Segmented Shelf Angle for Masonry Veneer on Curved Walls
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Solution Overview
Problem
Existing methods for mounting face brick or stone veneer on walls are challenging, especially on non-planar surfaces with interruptions like corners, doors, and windows, as they require complex steel support systems that are difficult to install and adjust.
Innovation Solution
A segmented shelf angle system with a web and flange design that allows for bending and flexibility, featuring a continuous web and discontinuous flange with notches, apertures, and retainer clips to securely mount masonry veneer on varying wall surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a continuous steel shelf angle is used to support masonry veneer, then structural strength and stability are improved, but adaptability to non-planar wall surfaces and interruptions (corners, doors, windows) deteriorates
Solution Approach 1:
The shelf angle is divided into multiple segments along its length, with each segment capable of independent positioning and attachment. This segmentation allows the shelf angle to conform to non-planar wall surfaces and accommodate interruptions such as corners, doors, and windows while maintaining structural integrity through rigid connections between segments.
2Adaptability or versatility
If a segmented shelf angle with discontinuous flange is used, then adaptability to complex wall surfaces improves, but manufacturing complexity increases
Solution Approach 1:
The flange is segmented into discrete sections that can be independently formed and positioned, allowing the shelf angle to adapt to complex wall geometries while simplifying manufacturing through modular production of individual segments that are later assembled.
Solution Approach 2:
The segments are pre-formed and prepared with attachment features before final assembly, allowing for standardized manufacturing processes and simplifying the overall construction process by separating fabrication from installation.
3Adaptability or versatility
If the flange is made discontinuous with notches, then flexibility for bending the web to conform to curved walls improves, but structural strength may deteriorate
Solution Approach 1:
The flange is divided into segments separated by notches, creating hinge points that allow the web to be bent and shaped to conform to curved or non-planar wall surfaces. The segmented structure maintains sufficient structural strength by distributing loads across multiple segments and connection points.
Solution Approach 2:
The notches in the flange create flexible joints that allow the web to be dynamically shaped and positioned during installation to match the specific geometry of the wall surface, while the rigid segments maintain structural integrity when assembled.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The segmented shelf angle system provides a flexible and secure mounting solution for masonry veneer on complex wall surfaces, allowing for easy installation and adjustment while maintaining structural integrity and aesthetic appeal.
Implementation Method 1
The flange is segmented to permit bending of the web
Data Source
AI summary
An assembly supports external masonry veneer. A bracket mounts to a load bearing wall support structure. A shelf angle has a horizontal leg that defines a shelf for the veneer, and an upstanding leg supported by mounting brackets that secure the assembly to the wall structure. The horizontal shelf is segmented. The back of the shelf angle flexes between the segments to allow the shelf angle to follow the shape of a curve wall. The shelf angle is secured to the mounting brackets with locking clips. The mounting brackets may be channels. They may have lower abutments. The abutments may extend rearwardly. An insulator may be placed between the back and structure. The mounting bracket may have lightening holes. The lightening holes may be in a framework array including alternating diagonal struts. A low thermal conductivity coating may be applied to the bracket.