CA2241920C - Single wythe wall system - Google Patents
Single wythe wall system Download PDFInfo
- Publication number
- CA2241920C CA2241920C CA 2241920 CA2241920A CA2241920C CA 2241920 C CA2241920 C CA 2241920C CA 2241920 CA2241920 CA 2241920 CA 2241920 A CA2241920 A CA 2241920A CA 2241920 C CA2241920 C CA 2241920C
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- Prior art keywords
- wall
- clip
- insulation
- interior
- masonry
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- 238000009413 insulation Methods 0.000 claims abstract description 65
- 239000004570 mortar (masonry) Substances 0.000 claims abstract description 22
- 239000002184 metal Substances 0.000 claims description 13
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- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 13
- 238000009428 plumbing Methods 0.000 description 12
- 239000000463 material Substances 0.000 description 5
- 238000010079 rubber tapping Methods 0.000 description 5
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Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
- E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
- E04B1/7608—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only comprising a prefabricated insulating layer, disposed between two other layers or panels
- E04B1/7612—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only comprising a prefabricated insulating layer, disposed between two other layers or panels in combination with an air space
- E04B1/7616—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only comprising a prefabricated insulating layer, disposed between two other layers or panels in combination with an air space with insulation-layer locating devices combined with wall ties
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/38—Connections for building structures in general
- E04B1/41—Connecting devices specially adapted for embedding in concrete or masonry
- E04B1/4178—Masonry wall ties
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F13/00—Coverings or linings, e.g. for walls or ceilings
- E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
- E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
- E04F13/0801—Separate fastening elements
- E04F13/0832—Separate fastening elements without load-supporting elongated furring elements between wall and covering elements
Abstract
A single wythe wall system comprising: a masonry wall comprising a plurality of masonry units laid up in a single wythe joined with mortar joints, the wall having an exterior surface and an interior surface; a plurality of interior finish support clips with a longitudinal axis extending perpendicular to the interior surface of the wall and disposed in a spaced apart two dimensional array, each clip having a base secured in a mortar joint of the wall interior surface, a shank extending from the base and an interior finish support head disposed a distance from the base; rigid insulation spaced from the wall and the interior finish sheathing and supported by insulation support abutments disposed on the clip shanks; a wet air cavity being defined between the interior surface of the structural wall and the insulation; and interior finish sheathing mounted to the heads of each clip, a dry air cavity defined between the insulation and the interior finish sheathing.
Description
Title: SINGLE WYTHE WALL SYSTEM
TECHNICAL FIELD
The invention is directed to a single wythe masonry rain screen wall system with interior finish support clips for supporting interior sheathing such as drywall and rigid insulation board a distance from the interior surface of the masonry wall, wherein the wall system has the capacity to contain and redirect any water permeating through the masonry structure within a wet air cavity preferably behind a vapour barrier or water to resistant rigid insulation and drywall sheathing.
BACKGROUND OF THE ART
A rain screen wall system is conventionally used in climates where rain water permeates through a vertical wall. This condition is generally due to excessive precipitation in wet climates and the air pressure differential across an exterior wall surface due to the effect of wind impacting a building structure.
A conventional rain screen wall system is constructed of a veneer exterior masonry wall an adjacent air cavity, insulation, vapour barner, a structural masonry support 2o wall or other type of structural support wall and the interior finish such as dry wall.
This conventional rain screen wall system is known as a "double wythe" wall and simply stated represents two parallel masonry walls jointed across an air filled cavity usually with wire or sheet metal ties, or with masonry units laid across the air cavity at regular intervals.
A double wythe wall is relatively expensive to build since the double wall itself is material and labour intensive, and since electrical services, plumbing services etc.
must be embedded within the masonry structure during masonry construction. Due to the cost and complexity, such a wall system is not feasible for many low cost projects.
3o The double wythe wall requires that two walls be constructed separately with an interior and exterior wall joined with ties or masonry units at intervals across the air cavity.
The air cavity serves to prevent moisture penetrating to the second parallel interior wall. Moisture passes through the exterior first wall and trickles down the air cavity to the base of the air cavity where it is allowed to flow out to the exterior of the building through weep holes. When electrical work and plumbing are installed hidden within the walls, a significant disadvantage of the double wythe wall results from the practical difizculties in coordinatvzg electrical work and plumbing throughout the duration of the to wall construction. The electricians, plumbers and masons must work side by side and together in a coordinated fashion. Often the result is that one trade works on a wall section while the other trade waits or relocates to a different work area. The constant relocation and waiting for work to be completed interferes with the natural flow of construction and significantly reduces efficiency.
1s The need to coordinate the work of different trades in a single area reduces the speed of installation and increases its complexity since neither trade can work independently of the other. Conventional construction methods usually involve the construction of exterior walls to provide a weather proof or protected enclosure within which 2o electricians and plumbers can then work completely independently. However, when a double wythe wall is used and hidden electrical and plumbing services are desired, the coordination of masonry and electrical and plumbing works must proceed simultaneously. The installation of electrical and plumbing services on the interior .
surface of a masonry wall is considered unsightly for most non-industrial buildings, and 25 therefore embedded or hidden services are usually specified by the owner or architect.
The simplest wall system involves a single wythe masonry wall. A single wythe wall is considered to be low cost, however, it is very ineffcient in respect of energy cost. The capital cost of constructing a single wythe masonry wall construction over time is 3o somewhat set off against the higher heating and cooling cost due to the low insulating value of the single wythe; wall. The single wythe wall suffers from a significant disadvantage since moisture from rain and wind. can permeate through the wall resulting in dampness on the interior of the building and efflorescence. The permeation of low volumes of water through the wall is generally not a matter for concern structurally, however, adjacent electrical services or other metal building elements can be short-circuited or corroded over time. The perception of such wall system is that the building is low quality and is usually appropriate for industrial or warehousing use.
