Field of the Invention

[0001] The present invention relates to cast stone decorative wall systems and to specialized tenon clips for fastening the cast stone elements to a segmental retaining wall or similar structure.

Background

[0002] Thin stone wall cladding products are available in the marketplace. When installed, an attractive natural stone appearance is presented. However, commercialization of this decorative wall facing option is slow in acceptance in part because of an inability to easily and inexpensively attach the facing stone elements to a vertical wall structure.

[0003] Typically in the art, thin stone wall systems are installed by the so-called “lick and stick” method, which involves the use of epoxy adhesive to secure the thin stone or thin brick to plywood or OSB wall cladding, which involves the use of a metal lath with a scratch coat of Portland mortar. Such an adhered thin stone system is inherently less secure since improper application of the adhesive can lead to stones separating from the wall, which is both a nuisance and a safety problem. Such adhered thin stone systems are typically only used in lower floor applications of residential and commercial buildings as there is a bias against their use on multifloor buildings. Further, the adhered thin stone system is not used in conjunction with other wall elements such as drainage board and weather-resistant wrap. Accordingly, thin stone products have in the main been used in commercial building applications.

[0004] Various bracket or clip systems have been developed to affix decorative veneer panels, made to look like stone, to a vertical structural wall. Although useful in particular cases, such systems lack versatility and simplicity, requiring brackets or clips with complicated structures and/or several separate components. Such brackets or clips are difficult to secure to structural walls and require time-consuming alignment of panels.

[0005] There remains a need in the art for a more versatile, secure, and mechanically stronger thin stone wall system that is less costly, easier and faster to install and requires less skilled labor.

Summary of the Invention

[0006] A tenon clip for affixing cast stone elements to a supporting wall surface, according to the present invention, has a U-shaped fastening portion with a first fastening side and opposing sidewalls generally perpendicular to the first fastening side. An anchoring flange extends from each of the sidewalls. A hook extends from one end of the first fastening side for fastening the tenon clip to the supporting wall surface. Each anchoring flange has one or more anchors to secure the tenon clip within the cast stone element.

[0007] In another embodiment, the hook is configured to engage with a corresponding groove in the supporting wall surface.

[0008] In another embodiment, the tenon clip is formed from a single monolithic piece of material and the hook is formed by a first bend and a second bend in the first fastening side. The first and second bends are separated by an intermediate portion and a tab extends beyond the second bend.

[0009] In another embodiment, the first fastening side has one or more slots near either or both ends and the hook is formed of a separate piece of material from the rest of the tenon clip. The hook has an engagement portion positioned against the first fastening side of the tenon clip with one or more engagement tabs configured to engage with the one or more slots to attach the hook to the tenon clip. [0010] In another embodiment, a cast stone decorative wall system, according to the present invention, may be used with segmental retaining walls comprised of a plurality of segments. The cast stone decorative wall system has a cast stone element having a front decorative face, a rear face, a top edge, a bottom edge, and one or more tenon clips embedded in the rear face. The one or more tenon clips each have a U-shaped fastening portion with a first fastening side and opposing sidewalls generally perpendicular to the first fastening side. An anchoring flange extends from each of the sidewalls. A hook extends from one end of the first fastening side for fastening the tenon clip to the segmental retaining wall. Each anchoring flange has one or more anchors to secure the tenon clip within the cast stone element.

Brief Description of the Drawings

[0011] In order that the invention may be more clearly understood, embodiments thereof will now be described in detail by way of example, with reference to the accompanying drawings, in which:

[0012] Figure 1 is a perspective rear view of a cast stone element with embedded tenon clips, according to the present invention.

[0013] Figure 2 is atop view of the cast stone element of Fig. 1.

[0014] Figure 3 is a rear view of the cast stone element of Fig. 1.

[0015] Figure 4 is a rear view of a number of cast stone elements with embedded tenon clips of a cast stone wall system, according to the present invention.

[0016] Figure 5 is a cross-sectional view of the cast stone wall system of Fig. 4, along the lines

A-A in Figure 4. [0017] Figure 6 is a cross-sectional view of the cast stone element of Fig. 1, along the lines C- C in Figure 3.

