WO2010012064A1

WO2010012064A1 - Apparatus and method for installing cladding to structures

Info

Publication number: WO2010012064A1
Application number: PCT/CA2008/001393
Authority: WO
Inventors: Dmytro Romanovich Lysyuk
Original assignee: Dmytro Romanovich Lysyuk
Priority date: 2008-07-29
Filing date: 2008-07-29
Publication date: 2010-02-04

Abstract

Apparatuses and methods for installing cladding to a structure, such as a building, are disclosed. A foundation apparatus is securable to a surface of the structure. The foundation apparatus presents a support surface facing generally away from the structure. A base profile is securable to at least one of the foundation apparatuses. The base profile presents an outer flange surface also facing generally away from the structure. The outer flange surface provides a surface for securing selected cladding to clad a desired area of the structure.

Description

TITLE: APPARATUS AND METHOD FOR INSTALLING CLADDING TO

STRUCTURES

FIELD

[0001] Applicant's teachings relate to apparatuses and methods for installing cladding to structures, such as, for example, a building.

INTRODUCTION [0002] Known methods exist for creating aluminum, stone, tile or other panel facades for buildings. The known methods typically employ techniques in which the existing wall of the building is decorated, i.e. finished, with insulation and covered by different exterior finishes like aluminum, ceramic, granite, brick or glass etc. However, in some cases, known methods for creating a panel facade involve relatively complicated support structures. In some cases, known methods for creating a panel facade are relatively time consuming. In some cases, known methods for creating a panel facade rely on relatively expensive materials. In some of these known methods, the building substructure, such as joists, railings, anchors, insulation and other wall components, such as insulation and external panels, are installed from the outside of the building. In some cases, known methods require the use of tools and/or equipment such as swing stages, scaffolding, safety lines and belts, hoists or jeylifts.

SUMMARY [0003] In some examples, a cladding support system comprises: at least one foundation apparatus for attachment to a floor slab, the foundation apparatus including a body including a supporting surface, a bottom surface for engaging the floor slab, a top surface, and a first channel extending between the top and bottom surfaces for receiving a connection member fixed to the floor slab; and at least one base profile, the base profile including an inner flange surface adapted to be secured to the supporting surface of the foundation apparatus, and an outer flange surface spaced apart from the inner flange surface, the inner and outer flange surfaces being generally opposing and parallel, the outer flange surface for supporting selected cladding to be secured thereto.

[0004] The supporting surface can be generally orthogonal relative to the bottom surface, and the top surface can be sloped relative to the bottom surface. The top and bottom surfaces of the body can be connected to the supporting surface and generally converge in a direction away from the supporting surface.

[0005] The top surface can include a plurality of first ridges surrounding the first channel, and the system can further comprise, in combination, a nut and a washer member for securing the body to the connection member, the washer member including a bottom surface having a plurality of second ridges complementary to the first ridges of the top surface of the body, the first and second ridges engageable to fix the nut in position relative to the body. The bottom surface of the washer member can be sloped corresponding to the top surface of the body.

[0006] The body can include at least one reinforcing web support provided between the bottom and top surfaces. The channel can be elongate enabling adjustable positioning of the foundation apparatus relative to the floor slab.

[0007] The supporting surface can comprise a second channel for securing the base profile to the supporting surface with a fastening mechanism. The second channel can be elongate enabling adjustable positioning of the foundation apparatus relative to the base profile. [0008] The base profile can comprise a web. The web can connect the inner and outer flange surfaces, and can be generally orthogonal to the inner and outer flange surfaces. [0009] The inner flange surface can comprise first and second inner flange surfaces. The first and second inner flange surfaces can be separated by a slot.

[0010] The system can further comprise a rod sized to be received in the slot, the rod for longitudinally aligning adjacent base profiles. The slot and the rod can have complementary dovetail cross-sections for retaining the rod with the slot. The rod can comprise threads adapted to receive a fastening mechanism provided through the second channel of the foundation apparatus for securing the base profile to the foundation apparatus. The slot of the base profile can comprise a recess for receiving an end of the fastening mechanism provided through the second channel of the foundation apparatus. The system can further comprise a spacer for spacing apart adjacent base profiles aligned by the rod.