In general, when constnrcting a building envelope, a weather tight and insulated the enclosure must be maintained. The building envelope must also be structurally and 1o chemically compatible v~rith adjoining components of the building.
Construction costs and scheduling are highly dependent on the simplicity of construction methods and the' nature of materials used. Briefly stated, the simpler the building systems, the more separate individual trades are, and the more traditional the methods used, the better.
Introducing seams or holes in a wall system significantly increases the labour content 15 and opportunity for errors, moisture penetration or loss of insulating properties. A
highly desirable feature of wall systems is in its adaptability different typical building environments and configurations without specialized components or materials.
In particular, the installation of electrical and plumbing services can present several 2o problems in maintaining the building envelope. For example, cutting into foam insulation to embed electrical wires significantly degrades the building envelope, increases the likelihood of errors, involves extra labour and delay, all of which are highly undesirable.
25 Therefore, it is an object of the present invention to provide a simply constructed rain screen wall system which incorporates a wet air cavity to capture and redirect any moisture permeating through the exterior wall portion in a simple economic and quickly built system.
3o It is a further object of the invention to completely separate the construction of single wythe masonry wall from the installation of electrical or other building services.
It is a further object of t:he invention to provide a rain screen wall system incorporating insulation and interior sheathing in a manner which enables installation of electrical services without requiring significant intrusion into the insulation itself.
Further objects of the invention will be apparent from review of the disclosure and description of the invention below.
DISCLOSURE OF THI: INVENTION
1o The invention provides a rain screen wall system and a sheet metal interior finish support clip for constructing the rain screen building wall system with a single wythe structural masonry wall having an exterior surface and an interior surface and a plurality of hollow masonry units laid in a single wythe with mortar joints.
15 The clips permit construction of a single wythe masonry wall that has the capacity to contain any water permeating through the otherwise traditional masonry wall within a wet air cavity immediately adjacent the interior surface of the single wythe masonry wall and preferably behind a vapour barner or water resistant rigid insulation. The wet air cavity serves to redirect the permeating water outward through conventional weep 2o holes at the base of the masonry wall.
The interior finish support clips extend perpendicular to the interior surface of the structural wall and are disposed in a spaced apart two dimensional array over the interior masonry wall surface, for example: in a two foot by two foot grid pattern.
25 Each clip has a base for securing the clip in the mortar joints of the structural wall interior surface, a shank extending from the base and an interior finish support head disposed a distance from the base for supporting interior finish sheathing mounted to the head.
3o To locate the clip quickly and securely the clip includes block abutments on the clip shank for engaging the interior surface of the structural wall and for longitudinally positioning the clip relative to the interior surface of the structural wall, lateral abutments on the clip base for engaging an interior surface of an adjacent peripheral wall within a hollow chamber of one said masonry block and for positioning the clip laterally relative to the interior surface of the structural wall, and an anchor on the base for resisting tensile pull-out forces on the clip from within the hollow chamber.
Preferably the anchor is a mortar filled pocket on the base of the clip. When the wall is to be insulated, the clip shanks include insulation support abutments for securing rigid insulation between the structural wall and the interior sheathing. To aid in the installation and sealing c>f insulation, and to remove obstacles during installation of to electrical or plumbing services, the clips can be made in two portions with a field connection between the portions. A first portion is embedded in the masonry wall mortar joints and includes insulation support tabs. A second portion is field connected with self tapping screws for example and includes the drywall sheathing support head.
The single wythe masonry wall system according to the invention is much less expensive than a traditional two-wythe rain screen wall. Mason and electrician labour costs as well as construction material costs are reduced through use of clips to support and space apart insulation and drywall. A wet air cavity bounded by the interior surface of the masonry wall and either a vapour burner or water resistant rigid 2o insulation contains watex permeating through the wall and redirects the water through weep holes at the base of the masonry wall.
Due to the uniform spacing of masonry units, the spacing of clips is automatic. For example, if an 8 high inch masonry block is used, the width is a standard 16 inches.
Drywall is provided in 4 foot wide boards of length a multiple of 2 feet, namely 8 foot, 10 foot, 12 foot and 14 iFoot lengths. Rigid insulation is usually provided in two foot wide boards. Therefore if clips are positioned in a 2 foot by 2 foot grid pattern, drywall and insulation can be simply applied without modification of traditional installation techniques. 'The positioning of clips every third course of masonry units 3o automatically positions clips in rows spaced vertically 2 feet apart. As well the 16 inch length of masonry blocks with interior hollow chambers permits simple lateral spacing by engaging the base of the clips inside the hollow cavities. A clip in every third block results in four foot spacing automatically. An additional clip midway between results in two foot spacing automatically. Therefore, the mason need not expend much ei~ort in quickly installing the clips in a 2 foot by 2 foot grid pattern appropriate for traditional insulation and drywall boards.
Preferably a dry air cavity is included bounded by the interior surface of the drywall sheathing and the insulation. The dry air cavity can conveniently house electrical and plumbing services in a manner which permits ease of installation and more efficient 1o separation of the constnzction trades. The dry air cavity also protects the services from corrosion and exposure to moisture. Conventional systems require services to be installed within hollow masonry significantly reducing the speed and efficiency of construction.
