Wall embodying masonry panels

March 4, 1958 j. j. brquk 2,825,221

WALL EMBODYING MASONRY PANELS

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March 4, 1958 j. j. brouk 2,825,221

WALL EMBODYING MASONRY PANELS Filed Dec. 18, 1952 2 Sheets-Sheet 2

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ATTa/MErs

United States Patent Office

2,825,221

Patented Mar. 4, 1958

2,825,221

WALL EMBODYING MASONRY PANELS Joseph John Brouk, St. Louis, Mo.

Application December 18,1952, Serial No. 326,726 1 Claim. (Cl. 72—17)

This invention relates to masonry panels and walls embodying same, and more particularly to an improved construction of panels for building purposes, and the walls into which such panels are incorporated, the panels being of an improved light-weight waterproof and nailable character, possessing high thermal insulation properties and characterized by low shrinkage. The principles of the present improvements may be utilized in connection with various actual or simulated masonry walls in which the masonry units are preassembled prior to erection of or at least separately from the building or other structure. Since the improvements will usually be applied in a wall of brick or simulated brick, terminology in reference to brick is used herein, but without restriction in describing typical embodiments.

This applicant is aware that certain panels have heretofore been proposed, in which a number of brick are cast in a matrix in panel form, to approximate in appearance, conventional brick walls. Such panels have, however, not met with high favor in the building trades because of excessive weight of the individual panels with consequent high transportation and handling costs, and with difficulty and great expense in actual erection. Further recognized difficulties include high water absorption, low effective thermal insulation, high labor costs, and excessive shrinkage in formation of the panels as well as in the walls constituted thereby. It is accordingly a general and principal object of the present invention to obviate the several short-comings heretofore experienced in the production, erection and usage of multiple brick panels of the types heretofore known.

A further important and general objective realized by the present improvements, consists in the production of a highly ornamental panel made in simulation of a brick wall and containing actual or simulated brick units, yet which may be securely and permanently assembled into the wall by the use of driven metal elements, such as wire nails.

Yet another object of the current improvements is attained in an improved panel having the properties referred to in preceding objects, in combination with nailable stud elements which may consist of nail-receiving metal studding, and which with still further advantages, may be incorporated into a complete wall providing both outside and inside finish surfaces, which is light in weight, permanent, highly resistant to _ passage of moisture through the wall either by direct impact or by capillarity, and which is characterized by high thermal insulating values. .

A further highly valuable object of the present improvements is attained in a panel as well as in complete walls utilizing such panels, and of such character that the panels may be quickly and easily tailored and trimmed to other than original dimensions; may be quickly and easily adapted to corners, and which are possessed of greater flexibility and resilience than usual cement panels and slabs, all with the advantages. of substantial reduction in weight, improved physical (>5 properties, and much lower erection and transportation costs.

The foregoing and numerous other objects and advantages of the invention will appear from the following detailed description of a commercial type of panel, considered alone, or as a component of the improved complete wall structure, particularly when the description to follow is considered in connection with the accompanying drawing, in which:

Fig. 1 is a top or plan view of a typical panel containing present improvements as same would appear when laid up in an open pan type of mold, the cast panel being serially broken away at different depths to illustrate various portions thereof;

Fig. 2 is a longitudinal vertical sectional view of the panel in the mold, as taken along line 2—2 of Fig. 1;

Fig. 3 is a slightly enlarged fragmentary sectional view through a portion of the cast panel in the mold, this view being located by line 3—3 of Fig. 1;

Fig. 4 is a fragmentary vertical section through a corner of the mold pan containing the cast panel, and located by line 4—4 of Fig. 1;

Fig. 5 is a front elevational view of a portion of a complete building wall, marginally broken away, to indicate the appearance of a plurality of the panels to constitute the outer portion of the wall;

Fig. 6 is an enlarged fragmentary section taken depthwise through the structure of Fig. 5, in a vertical plane depthwise of the wall, also showing a portion of the footing and anchorage of the wall thereto, Fig. 6 being located by line 6—6 of Fig. 5;

Fig. 7 is a fragmentary enlarged view in a horizontal plane through the finished wall showing attachment of the panel and other elements to metal studding, and

Fig. 8 is a fragmentary horizontal section depthwise of the wall as located by line 8—8 of Fig. 5.