[0011] The outer flange surface can comprise first and second outer flange surfaces. The first and second outer flange surfaces can be separated by a gap. The gap can be defined by first and second sidewalls. The first and second sidewalls can space apart the first and second outer flange surfaces from the web. The web can comprise a plurality of apertures.

[0012] In some examples, a foundation apparatus, for use with a base profile to secure the base profile to a floor slab, comprises a body, the body including a supporting surface for supporting a base profile secured thereto, a bottom surface for engaging the floor slab, a top surface, and a first channel extending between the top and bottom surfaces for receiving a connection member fixed to the floor slab. [0013] The supporting surface can be generally orthogonal to the bottom surface, and the top surface can be sloped relative to the bottom surface. The top and bottom surfaces of the body can generally converge in a direction away from the supporting surface. - A -

[0014] The top surface can include a plurality of first ridges surrounding the first channel, and further comprising, in combination, a nut and a washer member for securing the body to the connection member, the washer member including a bottom surface having a plurality of second ridges complementary to the first ridges of the top surface of the body, the first and second ridges engageable to fix the nut in position relative to the body. The bottom surface of the washer member can be sloped corresponding to the top surface of the body.

[0015] The body can include at least one reinforcing web support provided between the bottom and top surfaces. The channel can be elongate enabling adjustable positioning of the foundation apparatus relative to the floor slab.

[0016] The supporting surface can comprise a second channel for securing the base profile to the supporting surface with a fastening mechanism. The second channel can be elongate enabling adjustable positioning of the foundation apparatus relative to the base profile.

[0017] In some examples, the apparatus can be combined with a base profile, the base profile comprising: an inner flange surface adapted to be secured to the supporting surface of the foundation apparatus; and an outer flange surface spaced apart from the inner flange surface, the inner and outer flange surfaces being generally opposing and parallel, the outer flange surface for supporting selected cladding to be secured thereto.

[0018] The base profile can comprise a web. The web can connect the inner and outer flange surfaces, and can be generally orthogonal to the inner and outer flange surfaces.

[0019] The inner flange surface can comprise first and second inner flange surfaces. The first and second inner flange surfaces can be separated by a slot. [0020] The combination can further comprise a rod sized to be received in the slot, the rod for longitudinally aligning adjacent base profiles. The slot and the rod can have complementary dovetail cross-sections for retaining the rod within the slot. The rod can comprise threads adapted to receive a fastening mechanism extending through the second channel of the foundation apparatus to secure the base profile to the foundation apparatus. The slot can comprise a recess for receiving an end of the fastening mechanism extending through the rod. A spacer can be provided for spacing apart adjacent base profiles aligned by the rod. [0021] The outer flange surface can comprise first and second outer flange surfaces. The first and second outer flange surfaces can be separated by a gap. The gap can be defined by first and second sidewalls. The first and second sidewalls can space apart the first and second outer flange surfaces from the web. The web can comprise a plurality of apertures. [0022] In some examples, a structure comprises: a plurality of vertically spaced floor slabs; a plurality of foundation apparatuses, each of the foundation apparatuses including a body including a supporting surface, a bottom surface engaging one of the floor slabs, a top surface, and a first channel extending between the top and bottom surfaces receiving a connection member fixed to the one of the floor slabs; a plurality of base profiles, each of the base profiles including an inner flange surface secured to the supporting surface of at least one of the foundation apparatuses, and an outer flange surface spaced apart from the inner flange surface, the inner and outer flange surfaces being generally opposing and parallel; and at least one panel of selected cladding secured to the outer flanges of the base profiles.

[0023] Each of the base profiles can be secured to the supporting surfaces of two of the foundation apparatuses. The two of the foundation apparatuses can be secured to consecutive floor slabs. The two of the foundation apparatuses can be generally vertically aligned. [0024] The panel of selected cladding can be secured to the outer flanges of two of the base profiles. Each of the two of the base profiles can be generally vertical, and the two of the base profiles can be spaced apart horizontally. The two of the base profiles can be generally parallel. [0025] In some examples, a method of installing cladding to a structure, the structure including at least two vertically spaced floor slabs, comprises: providing a plurality of foundation apparatuses, each of the foundation apparatuses including a support surface; installing at least two foundation apparatuses to each of the floor slabs, each of the foundation apparatuses presenting the support surface facing externally in relation to the structure; providing a plurality of base profiles, each of the base profiles including inner and outer flange surfaces; securing the inner flange surface of each of the base profiles to at least two of the foundation apparatuses, each of the base profiles presenting the outer flange surface facing externally in relation to the structure; and securing at least one panel of selected cladding to the outer flange surfaces of the base profiles.

