Veneer tie and wall anchoring systems with in-cavity ceramic and ceramic-based thermal breaks
Thermally-isolating veneer ties and anchoring systems employing the same are disclosed. A ceramic based thermally-isolating coating is applied to the veneer tie, which is interconnected with a sheetmetal surface-mounted wall anchor. The thermally-isolating ceramic coating is selected from a distinct grouping of materials, that are applied using a specific variety of methods, in one or more layers and cured and cross-linked to provide high-strength adhesion. The ceramic coating maintains a thermal expansion similar to that of the underlying wire formative to prevent cracking. The thermally-coated veneer ties provide an in-cavity thermal break that severs the thermal threads running throughout the cavity wall structure, reducing the U- and K-values of the anchoring system by thermally-isolating the metal components.
1. A high-strength veneer tie for use with an anchoring system in a wall having an inner wythe and an outer wythe, the outer wythe formed from a plurality of successive courses with a bed joint, having a predetermined height, between each two adjacent courses, the inner wythe and the outer wythe in a spaced apart relationship the one with the other forming a cavity therebetween, the veneer tie comprising:
a wire formative insertion portion for disposition in the bed joint of the outer wythe;
two wire formative cavity portions contiguous with the insertion portion;
a wire formative attachment portion contiguous with each of the two cavity portions and opposite the insertion portion, the attachment portion being adapted for interengagement with a receptor of a wall anchor; and,
a thermally-isolating ceramic coating disposed only on the attachment portion, the coating having low thermal conductivity and transmissivity, the coating being adapted to form a thermal break in the cavity;
wherein upon installation within the anchoring system in the cavity wall, the veneer tie restricts thermal transfer between the veneer tie and the wall anchor and between the wall anchor and the veneer tie.
2. The veneer tie according to claim 1 , wherein the thermally-isolating coating has a thermal expansion substantially similar to the thermal expansion of the wire formative attachment portion.
3. The veneer tie according to claim 2 , wherein the coating includes a topcoat comprised of ceramic beads suspended in a base with binders.
4. The veneer tie according to claim 3 , wherein the ceramic beads are selected from a group consisting of silica, zirconia, magnesium zirconate, yttria-stabilized zirconia, and derivatives and admixtures thereof.
5. The veneer tie according to claim 2 , wherein the coating is applied in layers including a prime coat; and wherein, upon curing, the outer layers of the coating are cross-linked to the prime coat to provide high-strength adhesion to the attachment portion.
6. The veneer tie according to claim 4 , wherein the coating reduces the K-value of the veneer tie to a level not to exceed 1.0 W/m K.
7. A surface-mounted anchoring system for use in the construction of a wall having an inner wythe and an outer wythe, the outer wythe formed from a plurality of successive courses with a bed joint, having a predetermined height, between each two adjacent courses, the inner wythe and the outer wythe in a spaced apart relationship the one with the other forming a cavity therebetween, the anchoring system comprising:
a wall anchor adapted to be fixedly attached to the inner wythe constructed from a plate-like body having two major faces being the mounting surface and the outer surface, the wall anchor, in turn, comprising;
a pair of legs for insertion in the inner wythe, the pair of legs extending from the mounting surface of the plate-like body with the longitudinal axes of the pair of legs being substantially normal to the two major faces; and,
an apertured receptor portion adjacent the outer surface of the plate-like body;
a wire formative veneer tie having an attachment portion for interengagement with the apertured receptor portion;
a thermally-isolating ceramic coating with low thermal conductivity and transmissivity disposed only on the attachment portion, the coating having a thermal expansion substantially similar to the thermal expansion of the veneer tie; and,
a pair of fasteners for disposition adjacent the anchor pair of legs affixing the wall anchor to the inner wythe.
8. The anchoring system according to claim 7 , wherein the ceramic coating includes a topcoat comprised of ceramic beads suspended in a base with binders.
9. The anchoring system according to claim 8 , wherein the ceramic beads are selected from a group consisting of silica, zirconia, magnesium zirconate, yttria-stabilized zirconia, and derivatives and admixtures thereof.
10. The anchoring system according to claim 7 , wherein the ceramic coating reduces the K-value of the veneer tie to a level not to exceed 1.0 W/m K.
11. The anchoring system according to claim 7 , wherein the veneer tie further comprises:
two cavity portions contiguous with the attachment portion; and,
an insertion portion for disposition in the bed joint of the outer wythe, the insertion portion contiguous with the two cavity portions and opposite the attachment portion.
12. The veneer tie according to claim 10 , wherein the coating comprises a matte finish and the veneer tie insertion portion is selectively and compressibly reduced in height to a combined height substantially less than the predetermined height of the bed joint enabling the veneer tie to securely hold to the bed joint and increase the strength and pullout resistance thereof.
13. The anchoring system according to claim 12 , wherein the veneer tie insertion portion further comprises:
a swaged indentation dimensioned for a snap-fit relationship with a reinforcement wire; and
a reinforcement wire disposed in the swaged indentation;
whereby upon insertion of the reinforcement wire in the swaged indentation a seismic construct is formed.
14. A surface-mounted anchoring system for use in the construction of a wall having an inner wythe and an outer wythe, the outer wythe formed from a plurality of successive courses with a bed joint, having a predetermined height, between each two adjacent courses, the inner wythe and the outer wythe in a spaced apart relationship the one with the other forming a cavity therebetween, the inner wythe having wallboard mounted on columns and an exterior layer of insulation, the anchoring system comprising:
a wall anchor adapted to be fixedly attached to the inner wythe constructed from a metal plate-like body having two major faces being a mounting surface and an outer surface, the wall anchor, in turn, comprising;
a pair of legs each extending from the mounting surface of the plate-like body with the longitudinal axis of each of the legs being substantially normal to the mounting surface, the legs configured for insertion into the inner wythe; and,
an apertured receptor portion adjacent the outer surface of the plate-like body, the apertured receptor portion configured to limit displacement of the outer wythe toward and away from the inner wythe;
a wire formative veneer tie interlockingly connected with the apertured receptor portion and configured for embedment in the bed joint of the outer wythe to prevent disengagement from the anchoring system, the veneer tie further comprising:
an insertion portion for disposition in the bed joint of the outer wythe;
two cavity portions contiguous with the insertion portion;
an attachment portion contiguous with the cavity portions and opposite the insertion portion;
a thermally-isolating ceramic coating disposed only on the insertion portion, the cavity portions, and the attachment portion, the coating having low thermal conductivity transmissivity and a thermal expansion substantially similar to the thermal expansion of the veneer tie; and,
a pair of fasteners for disposition adjacent the wall anchor pair of legs affixing the wall anchor to the inner wythe.
15. The anchoring system according to claim 14 , wherein the coating includes a topcoat comprised of ceramic beads suspended in a base with binders.
16. The anchoring system according to claim 15 , wherein the ceramic beads are selected from a group consisting of silica, zirconia, magnesium zirconate, yttria-stabilized zirconia, and derivatives and admixtures thereof.
17. The anchoring system according to claim 16 , wherein the coating reduces the K-value of the veneer tie to a level not to exceed 1.0 W/m K.
18. The anchoring system according to claim 17 , wherein the coating is applied in layers including a prime coat; and wherein, upon curing, the outer layers of the coating are cross-linked to the prime coat to provide high-strength adhesion to the veneer tie attachment portion.
19. The anchoring system according to claim 14 , wherein the coating comprises a matte finish and the veneer tie insertion portion is selectively and compressibly reduced in height to a combined height substantially less than the predetermined height of the bed joint enabling the veneer tie to securely hold to the bed joint and increase the strength and pullout resistance thereof.