[0018] Figure 7 is a perspective view of a tenon clip, according to the present invention.

[0019] Figure 8 is a front view of the tenon clip of Fig. 7.

[0020] Figure 9 is a side view of the tenon clip of Fig. 7.

[0021] Figure 10 is a top view of the tenon clip of Fig. 7.

[0022] Figure 11 is a front view of another embodiment of the tenon clip, according to the present invention, showing a hook attached to the tenon clip.

[0023] Figure 12A is a side view of the tenon clip of Fig. 11.

[0024] Figure 12B is a detail view of the area D in Fig. 12A.

[0025] Figure 13 is a top view of the tenon clip of Fig. 11.

[0026] Figure 14 is a rear view of a tenon clip, according to the present invention, with intermediate flanges.

[0027] Figure 15 is a side view of the tenon clip of Fig. 14.

[0028] Figure 16 is a top view of the tenon clip of Fig. 14.

[0029] Figure 17 is a top view of another embodiment of a tenon clip, according to the present invention, showing the attachment portion formed into a hook.

[0030] Figure 18 is a rear view of the tenon clip of Fig. 17.

[0031] Figure 19 is a side view of the tenon clip of Fig. 17. [0032] Figure 20 is a side view of cast stone elements, including the clip of Fig. 17, showing the installation of the tenon clip on a SRW.

[0033] Figure 21 is a side view of a completed SRW, assembled as shown in Fig. 20.

[0034] Figure 22 is a front view of the hook of Fig. 11, shown without the tenon clip.

[0035] Figure 23 is a side view of the hook of Fig. 22.

[0036] Figure 24 is a detail view of the area E in Fig. 23.

[0037] Figure 25 is a top view of the hook of Fig. 22.

Description of the Preferred Embodiments

[0038] The tenon clip and cast stone wall facing system, according to the present invention, provide an aesthetically pleasing stone wall appearance with ease of installation on a segmental retaining wall (SRW). The cast stone elements may be affixed to a supporting wall surface, in particular a SRW, by means of the tenon clip, which provides a convenient means of attachment and spacing between the cast stone elements and the supporting wall to allow for drainage. The tenon clips are inserted into the cast stone, during the casting process while the material is wet, thereby embedding the tenon clip within the cast stone element.

[0039] During production, when shorter clips are used that do not extend across the mould in which the cast stone elements are formed, the clips have a tendency to sink into the uncured casting material. In order to overcome this production challenge, the clips are provided with intermediate flanges, as described herein, to prevent the clip from sinking into the uncured casting material during production of the cast stone element. [0040] As shown in Figures 1-3, a cast stone element 1 has a front decorative face 2, rear face 3, top edge 4, and bottom edge 5. The cast stone element is formed by pouring wet casting material, such as concrete, into a mold. In some embodiments, the front decorative face 2 is made up of a layer of natural stone, which is set in the mold prior to pouring wet casting material into the mold. In one exemplary embodiment, the cast stone element 1 has a height of 215 mm, a length of 620 mm, and a thickness of 40 mm, with two tenon clips 10 positioned along the length of the cast stone element 1 about 123 mm from either end 6. The ends 6 of the cast stone element 1 may be shaped to overlap with adjacent cast stone elements 1. As shown in Fig. 3, each end 6 has a cut-out 7 at the top or bottom edge 4 or 5, shaped complementary to a tab 8 at the other end 6. Alternatively, the ends 6 may be flat or have another convenient shape to facilitate engaging adjacent cast stone elements 1 to cover a supporting wall surface.

[0041] Although illustrated as extending between the top edge 4 and the bottom edge 5 in Figures 1-6, 11-13, and 17-21, the tenon clip 10, as described below and shown in Figures 7-10 and 14-16, may extend only a portion of the height of the cast stone element 1 and be placed at either the top edge 4 or the bottom edge 5, or both, of the cast stone element 1.

