of “horseshoe” plates that hang on the spine at every third brick joint and stitching rods which extend through openings in the plates and the bricks. During the course of construction, the bricks are supported on a framework and the openings in the bricks and plates, with the rods extending therethrough are packed with mortar. Grout is placed between the bricks, with the result that the spine support is totally concealed. The bearing plates supporting the spine on the piers are welded to the spine and grouted into place on the piers. 
   The present invention is an improvement over the concealed lintel system of HALFEN in that the bearing plates at either end of the spine are adjustable to accommodate various size and tolerance masonry units and maintain a standard grout width. As a result, the spine of the present invention does not need to be custom designed and fabricated for each project, as was necessary with the welded spine and support plate construction of the prior art HALFEN System. 
   SUMMARY OF THE INVENTION 
   The apparatus of the invention is for use in combination with a lintel support comprising a first spine member extending between piers disposed to either side of an area to be arched and support plates mounted on the spine member to suspend cored bricks from the member through means of stitching rods extending through apertures in the plates and bricks. The improvement of the inventive apparatus comprises separate bearing plates on each of the piers to support the spine member, and attachment means to selectively secure the spine member to the bearing plates at different positions of adjustment relative to the plates. Multiple spine embodiments of the invention further include means connecting the spines to the bearing plates which provide for selective adjustment of the relative spacing between the spines. The inventive apparatus may also provide adjustable intermediate supports to suspend the spines from support structure disposed between the piers. 
   In the method of the invention, a spine member to be concealed within a masonry lintel rests on support structure disposed to one end of the lintel. The method provides an adjustable support between the structure and the spine member to accommodate adjustment of the spine member relative to the structure. The support is adjusted to dispose the spine member in a desired condition of adjustment relative to the structure and then secured to maintain the desired condition of adjustment. 
   A principal object of the invention is to provide a concealed support system for a masonry lintel which will accommodate last minute adjustments and allow for variations in the sizes of the bricks used to construct the lintel. Another general and related object is to provide an adjustable support system for a concealed masonry lintel which allows adjustments for as built variations in the masonry. These and other objects of the invention will become more apparent when viewed in light of the following detailed description in the accompanying drawings. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a perspective view illustrating a pair of concealed support spines for a masonry lintel wherein the ends of the spines are supported on piers through means of the apparatus and method of the present invention, with bricks shown in phantom supported on horseshoe plates carried by the spines; 
       FIG. 2  is a perspective view, with parts thereof broken away, illustrating the detail of the spines and associated horseshoe plates and bricks of  FIG. 1 ; 
       FIG. 3  is a cross-sectional elevational view illustrating a first embodiment of the adjustable intermediate support of the invention; 
       FIG. 4   a  is a perspective view illustrating a horseshoe plate designed to be hung from one side of a support spine; 
       FIG. 4   b  is a perspective view of the horseshoe plate of  FIG. 4   a , shown hung from a spine member, with bricks suspended therefrom by stitching rods; 
       FIG. 5  is a cross-sectional elevational view of a second embodiment of the adjustable intermediate support of the invention; 
       FIG. 6  is a perspective view, with parts thereof broken away, illustrating an embodiment wherein the support of the invention accommodates two spine members, each of which supports a separate horseshoe plate; 
       FIG. 7  is a cross-sectional elevational view, with parts thereof broken away, illustrating a third embodiment of the adjustable intermediate support of the invention; 
       FIG. 8  is a cross-sectional elevational view, with parts thereof broken away, illustrating a modification of the third embodiment intermediate support of  FIG. 7 ; 
       FIG. 9  is a cross-sectional elevational view, with parts thereof broken away, illustrating a fourth embodiment of the adjustable intermediate support of the invention; 
       FIG. 10  is an elevational view, with parts thereof shown in section, illustrating a first embodiment of the bearing plate construction of the invention; 
       FIG. 11  is an elevational view, with parts thereof shown in section, illustrating a second embodiment of the bearing plate construction of the invention; 
       FIG. 12  is an elevational view, with parts thereof shown in section, illustrating a third embodiment of the bearing plate construction of the invention; 
       FIG. 13  is an elevational view, with parts thereof shown in section, illustrating a fourth embodiment of the bearing plate construction of the invention; 
       FIG. 14  is side-elevational view, illustrating the bearing plate construction of the present invention supporting a generally rectilinear spine; and 
       FIG. 15  is a side-elevational view similar to  FIG. 14 , illustrating the bearing plate construction of the present invention supporting a rectilinear spine with an intermediate support. 
   

   DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     FIG. 1  shows a concealed lintel system of the HALFEN type embodying the adjustable support system of the present invention. As there seen, piers P are disposed to either side of an area A to be arched. A pair of spine members S span the area A and are supported at their ends on the piers P. The spine members carry a horseshoe plates H which, in turn, carry cored bricks B through stitching rods  10  which extend through openings  12  in the bricks and openings  14  in the plates. The plates are formed with U-shaped slots  16  which engage over the spine members S. The openings  14  in the plates are disposed both to the outside and to the inside of the spines. The outside openings support bricks B to the outside of the spines. The inside openings supports bricks intermediate to spines. In a typical embodiment, the spines are fabricated from three-eighths inch steel plate, the horseshoe plates are fabricated of three-sixteenth thick plate and the stitching rods are fabricated of one-quarter inch diameter bar. The plate and bar elements are ideally either fabricated of a corrosion resistant steel, or hot-dipped galvanized steel. The stitching rod openings in the horseshoe plates P are of a elongate configuration and ideally correspond with at least two cored openings in the bricks. 