~5 Further details of the invention and its advantages will be apparent from the detailed description and drawings included below.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the invention may be readily understood, two preferred embodiments of 2o the invention will be described by way of example, with reference to the accompanying drawings wherein:
Figure 1 is a side perspective view of a typical middle wall clip with a horizontal shank as drawn, and starting at the left, having a base with a vertical tab for 25 embedding in a masonry wall mortar joint, a tab for engaging the interior surface of the masonry wall to locate the clip longitudinally, a pair of opposing insulation board support tabs and a hat section drywall supporting head having an outer flat surface for mounting drywall sheathing and an inner tab for retaining the rigid insulation board;
Figure 2 is a like side perspective view of a typical floor clip for securing the 3o insulation and drywall to a single wythe masonry wall at the base of the wall;
Figure 3 is a variation of the floor clip shown in Figure 2 with a modified outer tab adapted to support a. wooden backing board for receiving nails to attach baseboards or other trim to the drywall;
Figures 4, 5, and 6 show alternative variations to the clips shown respectively in Figs. 1, 2, and 3 where no insulation is to be supported and hence the insulation support tabs have been removed;
Figure 7 is an elevation sectional view through a typical wall and floor with clips embedded in masonry mortar joints with rigid insulation installation complete in the lower section and drywall sheathing and drywall screws with baseboard exploded 1o away to the right;
Figure 8 is a perspective view illustrating the installation of a floor clip below the bottom course of the masonry wall in the bottom mortar joint;
Figure 9 is a like perspective view illustrating the installation of a top wall clip;
and 15 Figure 10 is an elevation view of a progressively installed wall system, at the left progressing to the right, showing clips installed in a masonry block wall, insulation boards and backing boards installed, and then drywall installed covering the insulation.
2o DETAILED DESCRIPTION OF PREFERRED EMBODIIVVIENTS
With reference to Figures 7 and 10 in particular, the present invention provides a rain screen wall system with a single wythe masonry wall. The rain screen wall system provides and maintains a building envelope using conventional constructional 25 techniques and enables the separation of the construction of masonry from the installation of electrical ;>ervices. Insulation and dry wall are also installed in a manner which enables construction scheduling to follow a more flexible and convenient progression.
3o The key component of this system is the provision of an array of interior finish support clips extending perpendicular to the interior surface of the structural wall and disposed in a two-dimensional spaced apart array. The detailed construction and method of installation will be described below.
With reference to Figure 7, the masonry wall ( 1 ) is constructed of a plurality of masonry units laid up in a single wythe joined with mortar joints (2). As drawn, the structural masonry wall ( 1 ) has an exterior surface (3) to the left and an interior surface (4) to the right. As indicated in Figures 7 and 10, a plurality of interior finish support clips (5,6,7) have a base (8) secured to the masonry wall (1) extending perpendicular to the interior surface (4) of the structural wall ( 1 ). Figure 10 shows the l0 clips (5,6,7) disposed in a 2 foot by 2 foot spaced apart two-dimensional array.
Figures 8 and 9 respectively show the installation and detailed construction of the bottom clip (7) and top clip (5). Each clip whatever its construction (5,6,7) has a base (8) secured to the structural wall interior surface, a shank (9) extending from the base (8) and an interior finish support head (10) disposed a distance from the base (8).
As shown in Figures 7 and 8, interior finish sheathing (11) such as drywall, for example, is mounted to the heads (10) of each clip (5,6,7) with drywall screws (12), for example. As a result, an enclosed wet air cavity (13) is defined immediately adj acent the interior surface (4) of the structural wall ( 1 ) and external the finish interior sheathing ( 11 ).
As indicated in the alternative clips (6, 7) shown in Figures 4, 5 and 6, the installation of rigid insulation board ( 14) is optional. In Figure 7, rigid insulation boards ( 14) are disposed between the structural wall ( 1 ) and the interior finish sheathing ( 11 ). The rigid insulation boards ( 14) are supported by insulation support abutments preferably formed as sheet metal tabs (15, best seen in Figs 1-3) extending from the clip shanks (9). When no insulation (14) is used, the wet air cavity (13) is defined between interior surface of the structural wall (4) and the sheathing ( 11 ). When insulation ( 14) is used, a wet air cavity (13) is defined and further a dry air cavity (16) is defined between the insulation (14) and the interior finish sheathing (11). As shown in Figure 7, the electrical service conductors (17) and electrical enclosure housing (18) are conveniently disposed within the dry air cavity (16) such that they remain easily accessible for installation and are not exposed to the moisture contained within the wet air cavity (13). To maintain the insulating value, electrical housings (18) are surrounded by insulation (14).
Conveniently a small patch (19) of insulation is placed behind the cut out insulation board (14) to accommodate the housing (18). A permeable moisture backing (20) alternatively can be positioned behind the insulation patch (19) to allow moisture flow between the patch (19) and masonry wall surface (4).
Also preferably a continuous vapour barrier is provided by flexible membrane (21 ) 1 o and flashing (22) positioned underneath the membrane (21 ) and masonry wall ( 1 ).
Weep holes are provided at the base of the masonry wall as it is conventional to permit moisture to escape to the external wall surface (3). Therefore, the insulation can be completed prior to electrical installation. The vapour barner membrane (21 ) can be then completed and interior sheathing (11) placed on the support heads (10).
Referring to Figure 10, if necessary to support plumbing fixtures or other structures which hang on the interior of the finished wall, a wooden backing board (23) can be secured to the clips (5,6,7) with self tapping screws, for example, within the dry air cavity ( 16) as indicated in dashed outline in Figure 2. It can be seen from Figure 7 2o that the flexible Sheet metal strips which comprise the clips (5,6,7) enable insertion of the rigid insulation board ( 14) by flexibly prying up the clips (5,6,7) when necessary.
Once the insulation board (14) is in place, the clips (5,6,7) are retained by their resilience and are locked in place when the sheathing (11) is secured.
With reference to Figures 7, 8 and 9, preferably masonry units are hollow blocks of substantially uniform horizontal section with vertically extending peripheral walls (24) and hollow chambers (25). The base (8) of each clip (5,6,7) extends into these hollow chambers (25) in the embodiment illustrated in the drawings. Since the clips (5,6,7,) comprise a thin metal strip, the shank (9) of the clips (5,6,7) can be secured within the 3o mortar joint (2) without substantially effecting the bonding action of the mortar joint.
In general, the thickness of the mortar (2) is approximately 3/8tns of an inch and therefore a thin metal strip inserted in the mortar joint (2) is of little consequence. In order to longitudinally position the clip (5,6,7) relative to the interior surface (4) of the structural wall, the shank (9) of the clips each include a block abutment tab (26). In the embodiment , the block abutment tab (26) is a simple transverse sheet metal member which abuts the interior surface (4) of the adjacent masonry unit. By this simple means, the precise alignment of all clips (5,6,7) is ensured.
