Precast panel mounting system

Abstract

A rigid elongate mounting bracket has an embedment portion and an extension portion. The extension portion has a fastener opening and abutment means. When cast into a precast panel in an appropriate angular orientation adjacent to an edge of a cladding panel, the extension portion projects rearwardly and laterally away from the rear face of the panel end such that the end of the extension portion is disposed at a distance away from the panel's rear face corresponding to a desired air space, and the abutment means is substantially aligned with the panel's rear face. Each panel preferably has at least two brackets spaced along its upper edge and two more along its lower edge. A first panel may be mounted to a supporting structure using fasteners driven through the fastener openings of the upper brackets. A second panel may then be positioned with its lower brackets extending downward behind the first panel, with the abutment means of the second panel's lower brackets engaging the rear face of the first panel, such that the lower end of the second panel is laterally stabilized by the first panel, with a uniform air space being formed between the supporting structure and the panels' rear faces.

Description

FIELD OF THE INVENTION [0001] The present invention relates to precast cladding panels mounted to supporting structures, and relates in particular to mounting brackets cast into precast panels. BACKGROUND OF THE INVENTION [0002] Precast panels of various sizes and shapes are widely used as cladding on building walls, serving as components of building envelope systems intended to prevent infiltration of rain and outside air into the building. Precast cladding panels are commonly made of concrete, but may also be made with other cast materials known in the construction field. Concrete cladding panels are common on large structures such as office buildings, but they are also used on residential housing structures as an alternative to traditional cladding materials such as wood siding and brick. [0003] Whether installed on large or small buildings, it is desirable for cladding panels to be mounted in such a way that there will be a continuous air space between the rear (i.e., inner) fac...

AI Technical Summary

Benefits of technology

[0016] In a typical application, two or more mounting brackets are cast into a panel adjacent its upper edge, with two or more brackets being cast into the panel adjacent its lower edge. The upper brackets are used to fasten the panel to a supporting structure (such as a sheathed stud wall, for instance, in a residential construction scenario), using screws, spikes, or other suitable fasteners driven through the fastener openings in the upper brackets. The upper brackets thus support the full suspended weight of the panel, while also positioning the rear face of the panel at a desired distance away from the face of the supporting structure (i.e., corresponding to the desired air space). After a first panel has been thus fastened to the support structure, a second similar panel is positioned above the first panel, with the lower brackets of the second panel extending downward behind the first panel. By virtue of their inherent configuration and the orientation at which they are cast into the panel, the lower brackets of the second panel dispose the rear face of the second panel at the desired distance (i.e., air space thickness) away from the face of the supporting structure. At the same time, the abutment means of the lower brackets of the second panel extend below the upper edge of the first panel and engage the rear face of the first panel, thus effectively locking the second panel behind the first panel, and preventing the bottom of the second panel from being displaced outward away from the structure, without any direct connection between the bottom of the second panel and the supporting structure.

[0030] In a third aspect, the invention is a forming system that facilitates accurate placement of mounting brackets in precast panels to ensure the creation of a substantially uniform air space behind the panels after they are mounted on a supporting structure.

Problems solved by technology

Although caulking or other sealant materials are typically used to seal the spaces between cladding panels, the possibility of moisture infiltration behind the cladding—as a result of vapour migration, direct penetration of rainwater (due to sealant deterioration or other factors), or leakage at roof-to-wall junctures—cannot be entirely eliminated.

If such moisture is not removed from the building envelope fairly promptly, it will tend to migrate further into the building, potentially causing a variety of problems that could entail costly maintenance and repairs and could detract from the building's overall durability and value.

Such problems may include drywall damage due to moisture absorption, rot and mold in wooden construction components (e.g., studs and sheathing), corrosion of non-rust-resistant construction hardware, and staining on interior building finishes.

The essential problem facing designers of cladding panel support systems is to provide hangers or brackets that can adequately support weight of the panels at a distance away from the face of the supporting structure (i.e., so as to provide the desired air space), without significantly impeding the passage of water or water vapour through the air space.

It is readily apparent that cladding panels using vertical hangers of this general type cannot be effectively used on unsheathed walls unless the hangers coincide with stud locations, or unless horizontal strapping is installed across the studs at specific vertical intervals (and at additional cost) to receive the hanger fasteners.

However, none of these prior art systems addresses all of the problems and desirable features discussed above.

Moreover, these systems are primarily intended for use in the construction of curtain wall systems or mounting large, heavy concrete cladding panels on large buildings, and are not conveniently adaptable for use with comparatively small and light concrete cladding panels for residential housing structures.

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