   In the course of constructing a lintel the bricks are positioned as shown in  FIG. 1 , with the horseshoe plates at three brick intervals, and the stitching rods are threaded through the openings in the plates and bricks. The openings in the bricks are packed with mortar around the stitching rods. The horseshoe plates are received in the grouting space between each third brick and the bricks are assembled so that a uniform grout space is provided therebetween. The grout space is filled with mortar. The bricks are supported on a form work (not illustrated) until such time as the mortar has sufficient strength to support the load of the bricks. After the form work is removed, the lintel is cleaned of excess mortar and the joints are pointed. 
     FIG. 1  illustrates a first embodiment of the inventive spine support system wherein angles  18  are disposed on the piers P to either side of each of the spines S. Each angle comprises a bearing plate portion  20  resting on top of the pier and an upright portion  22  extending vertically therefrom in generally parallel relationship to the spine member which it supports. (This arrangement may be seen in more detail in  FIG. 10. ) 
   Lower bolts  24  extend slidably through complimental openings therefor in the upright portions and through enlarged openings  26  in the spine members S. Elongate upper bolts  28  also extend through complimental openings therefor in the upright portions  20  and through enlarged openings  30  in the spine members S. The bolts  28  also span the space between the spine members S and, together with nuts  32  threadably received thereon serve as means to adjust the spacing of the spine members relative to one another. Vertical and horizontal adjustment of the support angles  18  relative to the spine members S is provided through means of the enlarged openings  26  and  30  in the spine members and the smaller diameter of the bolts  24  and  28  extending therethrough. In the course of such adjustments, the nuts on the bolts  24  and  28  are initially left in a loose condition so that the position of the angles  18  relative to the spines may be adjusted to position the bearing plate portions firmly on the piers. Once so adjusted, nuts  34  on the bolts  24  are tightened to clamp the spine members S between the upright portions  22 . The inside nuts  32  on the elongate bolt  28  are then adjusted to provide the desired spacing of the spine members S and the outside bolts  32  are then tightened into place to both fix this condition of adjustment and further clamp the spine members S between the upright portions  22 . The clamping action of the bolts functions to force the upright portions  22  into secure frictional engagement with the spine members S, thus selectively establishing a secure adjusted condition between the angles  18  and the spine members. Once fully adjusted and clamped, the bearing plate portions of the angles  18  are mortared into place on the piers. 
   The adjustable intermediate support shown in  FIG. 3  is secured to an I-beam  34  fixed above the area being arched. The first component of the adjustable intermediate support comprises a T-shaped or angle-shaped member  36  clamped to the I-beam. Clamping is provided by bolts  38  which extend through the T-shaped member, clamp elements  40  slidably received on the bolts, and nuts  42  threadably engaged with the bolts above the clamp elements  40 . In the course of adjustment, the nuts are initially loosened to enable the clamp elements to slide on the I-beam, and once the desired condition of adjustment is achieved, the bolts are tightened to secure the T-shape member in place. Links  44  extend between the member  36  and the spine members S to suspend and lend intermediate support to the spine members. The ends of the links are hooked through apertures provided therefor in the member  36  and the spine members S. Turnbuckles  46  provide for select adjustment of the length of the links. 
   The horseshoe plate of  FIG. 4A , designated H 1 , is designed for the construction of a lintel having a single brick width, as might be used for creating the appearance of a brick arch on the opening in a preexisting wall. It comprises a main plate portion  48  having oblong stitching rod openings  50  extending therethrough and a hanger plate  52  welded in normal relationship to the plate  48  for hooking over a spine member, as seen in FIG.  4 B. The ends of the spine member would be supported on piers, or other support structure, through means of the adjustable support structure of the present invention, for example the first embodiment structure previously described with respect to  FIGS. 1 and 10 . 
   The adjustable intermediate support of  FIG. 5  may be used with a single thickness brick lintel, such as that shown in  FIGS. 4A and 4B . It is of a construction similar to that of  FIG. 3  in that it includes an I-beam  34 , a T-shaped member  36  and bolted clamp elements  40 . The T-shaped member, however, is asymmetrical relative to the I-beam and extends to one side thereof to support an elongate vertically extending bolt  54 . The bolt  54  supports the spine member S through means of an angle  56  welded to the spine member. Nuts  58  are threadably engaged on the bolt  54  to either side of the horizontal flanges of the T-shaped member  36  and the angle. These nuts are selectively adjusted and tightened into place to adjust the length of the  FIG. 5  support. 