In order to laterally position the clip relative to the interior surface (4) of the structural wall (1), the base (8) of each clip (5,6,7) includes lateral abutment side edges (27) 1o engaging an interior surivace of an adjacent peripheral wall (24) within the hollow chamber of the masonry blocks as best illustrated in Figure 9. Due to the uniform configuration of each masonry, as shown in Figure 10, the lateral spacing of the clips (5,6,7) is automatically accomplished by positioning a clip (5,6,7) in every third block and mid-way between the blocks in order to provide a two-foot horizontal spacing. It 15 is a simple matter to adapt the width of the clip shank (9) to ensure a two-foot horizontal centre distance or any other desired distance depending on the particular configuration of blocks utilized in a wall.
As best indicated in Figure 7, the base (8) of each clip includes means to anchor it 2o within the hollow chambers (25) of the masonry units to resist tensile pull out forces on the clip (5,6,7). A simple anchoring means is illustrated where the base (8) includes an upstanding vertical tab to form a pocket for filling with mortar (28) as shown in Figure 7. Therefore, tension on the clips (5,6,7) is resisted by the hardened mortar (28) held within the pocket of the base {8) and compression on the clips (5,6,7) is 25 resisted by the block abutment tabs (26) as well as anchoring of the clip shanks (9) within the mortar joints (2).
In order to provide an alternative clip which enables easy insertion and sealing of the rigid insulation board (14), an alternative embodiment includes clips which have a field 3o connection joining a first clip portion which includes the base and shank to a second clip portion including the; interior finish support head ( 10). As indicated in Figures 1 through 6, the first and second clip portions can be joined simply with a field connection formed by an overlapping shank plate (9) and a self tapping screw (29).
Therefore conveniently the base (8) and shank (9) can be inserted in the mortar joint (2) while constructing the masonry wall. Insulation can be installed between the insulation support tab (15) and thereafter the field connection can be completed with installation of the second clip portion and securing with field connection self tapping screw (29).
Depending upon the type of baseboard or floor finishing material that are used, as 1o shown in Figure 7, the base board (30) can merely be attached with adhesives to the interior surface of the drywall sheathing (11). If mechanical fasteners such as nails or screws are required to fasten the baseboard, a floor level backing board (31) as shown in Figures 3 and 6 can be attached with self tapping screws or adhesives to the interior finish support head (10). As well, it will apparent to those skilled in the art that 15 framing around the windows and doors is generally necessary. Conventional wooden or sheet metal studs can be used to supplement the above system to adequately frame doors and windows, inside and outside corners as required in conjunction with the clips (5,6,7).
2o In accordance with the above description, the system for constructing a rain screen wall is less complex than the conventional method of constructing a double wythe masonry wall with air cavity between the two parallel masonry walls. The separation of electrical and plumbing services from the masonry construction is a significant advantage in that more efficient scheduling of construction and organization of 25 different trades results.
To recap, the masonry support wall is built being exterior to the building with hollow core chambers (25) filled with insulation if desired. During construction of the masonry wall, the clips (5,6,7) or merely their first portions including the base and 3o shank are installed extending from the interior face (4) of the masonry wall. Once the m mortar (2) is cured, rigid insulation boards ( 14) can be installed and secured in place abutting the insulation support tabs (15). A wet air cavity (13) is automatically formed to the required width by the positioning of the insulation support tabs (15).
The rigid insulation boards ( 14) require no mechanical fasteners to hold them in place since the tabs ( 15) serve adequately for this function. If required, caulking or other sealant can be applied to provide a water tight seal between joints in the insulation boards (14). A
vapour burner membrane (21) and flashing (22) trap and redirect permeating water within the wet air cavity (13) and the water to flows out weep holes at the base of the masonry wall. Electrical housings (18) and conductors (17) can therefore be placed to within the insulation board (14) and run without obstacle in the dry air gap (16) formed between the insulation board (14) and the drywall sheathing (11). If required, backing support boards (23) can also be provided within the dry air cavity to support sinks, handrails, or other building elements that hang on the finished drywall (11) surface. As shown in Figure 2, the backing board (23) is secured in place with screws (12) to a flange (32) which serves the dual function of clamping the adjacent insulation board (14) in place and providing means to screw the backing board (23) securely in place.
The rain screen wall system results in a reduction in materials and labour required as compared to the building of a conventional doubt wythe wall. Construction duration is 2o reduced and interior dampness and efflorescence eliminated. The wet air cavity traps permeating water whereas the dry air cavity provides a dry, accessible, and convenient area for installation of plumbing, wiring, and backing boards. The advantages and integrity of a traditional cavity wall rain screen system are retained while significant reduction in costs and construction labour results.
Although the above description and accompanying drawings relate to a specific preferred embodiment as presently contemplated by the inventors, it will be understood that the invention in its broad aspect includes mechanical and fixnctional equivalents of the elements described and illustrated.
TECHNICAL FIELD
The invention is directed to a single wythe masonry rain screen wall system with interior finish support clips for supporting interior sheathing such as drywall and rigid insulation board a distance from the interior surface of the masonry wall, wherein the wall system has the capacity to contain and redirect any water permeating through the masonry structure within a wet air cavity preferably behind a vapour barrier or water to resistant rigid insulation and drywall sheathing.
BACKGROUND OF THE ART
A rain screen wall system is conventionally used in climates where rain water permeates through a vertical wall. This condition is generally due to excessive precipitation in wet climates and the air pressure differential across an exterior wall surface due to the effect of wind impacting a building structure.
A conventional rain screen wall system is constructed of a veneer exterior masonry wall an adjacent air cavity, insulation, vapour barner, a structural masonry support 2o wall or other type of structural support wall and the interior finish such as dry wall.