Referring now by characters of reference to the drawing and first to Fig. 1, the cast panels usually constituting the outside wall elements, are or may be conveniently formed in a flat receptacle such as indicated by the metal mold pan MP consisting of a shallow, metal, opentop receptacle, the walls of which are outwardly tapered to provide draft and facilitating release of the cast panels from, the pan. In the formation of the individual panels according to present preference, the bottom of the mold pan MP is coated with a heavy mineral oil to prevent unwanted bonding or sticking of the matrix to the metal of the mold. Over the coated bottom MPB are laid in uniformly spaced relation and preferably in predetermined pattern, a plurality of brick units, of full or fractional face dimensions, and indicated at 10. The spacing between the units 10 approximates the width of the usual mortar joints of a conventional brick wall. It is preferred that the units 10 have face dimensions identical, with those of conventional brick, but for reduced weight and thickness of panel, it is preferred that the thickness or depth dimension of the units 10, be one half or less of that of conventional brick. Suitable spacers may be employed if desired, to assure uniform spacing of the elements 10 in the finished panel.

When the brick units are laid over the bottom of the pan, except for certain marginal recesses hereinafter described, it is preferred to locate in and substantially over the area of the mold pan, a course of wire mesh having reasonable flexibility. For this purpose mesh of a type designated as 2 x 2, is usually employed, and is indicated at 11 (Fig. 1), After the mesh 11 is in place, the material to constitute the matrix or body of the panel is poured in place up to a level flush with the top margins of the pan MP, permitted to set, and upon at least substantial completion of setting, is removed from the pan for further

2,826,281 curing or setting if needed, thence to storage or shipment.

Many of the improved properties of the present panel are realized by the use of a special, light-.weight nailable concrete which sets to form the matrix or body of the panel unit, the matrix being indicated at 12. This concrete matrix includes in a proportion of approximately 282 lbs. of Portland cement, 12 cu. ft. of aggregate of a weight of the order of 8-12 lbs. per cu ft.; also added water to produce the desired consistency of, mix to facilitate thorough hydration and easy processing prior to and at the time of introduction of the mix to the mold. The aggregate is by greater preference, of an expanded .mineral type, and by still further preference consists of perlite, this being a thermally expanded mineral derived· by heat-treating a natural product for a length of time under such temperatures as to result in some dehydration, and in expansion, of. the raw mineral to several times its original volume. Other ingredients may be added to the mix, as desired or as specified for particular purposes. It is pointed out, however, that proportions of perlite and Portland or perhaps other cements, possess a high inherent moisture proofing character, when cast as described. Also, because of the highly, porous, .flocculent and light weight character of thjs.. aggregate,, there results a slab or panel unit which has a high resistance .to spalling and cracking even under hammer blow impacts, and may be readily cut to provide panels of reduced Or special· dimensions, and which inherently possesses a high thermal insulation value or conversely, expressed, a low heat conductivity. It will be understood, however, as distinctly contemplated that added waterproofing ingredients, several of which are well known in the building trades, may be either incorporated in the mix or if desired, may be. applied to the surface or surfaces of the finished panel. Obviously other ingredients, usually in low proportions, may be added for special effects, such as tinting or other particularly desired effects, all without affecting the essential properties of the finished panel and particularly the highly waterproof, insulating and nailable characteristics.