[0042] A tenon clip 10 is, preferably, used for attaching the cast stone elements 1 to a segmental retaining wall (SRW) or other similar supporting wall structure. By inserting the tenon clip 10 into the cast stone element 1 during casting, the tenon clip 10 is embedded and securely retained therein. The tenon clip 10 has a generally U-shaped fastening portion 11 with a first fastening side 12 and two opposing sidewalls 13. The sidewalls 13 are connected to the first fastening side 12 at the comers of the U-shape and generally perpendicular to the first fastening side 12. An anchoring flange 14 extends from each of the sidewalls 13 and is at least partially embedded in the rear face 3 of the cast stone element 1, as shown in Fig. 6. Preferably, the anchoring flanges 14 are entirely or substantially embedded within the cast stone element 1, while the fastening portion 11 of the tenon clip 10 extends outwardly from the rear face 3 of the cast stone element 1 to provide spacing between the rear face 3 of the cast stone element 1 and the supporting wall surface. Preferably, the anchoring flanges 14 are embedded in the cast stone element 1 when the concrete or other material of the cast stone element 1 is in a wet state, prior to curing. Alternatively, the anchoring flanges 14 may be inserted into angle grooves or kerfs cut into the rear face 3 of the cast stone element 1.

[0043] The anchoring flanges 14 have one or more anchors to improve the pull-out strength and help secure the tenon clip 10 within the cast stone element 1. As shown in Figs. 6-9, 11, 12, 15, 18, and 19, the anchors may be apertures 16 through the anchoring flanges 14 that permit the material of the cast stone element 1 to flow through the anchoring flanges 14 to secure the tenon clip 10 and prevent it from moving or slipping relative to the cast stone element 1. Additionally, tabs 17 may be provided extending perpendicularly from the anchoring flanges 14, parallel to the top and bottom edges 4 and 5 of the cast stone element 1. Preferably, as shown in Figs. 3 and 6, the tabs 17 are positioned at or just beneath the top or bottom edges 4 or 5 of the cast stone element 1, but other configurations of tabs may be used in addition to or in place of apertures 16 or other types of anchors to secure the anchoring flanges 14 within the cast stone element 1. Preferably, the tenon clip 10 is configured such that it can be made by bending and cutting a single monolithic piece of metal. Alternatively, the hook 35 may be formed separately and attached to the tenon clip 10, as shown in Figures 11-14.

[0044] As shown in Figures 20 and 21, the tenon clip 10 attaches to a continuous groove 28 in the top surface 29 along the front edge 31 of each segment 27 of the segmental retaining wall (SRW) 26. The SRW 26 is made up of a plurality of individual segments 27, each of which have a top surface 29 shaped to engage with the bottom surface 30 of a vertically adjacent segment 27 of the SRW 26. The top and bottom surfaces 29 and 30 of each adjacent segment 27 thereby prevent or resist relative movement between adjacent segments 27, at least in the direction perpendicular to the plane of the SRW 26. Preferably, a ridge 32 runs along the top surface 29 of each segment 27 that is shaped complimentary to a recess 33 running along the bottom surface 30 of each segment 27, as shown in Fig. 20.

[0045] The groove 28 in the top surface 29 of each segment 27 of the SRW 26 is shaped to receive the hook 35 of the tenon clip 10 that is positioned at the top edge 4 of the cast stone element 1. As shown in Figures 17-19, the hook 35 is formed from a first and second bend 36 and 37 in the fastening portion 11 of the tenon clip 10. The first bend 36 is a 90° bend in the fastening portion 11, away from the rear face 3 of the cast stone element 1. The second bend 37 is another 90° bend in the fastening portion 11 in the same direction, such that the end of the tenon clip 10 is now pointing towards the bottom edge 5 of the cast stone element 1. Between the first and second bends 36 and 37 is an intermediate portion 38 of the hook 35, which is sized to extend from the front edge 31 of the segment 27, over the top surface 29 to the groove 28. Between the second bend 37 and the end of the tenon clip 10 is a tab 39, which extends at least partially into the groove 28.