   The modified arrangement of  FIG. 6  differs from that of  FIGS. 1 and 2  in that the spine members S are spaced apart by a greater distance and a separate horseshoe plate H 3  is provided on each spine member. This arrangement accommodates different proportions and combinations of bricks intermediate to spine members. The adjustable supports of the present invention enable the spacing of the spine members to be adjusted to compliment such differences, while maintaining uniform grout width. 
   The third embodiment adjustable intermediate support shown in  FIG. 7  corresponds to the first embodiment shown in  FIG. 3 , except that it is the greater width to accommodate wider spacing of the spine members and the separate horseshoe plates of FIG.  6 . Accordingly, the elements of the  FIG. 7  intermediate support are designated by numerals corresponding to those used for the like elements of the  FIG. 3  embodiment. Like the  FIG. 3  embodiment, the  FIG. 7  embodiment provides for adjustment of the intermediate support both longitudinally and vertically, relative to the fixed I-beam  34 . 
   The modification of the third embodiment intermediate support shown in  FIG. 8  differs from that of  FIG. 7  only in the construction of the T-shaped member, designated  36 A and the clamp elements which secure the member  36 A to the I-beam  34 . The top of the T-shape member  36 A is formed with what is known as a HALPEN channel for slidably receipt of special bolts  38 A which carry washer like clamp elements  40 A and threadably receive clamping nuts  42 A. When the nuts  42 A are loosened, the bolts  38 A may be slid over the flange of the I-beam  34  to enable the T-shaped member to be adjusted in position relative to the I-beam both longitudinally and transversely. Once in the desired position of adjustment, tightening of the nuts  42 A serves to fix the position of the T-shaped member  36 A relative to the I-beam. 
   The fourth embodiment intermediate support of  FIG. 9  differs from the first embodiment of  FIG. 3  only in the construction of the clamp used to secure the intermediate support to the I-beam  34 . In the  FIG. 9  embodiment, the clamp comprises angle-shaped members  58  engaged over the lower flange of the I-beam, which members have intermediate L-shaped extensions  60  welded thereto and extending downwardly therefrom. The extensions are adjustably secured together by a threaded rod  62  extending therethrough and nuts threadably engaged with the rod to either side of each of the extensions. The nuts are adjusted and tightened in place to lock the angle-shaped members  58  in select conditions of adjustment relative to the I-beam  34 . Links  44 , corresponding to those of the  FIG. 3  embodiment, adjustably suspend the spine members (not illustrated) from the  FIG. 9  clamp. 
   The second embodiment bearing plate construction ( FIG. 11 ) differs from the first embodiment in that a single T-shaped support  66  is provided for each of the spine members S in place of the paired angles  18 . Each T-shaped support comprises a bearing plate portion  68  having an upright portion  70  welded thereto. The upright portions  70  are bolted to the spine members S through means of lower bolts  24  and elongate bolts  28  corresponding to the like numbered bolts of the first embodiment support illustrated in FIG.  10 . The bolts  24  and  28  extend through complimental openings therefor in the upright portions  70  and through enlarged openings  26 ,  30  in the spine members. Like the first embodiment of  FIG. 10 , the enlarged openings  26  and  30  of the  FIG. 11  embodiment permit the spine members to be adjusted horizontally and vertically relative to the bearing plate portions  68 . Tightening of the bolts through means of the nuts thereon serves to clamp the spine members to the upright portion  70 . The nuts on the elongate bolt  28  also accommodate adjustment of the spine members towards and away from each other. 
   The third embodiment bearing plate construction of  FIG. 12  corresponds identically to the first embodiment construction of  FIG. 10 , except that the inner angles, designated  18 A, are provided with more elongate bearing plate portions  20 A. These more elongate portions provide additional stability and are desirable in applications of the invention where the distance between paired spine members is increased. 
   The fourth embodiment bearing plate construction of  FIG. 13  is essentially a variation of the second embodiment of  FIG. 11 , wherein the single support plate for the spine member S comprises an L-shaped angle  18 B, rather than a T-shaped member. The L-shaped member  18 B has a lower bearing plate portion  20 B and an upright portion  22 B. As shown in  FIG. 13 , however, a single spine member, only, is supported on the angle  18 B. Short bolts  24  extend through the enlarged openings  26 ,  30  of the spine member and complimental openings therefor in the upright portion  22 B. Like the other embodiments, the enlarged openings in the spine member permit adjustments of the spine member relative to the angle  18 B. Tightening of the bolts serves to secure the spine members in adjusted condition. 
     FIG. 14  illustrates that the support structure of the present invention may be used to adjustably support a generally rectilinear spine member, designated S 1 . As there shown, the spine member S 1  is provided with a centrally disposed aperture  74  for receipt of an intermediate support link, such as that shown in FIG.  3 . 
     FIG. 15  also shows the support system of the present invention used to support a generally rectilinear spine member, designated S 2 . The spine member S 2  has an angle  56 A, similar to the angle  56  of the  FIG. 5  embodiment, welded thereto intermediate S-ends for engagement with an intermediate support such as that shown in FIG.  5 . 
   CONCLUSION 
   All embodiments of the present invention provide multi-directional adjustment for the lintel support, thus avoiding the requirement that special supports be preconstructed for each job. The invention is defined in the following claims.