Brief reference was heretofore made to the desirability of providing certain marginal recesses in the finished panel. These are, as will now be.obvious from Figs.T and 5, utilized for the reception of tie brick or key brick for structural interconnection of marginally adjacent panels when erected in the wall. A low cost expedient for this purpose consists in introducing pieces of wood such as indicated at 20 to the mold, prior to pouring the matrix. When the panel is removed from the mold pan, the dummy pieces 20 are readily removed leaving accurately defined brick or half brick receiving recesses in the frontal faces of the margins of the unit. Thus, when adjacent panels are erected margin to margin in the wall, separate elements 10 are fitted into the spaces left by the dummies 20, are mortared in place with a mix similar to or identical with that constituting the body 12 of the panel, thus resulting in an indistinguishable marginal interlocking effect. It should be noted as a preference that the cavities caused to remain in the margins of the cast panels are confined to the surface portions of the panel so that exact depth wise placement of the key brick units is automatically provided for in the finished wall.

Many of the properties of the panel to which the description thus far has been limited, may be carried into a complete wall providing finished inside and outside surfaces such a wall possessing high insulating .and moisture resistant properties, and being of a character such as to insure low heat loss through the wall.

One example of such a wall is best shown by Figs. 5, 6 and 7, Figs. 5 and 6 showing a conventional concrete footing CF in which, at predetermined center spacings, are located a number of anchor bolts AB. These may be extended into suitable plate members shown as channels, and indicated at CM. Into the-channel members are set a suitable number, at predetermined spacings, of nail-receiving steel stud elements S. Nail-receiving beam sections of this type are per se, heretofore known in the trade, being sold under the trade name of “Stransteel” and S perhaps others. The steel studding shown is characterized by spaced web members W providing therebetween nail receiving slots. The nail opening NS permits, with holding deformation and interlocking effect, the reception of a wire mail or the . like WN or .other suitable driven 10 metal fasteners. Thus erection of the plurality of wallforming panels involves, by reason of the nailable character of the matrix 12, the driving of nails through certain of the mortar joints of each panel, along the lines defined by the studs S, it being noted that care has been taken to 15 select such a size of wire mesh and so to locate the wires 11 thereof in the mold, that for the most part these wires fall out of line and away from registry with the mortaljoints of the panel. Driving of the nails WN is preferably carried to a degree such that the nail heads are recessed 20 somewhat below a flush, relation'with the outer portion of the mortar joint, the resulting countersink or cavity outwardly of the head and indicated at 22 being sealed with mortar or concrete matching that appearing in the mortar lines, and thus avoiding any marring of appear25 ance or possible rust streaking effects.

It: is of course entirely feasible to employ the brick panel, units by application thereof externally to existing buildings, even over weatherboarding or directly to wood sheathing, or, when desired, to wood studding elements. 30 When the panels, are. mounted by nails or driven metal fasteners, the only, requisite as to the support, is that it include nail-receiving and -retention portions.

In the case of new buildings the choice of studding and inner .finish will be dictated by various requirements 35 of appearance, imposed loading, and other factors. In many cases however, a highly desirable and novel wall structure utilizes a lath of metal ML which may be attached for example, by. nails WN extended through the lath and into'the nail seats NS of the metal studs, the 40 wire lath forming a support for a layer of plaster PL which, in fullest embodiment of the several possible combinations, may consist of a usual plaster mix, except it contains a substantial proportion of an expanded mineral, herein referred to as an aggregate, and by particular pref45 erence, the use of perlite as such aggregate in a proportion substantially that of the sand or other inert ingredients usually utilized.

As the complete wall has been thus far described, there will exist a space between each of the adjacent vertical ⁵⁰ studding elements. Such air space affords a fair degree of thermal insulation. However,:the load bearing capacity of, the wall may be materially enhanced, and also its insulating characteristics, by the use of a concrete layer CL serving as a filler between the vertical stud elements. ⁵⁵ The filler material may consist of a concrete mix of the same general character as that constituting the matrix 12 of the brick panels or slabs but, for economy, may contain somewhat less of the expanded mineral aggregate such as. perlite.