[0046] As shown in Figure 20, a first cast stone element 1 and tenon clip 10 are in position against a segment 27 of the SRW 26, with the intermediate portion 38 of the hook 35 extending over the top surface 29 of the segment 27 and the tab 39 extending into the groove 28, thereby retaining the cast stone element 1 in place on the SRW 26. A row of cast stone elements 1 may be installed in this way and then another row of segments 27 may be placed on top of the completed row. The bottom surface 30 of this next row of segments 27 rests on top of the top surface 29 of the current row, thereby trapping the hook 35 of the completed row of cast stone elements 1 within the groove 28. As shown in Figure 20, a second cast stone element 1 may be attached to the SRW 26 by sliding the tab 39 of the hook 35 into the groove 28 on the top surface 29 of the segment 27 above the first. Each successive row of cast stone elements 1, may be positioned resting directly on top of the row below with substantially no space therebetween.

Preferably, the fastening portion 11 of the tenon clip 10 also extends below the bottom edge 5 of the cast stone element 1. This permits the fastening portion 11 of the tenon clip 10 extending below the bottom edge 5 of the cast stone element 1 to slide into the space between the rear face 3 of the below- adjacent cast stone element 1 and the supporting wall surface (in this case, the front edge 31 of the segment 27). Successive rows of cast stone elements 1 and segments 27 may then be installed in a similar manner until the SRW 26 is completed, as shown in Figure 21.

[0047] As shown in Figures 11-13, the hook 35 may be formed of a separate piece of material from the rest of the tenon clip 10 and attached to the first fastening side 12, extending away from the sidewalls 13 and anchoring flanges 14. Preferably, in this embodiment, the hook 35 has an engagement portion 40 that extends from the intermediate portion 38 at a 90° angle and is positioned against the first fastening side 12 of the tenon clip 10 for attachment thereto. In this embodiment, the first bend 36 is between the engagement portion 40 and the intermediate portion 38, rather than between the first fastening side 12 and the intermediate portion 38. The hook 35 may be attached to the tenon clip 10 in any suitably secure fashion. Preferably, the first fastening side 12 has one or more slots 18 near either or both ends of the tenon clip 10 and the engagement portion 40 has one or more engagement tabs 41 or hooks. As shown in Figures 22-25, the engagement tabs 41 are cut and bent at an angle 0 to the engagement portion 40, so as to slide into the slots 18 to attach the hook 35 to the tenon clip 10 and hold the tenon clip 10 in place. Preferably, the engagement tabs 41 have a triangular shape and the angle 0 is about 150° to facilitate easy attachment of the hook 35 to the first fastening side 12 of the tenon clip 10.

[0048] Although the examples illustrated and described herein depict the cast stone elements 1 installed on a vertical wall surface, the tenon clip 10 may also be used to attach cast stone elements 1 to a horizontal support, such as a series of horizontal, spaced apart rails. In such applications, the hook 35 may be sized and shaped complimentary to the rails, so as to fit over the rail and hold the cast stone elements 1 in place. [0049] Optionally, the tenon clip 10 may be shorter than the height of the cast stone element 1. A tenon clip 10 may be positioned at the top edge 4 and another at the bottom edge 5 of the cast stone element 1. Alternatively, tenon clips 10 may be used along only the top edge 4 of the cast stone element 1. These shorter tenon clips 10, preferably, do not have tabs 17 at both ends and the fastening portion 11 does not extend beyond the anchoring flanges 14 at both ends. In this embodiment, tabs 17 are positioned substantially at the top or bottom edge 4 or 5 of the cast stone element 1, the fastening portion 11 of the tenon clip 10 extends beyond the same top or bottom edge 4 or 5, and the tenon clip 10 extends towards the other top or bottom edge 4 or 5 by a distance less than the height of the cast stone element 1.