This conventional rain screen wall system is known as a "double wythe" wall and simply stated represents two parallel masonry walls jointed across an air filled cavity usually with wire or sheet metal ties, or with masonry units laid across the air cavity at regular intervals.
A double wythe wall is relatively expensive to build since the double wall itself is material and labour intensive, and since electrical services, plumbing services etc.
must be embedded within the masonry structure during masonry construction. Due to the cost and complexity, such a wall system is not feasible for many low cost projects.
3o The double wythe wall requires that two walls be constructed separately with an interior and exterior wall joined with ties or masonry units at intervals across the air cavity.
The air cavity serves to prevent moisture penetrating to the second parallel interior wall. Moisture passes through the exterior first wall and trickles down the air cavity to the base of the air cavity where it is allowed to flow out to the exterior of the building through weep holes. When electrical work and plumbing are installed hidden within the walls, a significant disadvantage of the double wythe wall results from the practical difizculties in coordinatvzg electrical work and plumbing throughout the duration of the to wall construction. The electricians, plumbers and masons must work side by side and together in a coordinated fashion. Often the result is that one trade works on a wall section while the other trade waits or relocates to a different work area. The constant relocation and waiting for work to be completed interferes with the natural flow of construction and significantly reduces efficiency.
1s The need to coordinate the work of different trades in a single area reduces the speed of installation and increases its complexity since neither trade can work independently of the other. Conventional construction methods usually involve the construction of exterior walls to provide a weather proof or protected enclosure within which 2o electricians and plumbers can then work completely independently. However, when a double wythe wall is used and hidden electrical and plumbing services are desired, the coordination of masonry and electrical and plumbing works must proceed simultaneously. The installation of electrical and plumbing services on the interior .
surface of a masonry wall is considered unsightly for most non-industrial buildings, and 25 therefore embedded or hidden services are usually specified by the owner or architect.
The simplest wall system involves a single wythe masonry wall. A single wythe wall is considered to be low cost, however, it is very ineffcient in respect of energy cost. The capital cost of constructing a single wythe masonry wall construction over time is 3o somewhat set off against the higher heating and cooling cost due to the low insulating value of the single wythe; wall. The single wythe wall suffers from a significant disadvantage since moisture from rain and wind. can permeate through the wall resulting in dampness on the interior of the building and efflorescence. The permeation of low volumes of water through the wall is generally not a matter for concern structurally, however, adjacent electrical services or other metal building elements can be short-circuited or corroded over time. The perception of such wall system is that the building is low quality and is usually appropriate for industrial or warehousing use.
In general, when constnrcting a building envelope, a weather tight and insulated the enclosure must be maintained. The building envelope must also be structurally and 1o chemically compatible v~rith adjoining components of the building.
Construction costs and scheduling are highly dependent on the simplicity of construction methods and the' nature of materials used. Briefly stated, the simpler the building systems, the more separate individual trades are, and the more traditional the methods used, the better.
Introducing seams or holes in a wall system significantly increases the labour content 15 and opportunity for errors, moisture penetration or loss of insulating properties. A
highly desirable feature of wall systems is in its adaptability different typical building environments and configurations without specialized components or materials.
In particular, the installation of electrical and plumbing services can present several 2o problems in maintaining the building envelope. For example, cutting into foam insulation to embed electrical wires significantly degrades the building envelope, increases the likelihood of errors, involves extra labour and delay, all of which are highly undesirable.
25 Therefore, it is an object of the present invention to provide a simply constructed rain screen wall system which incorporates a wet air cavity to capture and redirect any moisture permeating through the exterior wall portion in a simple economic and quickly built system.
3o It is a further object of the invention to completely separate the construction of single wythe masonry wall from the installation of electrical or other building services.
It is a further object of t:he invention to provide a rain screen wall system incorporating insulation and interior sheathing in a manner which enables installation of electrical services without requiring significant intrusion into the insulation itself.
Further objects of the invention will be apparent from review of the disclosure and description of the invention below.
DISCLOSURE OF THI: INVENTION
1o The invention provides a rain screen wall system and a sheet metal interior finish support clip for constructing the rain screen building wall system with a single wythe structural masonry wall having an exterior surface and an interior surface and a plurality of hollow masonry units laid in a single wythe with mortar joints.
15 The clips permit construction of a single wythe masonry wall that has the capacity to contain any water permeating through the otherwise traditional masonry wall within a wet air cavity immediately adjacent the interior surface of the single wythe masonry wall and preferably behind a vapour barner or water resistant rigid insulation. The wet air cavity serves to redirect the permeating water outward through conventional weep 2o holes at the base of the masonry wall.
The interior finish support clips extend perpendicular to the interior surface of the structural wall and are disposed in a spaced apart two dimensional array over the interior masonry wall surface, for example: in a two foot by two foot grid pattern.
25 Each clip has a base for securing the clip in the mortar joints of the structural wall interior surface, a shank extending from the base and an interior finish support head disposed a distance from the base for supporting interior finish sheathing mounted to the head.
3o To locate the clip quickly and securely the clip includes block abutments on the clip shank for engaging the interior surface of the structural wall and for longitudinally positioning the clip relative to the interior surface of the structural wall, lateral abutments on the clip base for engaging an interior surface of an adjacent peripheral wall within a hollow chamber of one said masonry block and for positioning the clip laterally relative to the interior surface of the structural wall, and an anchor on the base for resisting tensile pull-out forces on the clip from within the hollow chamber.
Preferably the anchor is a mortar filled pocket on the base of the clip. When the wall is to be insulated, the clip shanks include insulation support abutments for securing rigid insulation between the structural wall and the interior sheathing. To aid in the installation and sealing c>f insulation, and to remove obstacles during installation of to electrical or plumbing services, the clips can be made in two portions with a field connection between the portions. A first portion is embedded in the masonry wall mortar joints and includes insulation support tabs. A second portion is field connected with self tapping screws for example and includes the drywall sheathing support head.