It was heretofore noted as desirable, to provide for a slight draw or taper, as by upward and outward slope of the side walls of the mold pan MP. This provision results in a slight deviation froih a right angular relation of the marginal edges of each panel, and tbe ^^ace thereof, 65 thus resulting in a mortar joint 23 the sectional form of which will appear from Figs. 7 and 8. These joints, where same occur in positions to. be frontally visible, will at the time of erection of the panels on the job, be filled with a concrete, or. mortar matching in .appearance that ⁷⁰ utilized in the matrix 12 and between the brick units 10, thus rendering virtually invisible any lines of demarcation, between adjacent panels.

In addition to the unusually high insulation properties of the brick panels heretofore described, apd in fact also 75 of the concrete fillers CL and the plaster layer PL, these

2,836,031 several elements are characterized by a high resistance to moisture absorption. In addition, it is important to note that particularly the brick panels, but to a high degree also the concrete CL and the plaster layer PL, are characterized by a degree of flexibility or elasticity 5 greatly in excess of the degree to which these properties exist in concrete mixes conventionally utilized for building purposes. The flexible character of these wall elements conduces to many advantages in that they are thereby rendered much less subject to cracking tendencies due 10 to minor settling effects of the building. This factor is still further enhanced by the low shrinkage of the panels and other elements containing the light weight aggregate. Furthermore, it will appear as highly advantageous that this unusual degree of flexibility enables the adaptation of 15 the brick panels to slight aplanar inequalities of the supporting wall structure. For example, when the panels are applied to an old wall, it is often the case that for many reasons, the sheathing of the various parts of the wall may not lie exactly in a true common plane. The 20 flexibility of the present panels as the outer facing enables nevertheless a close supporting contact at all points between the panels and the support rearwardly thereof.

It should be further noted as of particular advantage, that the fabricated panels or units may be quickly and 25 readily severed along predetermined lines, so as to adapt them to irregular wall areas, or to bring them to smaller dimensions at the end of an applied course of row of the panels. Thus severance of the brick units may be readily effected by usual masonry practice. Heavy duty 30 wire cutters or steel hack saws are employed to sever the wires 11 of the mesh layer, and the matrix 12 is readily saw-cut along the predetermined line of severance, all without highly skilled or specialized labor.

The manner of forming up the individual panels con- 35 sisting of the brick units 10 and the layer 12 extended between the units to constitute the mortar joint portions, will have been apparent from the preceding description. In the erection of a complete wall as described, the usual order of events will consist of the pouring and setting of 40 the concrete foundation CF with the anchor bolts AB suitably spaced, and with the channeled plates secured to the top of the footing as shown. The vertical studding elements, if of metal as shown, will be set in place and if desired, welded or bolted to the channel plate members ⁴⁵and suitably tied at their upper ends to assure parallelism through the period of building the wall. The concrete filler between the studs as indicated at CL, may be applied from either side of the wall, or as usually preferred, may be poured from above after application of the panels to ⁸⁰the studs, and after attachment of the metal lath ML, but before the application of the plaster layer PL. When this order of steps is followed, it will have appeared that the setting of the fillers CL will serve to bond together as virtually a monolithic unit, the inner and outer face por- ⁸⁸tions of the wall so that the outer panel, the inner plastic layer and the filler portion CL will completely embed the studding elements. Such a wall possesses a high loading capacity.

It will of course be understood that any of the struc- ⁶⁰turally useful and feasible subcombinations of the elements PL, CL, and the panels, may be utilized without necessarily embodying all of the major parts of the wall as described in detail.

The phrase “simulated brick” as frequently used here- ⁰⁸in, is selected due to the preference for brick of reduced thickness. The units 10 may however consist of fired clay or of any other desired ceramic material, including either natural or simulated stone units.

Although the invention has been referred to by particularized reference to certain examples, the detail of description should be understood solely in an instructive, rather than in any limiting sense, numerous variants being possible within the fair scope of the claim hereunto appended.