[0050] As shown in Figs. 14-16, the tenon clips 10 may have an intermediate flange 25 between the sidewalls 13 and the anchoring flanges 14 to prevent the tenon clips 10 from sinking in to the uncured concrete during production. As shown in Fig. 16, the intermediate flanges 25 extend from each sidewall 13, outwardly from the U-shaped fastening portion 11 and generally perpendicular to the sidewalls 13. In this embodiment, the tabs 17 preferably extend from the intermediate flanges 25, rather than from the anchoring flanges 14. As shown in Figs. 15 and 16, the anchoring flanges 14 extend from each of the intermediate flanges 25. Preferably, the anchoring flanges 14 extend generally perpendicular to the intermediate flanges 25, however, they may extend at other angles. For example, the anchoring flanges 14 may extend at an obtuse angle to the intermediate flanges 25, so as to embed in the rear face 3 of the cast stone element 1 at an angle similar to that illustrated in Figs. 7-10. In this way the anchoring flanges 14 are embedded in the rear face 3 of the cast stone element 1 and the U-shaped fastening portion 11 is prevented from sinking into the uncured concrete by the intermediate flanges 25.

[0051] A starter strip may be used to support the bottom row of cast stone elements 1 from below, from above, or from one side. The starter strip has a support flange and a base flange extending from the support flange, preferably, at a right angle. The support flange has one or more apertures for receiving fasteners to attach the starter strip to the supporting wall surface. The base flange may have one or more drainage apertures for permitting moisture to escape from between the cast stone elements 1 and the supporting wall surface. The starter strip has a length long enough to span two or more cast stone elements 1 and, preferably, between about 3’ to 12’, more preferably, between 4’ and 8’.

[0052] The starter strip may be straight or curved and may have an L-shaped or J-shaped cross section. Where the tenon clip 10 extends beyond both the top and bottom edges 4 and 5 of the cast stone element 1, a J-shaped starter strip may be used to accommodate the tenon clip 10 extending below the bottom edge 5 of the cast stone element 1. Curved starter strips may be used to span archways, windows, and the like.

[0053] Optionally, the tenon clip 10 may be shimmed with reference to the supporting wall surface to leave space between the supporting wall surface and the first fastening side 12 of the tenon clip 10. In this way the spacing between the cast stone element 1 and the supporting wall surface may be selectively adjusted, as required, for example, to accommodate any uneven areas on the supporting wall surface. A shim feature may be provided at the rear of the tenon clip 10, such as a raised flexible indent portion or biasing tab. An installer may incrementally depress the tab to provide the desired spacing.

[0054] The vertices of the tenon clip 10, such as the comers of the U-shaped fastening portion 11, the first and second bends 36 and 37, and the point at which the anchoring flanges 14 extend from the sidewalls 13 or intermediate flanges 25, may be structurally reinforced to prevent relative bending between the parts of the tenon clip 10. Preferably the vertices are structurally reinforced by way of crimps, welds, or channels formed on the vertices of the tenon clip 10.

[0055] A cast stone element 1, according to the present invention, may be prepared by placing a tenon clip 10 in a mold with the anchoring flanges 14 facing downwardly and at least partially immersed in the wet casting material in the mold. The tenon clip 10 is positioned with the U- shaped fastening portion 11 above the casting material and resting on the top edges of the mold. Several tenon clips 10 may be positioned across the top or bottom of the mold, or both, as required. Preferably, two tenon clips 10 are used, located to each side of the mold, as shown in Figs. 1-3. Optionally, the tabs 17 may be used to locate and guide the tenon clip 10 into position in the mold. As the casting material hardens, the tenon clips 10 become securely attached to the cast stone element 1 by means of the anchoring flanges 14 embedded within the rear face 3. A cast stone element 1 is thereby produced, which may be attached to a supporting wall surface by engaging the hook 35 with the groove 28 of the segments 27 of an SRW 26 or by driving a fastener through the fastening aperture 15 of the tenon clip 10.

[0056] A cast stone wall system, according to the present invention, permits the convenient and secure installation of cast stone elements 1, with embedded tenon clips 10, as described herein, on a supporting wall surface to provide a decorative stone finish to the wall, without using adhesives to affix the cast stone elements 1 to the wall. [0057] The present invention has been described and illustrated with reference to an exemplary embodiment, however, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention as set out in the following claims. Therefore, it is intended that the invention not be limited to the particular embodiments disclosed herein.