The single wythe masonry wall system according to the invention is much less expensive than a traditional two-wythe rain screen wall. Mason and electrician labour costs as well as construction material costs are reduced through use of clips to support and space apart insulation and drywall. A wet air cavity bounded by the interior surface of the masonry wall and either a vapour burner or water resistant rigid 2o insulation contains watex permeating through the wall and redirects the water through weep holes at the base of the masonry wall.
Due to the uniform spacing of masonry units, the spacing of clips is automatic. For example, if an 8 high inch masonry block is used, the width is a standard 16 inches.
Drywall is provided in 4 foot wide boards of length a multiple of 2 feet, namely 8 foot, 10 foot, 12 foot and 14 iFoot lengths. Rigid insulation is usually provided in two foot wide boards. Therefore if clips are positioned in a 2 foot by 2 foot grid pattern, drywall and insulation can be simply applied without modification of traditional installation techniques. 'The positioning of clips every third course of masonry units 3o automatically positions clips in rows spaced vertically 2 feet apart. As well the 16 inch length of masonry blocks with interior hollow chambers permits simple lateral spacing by engaging the base of the clips inside the hollow cavities. A clip in every third block results in four foot spacing automatically. An additional clip midway between results in two foot spacing automatically. Therefore, the mason need not expend much ei~ort in quickly installing the clips in a 2 foot by 2 foot grid pattern appropriate for traditional insulation and drywall boards.
Preferably a dry air cavity is included bounded by the interior surface of the drywall sheathing and the insulation. The dry air cavity can conveniently house electrical and plumbing services in a manner which permits ease of installation and more efficient 1o separation of the constnzction trades. The dry air cavity also protects the services from corrosion and exposure to moisture. Conventional systems require services to be installed within hollow masonry significantly reducing the speed and efficiency of construction.
~5 Further details of the invention and its advantages will be apparent from the detailed description and drawings included below.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the invention may be readily understood, two preferred embodiments of 2o the invention will be described by way of example, with reference to the accompanying drawings wherein:
Figure 1 is a side perspective view of a typical middle wall clip with a horizontal shank as drawn, and starting at the left, having a base with a vertical tab for 25 embedding in a masonry wall mortar joint, a tab for engaging the interior surface of the masonry wall to locate the clip longitudinally, a pair of opposing insulation board support tabs and a hat section drywall supporting head having an outer flat surface for mounting drywall sheathing and an inner tab for retaining the rigid insulation board;
Figure 2 is a like side perspective view of a typical floor clip for securing the 3o insulation and drywall to a single wythe masonry wall at the base of the wall;
Figure 3 is a variation of the floor clip shown in Figure 2 with a modified outer tab adapted to support a. wooden backing board for receiving nails to attach baseboards or other trim to the drywall;
Figures 4, 5, and 6 show alternative variations to the clips shown respectively in Figs. 1, 2, and 3 where no insulation is to be supported and hence the insulation support tabs have been removed;
Figure 7 is an elevation sectional view through a typical wall and floor with clips embedded in masonry mortar joints with rigid insulation installation complete in the lower section and drywall sheathing and drywall screws with baseboard exploded 1o away to the right;
Figure 8 is a perspective view illustrating the installation of a floor clip below the bottom course of the masonry wall in the bottom mortar joint;
Figure 9 is a like perspective view illustrating the installation of a top wall clip;
and 15 Figure 10 is an elevation view of a progressively installed wall system, at the left progressing to the right, showing clips installed in a masonry block wall, insulation boards and backing boards installed, and then drywall installed covering the insulation.
2o DETAILED DESCRIPTION OF PREFERRED EMBODIIVVIENTS
With reference to Figures 7 and 10 in particular, the present invention provides a rain screen wall system with a single wythe masonry wall. The rain screen wall system provides and maintains a building envelope using conventional constructional 25 techniques and enables the separation of the construction of masonry from the installation of electrical ;>ervices. Insulation and dry wall are also installed in a manner which enables construction scheduling to follow a more flexible and convenient progression.
3o The key component of this system is the provision of an array of interior finish support clips extending perpendicular to the interior surface of the structural wall and disposed in a two-dimensional spaced apart array. The detailed construction and method of installation will be described below.
With reference to Figure 7, the masonry wall ( 1 ) is constructed of a plurality of masonry units laid up in a single wythe joined with mortar joints (2). As drawn, the structural masonry wall ( 1 ) has an exterior surface (3) to the left and an interior surface (4) to the right. As indicated in Figures 7 and 10, a plurality of interior finish support clips (5,6,7) have a base (8) secured to the masonry wall (1) extending perpendicular to the interior surface (4) of the structural wall ( 1 ). Figure 10 shows the l0 clips (5,6,7) disposed in a 2 foot by 2 foot spaced apart two-dimensional array.
Figures 8 and 9 respectively show the installation and detailed construction of the bottom clip (7) and top clip (5). Each clip whatever its construction (5,6,7) has a base (8) secured to the structural wall interior surface, a shank (9) extending from the base (8) and an interior finish support head (10) disposed a distance from the base (8).
As shown in Figures 7 and 8, interior finish sheathing (11) such as drywall, for example, is mounted to the heads (10) of each clip (5,6,7) with drywall screws (12), for example. As a result, an enclosed wet air cavity (13) is defined immediately adj acent the interior surface (4) of the structural wall ( 1 ) and external the finish interior sheathing ( 11 ).
As indicated in the alternative clips (6, 7) shown in Figures 4, 5 and 6, the installation of rigid insulation board ( 14) is optional. In Figure 7, rigid insulation boards ( 14) are disposed between the structural wall ( 1 ) and the interior finish sheathing ( 11 ). The rigid insulation boards ( 14) are supported by insulation support abutments preferably formed as sheet metal tabs (15, best seen in Figs 1-3) extending from the clip shanks (9). When no insulation (14) is used, the wet air cavity (13) is defined between interior surface of the structural wall (4) and the sheathing ( 11 ). When insulation ( 14) is used, a wet air cavity (13) is defined and further a dry air cavity (16) is defined between the insulation (14) and the interior finish sheathing (11). As shown in Figure 7, the electrical service conductors (17) and electrical enclosure housing (18) are conveniently disposed within the dry air cavity (16) such that they remain easily accessible for installation and are not exposed to the moisture contained within the wet air cavity (13). To maintain the insulating value, electrical housings (18) are surrounded by insulation (14).
Conveniently a small patch (19) of insulation is placed behind the cut out insulation board (14) to accommodate the housing (18). A permeable moisture backing (20) alternatively can be positioned behind the insulation patch (19) to allow moisture flow between the patch (19) and masonry wall surface (4).
Also preferably a continuous vapour barrier is provided by flexible membrane (21 ) 1 o and flashing (22) positioned underneath the membrane (21 ) and masonry wall ( 1 ).
Weep holes are provided at the base of the masonry wall as it is conventional to permit moisture to escape to the external wall surface (3). Therefore, the insulation can be completed prior to electrical installation. The vapour barner membrane (21 ) can be then completed and interior sheathing (11) placed on the support heads (10).
Referring to Figure 10, if necessary to support plumbing fixtures or other structures which hang on the interior of the finished wall, a wooden backing board (23) can be secured to the clips (5,6,7) with self tapping screws, for example, within the dry air cavity ( 16) as indicated in dashed outline in Figure 2. It can be seen from Figure 7 2o that the flexible Sheet metal strips which comprise the clips (5,6,7) enable insertion of the rigid insulation board ( 14) by flexibly prying up the clips (5,6,7) when necessary.
Once the insulation board (14) is in place, the clips (5,6,7) are retained by their resilience and are locked in place when the sheathing (11) is secured.
With reference to Figures 7, 8 and 9, preferably masonry units are hollow blocks of substantially uniform horizontal section with vertically extending peripheral walls (24) and hollow chambers (25). The base (8) of each clip (5,6,7) extends into these hollow chambers (25) in the embodiment illustrated in the drawings. Since the clips (5,6,7,) comprise a thin metal strip, the shank (9) of the clips (5,6,7) can be secured within the 3o mortar joint (2) without substantially effecting the bonding action of the mortar joint.
In general, the thickness of the mortar (2) is approximately 3/8tns of an inch and therefore a thin metal strip inserted in the mortar joint (2) is of little consequence. In order to longitudinally position the clip (5,6,7) relative to the interior surface (4) of the structural wall, the shank (9) of the clips each include a block abutment tab (26). In the embodiment , the block abutment tab (26) is a simple transverse sheet metal member which abuts the interior surface (4) of the adjacent masonry unit. By this simple means, the precise alignment of all clips (5,6,7) is ensured.
In order to laterally position the clip relative to the interior surface (4) of the structural wall (1), the base (8) of each clip (5,6,7) includes lateral abutment side edges (27) 1o engaging an interior surivace of an adjacent peripheral wall (24) within the hollow chamber of the masonry blocks as best illustrated in Figure 9. Due to the uniform configuration of each masonry, as shown in Figure 10, the lateral spacing of the clips (5,6,7) is automatically accomplished by positioning a clip (5,6,7) in every third block and mid-way between the blocks in order to provide a two-foot horizontal spacing. It 15 is a simple matter to adapt the width of the clip shank (9) to ensure a two-foot horizontal centre distance or any other desired distance depending on the particular configuration of blocks utilized in a wall.
As best indicated in Figure 7, the base (8) of each clip includes means to anchor it 2o within the hollow chambers (25) of the masonry units to resist tensile pull out forces on the clip (5,6,7). A simple anchoring means is illustrated where the base (8) includes an upstanding vertical tab to form a pocket for filling with mortar (28) as shown in Figure 7. Therefore, tension on the clips (5,6,7) is resisted by the hardened mortar (28) held within the pocket of the base {8) and compression on the clips (5,6,7) is 25 resisted by the block abutment tabs (26) as well as anchoring of the clip shanks (9) within the mortar joints (2).
In order to provide an alternative clip which enables easy insertion and sealing of the rigid insulation board (14), an alternative embodiment includes clips which have a field 3o connection joining a first clip portion which includes the base and shank to a second clip portion including the; interior finish support head ( 10). As indicated in Figures 1 through 6, the first and second clip portions can be joined simply with a field connection formed by an overlapping shank plate (9) and a self tapping screw (29).
Therefore conveniently the base (8) and shank (9) can be inserted in the mortar joint (2) while constructing the masonry wall. Insulation can be installed between the insulation support tab (15) and thereafter the field connection can be completed with installation of the second clip portion and securing with field connection self tapping screw (29).
Depending upon the type of baseboard or floor finishing material that are used, as 1o shown in Figure 7, the base board (30) can merely be attached with adhesives to the interior surface of the drywall sheathing (11). If mechanical fasteners such as nails or screws are required to fasten the baseboard, a floor level backing board (31) as shown in Figures 3 and 6 can be attached with self tapping screws or adhesives to the interior finish support head (10). As well, it will apparent to those skilled in the art that 15 framing around the windows and doors is generally necessary. Conventional wooden or sheet metal studs can be used to supplement the above system to adequately frame doors and windows, inside and outside corners as required in conjunction with the clips (5,6,7).
2o In accordance with the above description, the system for constructing a rain screen wall is less complex than the conventional method of constructing a double wythe masonry wall with air cavity between the two parallel masonry walls. The separation of electrical and plumbing services from the masonry construction is a significant advantage in that more efficient scheduling of construction and organization of 25 different trades results.
To recap, the masonry support wall is built being exterior to the building with hollow core chambers (25) filled with insulation if desired. During construction of the masonry wall, the clips (5,6,7) or merely their first portions including the base and 3o shank are installed extending from the interior face (4) of the masonry wall. Once the m mortar (2) is cured, rigid insulation boards ( 14) can be installed and secured in place abutting the insulation support tabs (15). A wet air cavity (13) is automatically formed to the required width by the positioning of the insulation support tabs (15).
The rigid insulation boards ( 14) require no mechanical fasteners to hold them in place since the tabs ( 15) serve adequately for this function. If required, caulking or other sealant can be applied to provide a water tight seal between joints in the insulation boards (14). A
vapour burner membrane (21) and flashing (22) trap and redirect permeating water within the wet air cavity (13) and the water to flows out weep holes at the base of the masonry wall. Electrical housings (18) and conductors (17) can therefore be placed to within the insulation board (14) and run without obstacle in the dry air gap (16) formed between the insulation board (14) and the drywall sheathing (11). If required, backing support boards (23) can also be provided within the dry air cavity to support sinks, handrails, or other building elements that hang on the finished drywall (11) surface. As shown in Figure 2, the backing board (23) is secured in place with screws (12) to a flange (32) which serves the dual function of clamping the adjacent insulation board (14) in place and providing means to screw the backing board (23) securely in place.
The rain screen wall system results in a reduction in materials and labour required as compared to the building of a conventional doubt wythe wall. Construction duration is 2o reduced and interior dampness and efflorescence eliminated. The wet air cavity traps permeating water whereas the dry air cavity provides a dry, accessible, and convenient area for installation of plumbing, wiring, and backing boards. The advantages and integrity of a traditional cavity wall rain screen system are retained while significant reduction in costs and construction labour results.
Although the above description and accompanying drawings relate to a specific preferred embodiment as presently contemplated by the inventors, it will be understood that the invention in its broad aspect includes mechanical and fixnctional equivalents of the elements described and illustrated.
Claims (9)
1. A single wythe wall system comprising:
a masonry wall comprising a plurality of masonry units laid up in a single wythe joined with mortar joints, the wall having an exterior surface and an interior surface, wherein the masonry units are hollow blocks of substantially uniform horizontal cross-section with a vertically extending peripheral walls defining at least one hollow chamber therein;
a plurality of interior finish support clips with a longitudinal axis extending perpendicular to the interior surface of the wall and disposed in a spaced apart two dimensional array, each clip having a base secured in a mortar joint of the wall interior surface, a shank extending from the base and an interior finish support head disposed a distance from the base, the base of the clip extending into the hollow chambers of the masonry blocks, the shanks of each clip including block abutment means for engaging the interior surface of said hollow chamber thereby spacing the clips apart a predetermined distance along the structural wall, and the base of each clip including a mortar filled pocket for resisting tensile pull-out forces on the clip;
rigid insulation spaced from the wall and the interior finish sheathing and supported by insulation support abutments disposed on the clip shanks;
a wet air cavity being defined between the interior surface of the structural wall and the insulation; and interior finish sheathing mounted to the heads of each clip, a dry air cavity defined between the insulation and the interior finish sheathing.
a masonry wall comprising a plurality of masonry units laid up in a single wythe joined with mortar joints, the wall having an exterior surface and an interior surface, wherein the masonry units are hollow blocks of substantially uniform horizontal cross-section with a vertically extending peripheral walls defining at least one hollow chamber therein;
a plurality of interior finish support clips with a longitudinal axis extending perpendicular to the interior surface of the wall and disposed in a spaced apart two dimensional array, each clip having a base secured in a mortar joint of the wall interior surface, a shank extending from the base and an interior finish support head disposed a distance from the base, the base of the clip extending into the hollow chambers of the masonry blocks, the shanks of each clip including block abutment means for engaging the interior surface of said hollow chamber thereby spacing the clips apart a predetermined distance along the structural wall, and the base of each clip including a mortar filled pocket for resisting tensile pull-out forces on the clip;
rigid insulation spaced from the wall and the interior finish sheathing and supported by insulation support abutments disposed on the clip shanks;
a wet air cavity being defined between the interior surface of the structural wall and the insulation; and interior finish sheathing mounted to the heads of each clip, a dry air cavity defined between the insulation and the interior finish sheathing.
2. A single wythe wall system according to claim 1, including a vapour barrier between the insulation and the interior finish sheathing.
3. A single wythe wall system according to claim 1, including electrical service conductors and electrical enclosure housings disposed within the dry air cavity.
4. A single wythe wall system according to claim 1, including a backing board disposed within the dry air cavity.
5. A single wythe wall system according to claim 1, wherein the clips comprise a sheet metal strip.
6. A single wythe wall system according to claim 1, wherein the clips comprise a sheet metal strip, and wherein the insulation support abutments comprise a transverse sheet metal tab.
7. A rain screen wall system according to claim 1, wherein the block abutment means comprise a transverse sheet metal tab.
8. A single wythe wall system according to claim 1, wherein the clips comprise field connection means for joining a first clip portion including the base and shank to a second clip portion including the interior finish support head after the first clip portion has been separately secured to the structural wall.
9. A single wythe wall system according to claim 8, wherein the first clip portion includes insulation support abutment means for supporting rigid insulation disposed between the structural wall and the interior finish sheathing and for installing the rigid insulation before engaging the field connection of the second clip portion.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2241920 CA2241920C (en) | 1998-06-29 | 1998-06-29 | Single wythe wall system |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2241920 CA2241920C (en) | 1998-06-29 | 1998-06-29 | Single wythe wall system |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2241920A1 CA2241920A1 (en) | 1999-12-29 |
| CA2241920C true CA2241920C (en) | 2004-12-07 |
Family
ID=29409552
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2241920 Expired - Fee Related CA2241920C (en) | 1998-06-29 | 1998-06-29 | Single wythe wall system |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2241920C (en) |
-
1998
- 1998-06-29 CA CA 2241920 patent/CA2241920C/en not_active Expired - Fee Related
Also Published As
| Publication number | Publication date |
|---|---|
| CA2241920A1 (en) | 1999-12-29 |
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