[0026] The foundation apparatuses can each be secured to top surfaces of each of the floor slabs. The base profiles can be secured to foundation apparatuses installed on consecutive floor slabs so that the base profiles extend between the consecutive floor slabs. The base profiles can extend vertically to span at least two of the vertically spaced floor slabs. The foundation apparatuses can be installed spaced apart along each of the floor slabs so as to match a width of the panels of selected cladding.

[0027] The method can further comprise installing a plurality of connection members to the floor slabs prior to the step of installing the foundation apparatuses, wherein each of the foundation apparatuses is installed on the floor slabs by securing each of the foundation apparatuses to one of the connection members. [0028] The method can further comprise providing a plurality of rods for longitudinally aligning adjacent base profiles, and inserting one of the rods in a slot provided at an end of each of the base profiles, the slot adapted to receive and retain the rod. The base profile can be secured to the foundation apparatus by receiving a fastening mechanism in threads provided by the rod, the fastening mechanism coupled to the support surface of the foundation apparatus. A free end of the rod can be inserted in a slot provided at another end of a longitudinally adjacent base profiles. A plurality of spacers can be provided coupled to the rods between adjacent base profiles, the spacers providing a thermal break between the adjacent base profiles.

[0029] The method can further comprise installing insulation material in a space between the inner flange surfaces of the base profiles and interior surfaces of the panels of selected cladding. The method can further comprise installing a board member on the inner flange surfaces of the base profiles. The method can further comprise installing generally horizontal flanges on the board member, wherein the board member and the horizontal flanges are adapted to receive mortar and a layer of masonry.

BRIEF DESCRIPTION OF THE DRAWINGS

[0030] The skilled person in the art will understand that the drawings, described below, are for illustration purposes only. The drawings are not intended to limit the scope of the applicant's teachings in any way.

[0031] FIGS. 1A and 1 B show front and rear perspective views of a foundation member, respectively;

[0032] FIGS. 2A and 2B show front and rear perspective views of a base profile, respectively;

[0033] FIGS. 3A and 3B show front and rear perspective views of a base profile including a rod member, respectively;

[0034] FIG. 4 shows a front perspective view of a foundation member secured to a base profile; [0035] FIG. 5 shows a front perspective view of a foundation member secured to two base profiles;

[0036] FIG. 6 shows a front perspective view of two foundation members, each foundation member secured to a floor slab and to two base profiles;

[0037] FIGS. 7A to 7E show rear perspective, rear elevation, end and two close-up end views of a panel of selected cladding, respectively;

[0038] FIGS. 8A and 8B show front and rear perspective views of panels of selected cladding secured to two base profiles, respectively; [0039] FIGS. 9A and 9B show close-up front and rear perspective views of panels of selected cladding secured to base profiles, respectively;

[0040] FIGS. 10A to 10C show end views of a panel of selected cladding engaging a subsequent panel of selected cladding;

[0041] FIG. 11 shows a close-up front perspective view of three panels of selected cladding secured to base profiles;

[0042] FIG. 12 shows a close-up rear perspective view of four panels of selected cladding secured to base profiles;

[0043] FIGS. 13A and 13B show front and rear perspective views of panels of selected cladding secured to base profiles, respectively; [0044] FIG. 14 shows a rear perspective view of insulation installed between adjacent base profiles, the insulation being internal in relation to the panels of selected cladding;

[0045] FIG. 15 shows a sectional view of a wall section including panels of selected cladding, base profiles, insulation, foundation members and a floor slab;

[0046] FIGS. 16A and 16B show upper and lower rear perspective views of a wall section including flooring insulation, respectively; [0047] FIG. 17 shows a rear perspective view of a wall section including masonry supports;

[0048] FIG. 18 shows a rear perspective view of a wall section including masonry; and [0049] FIG. 19 shows a rear perspective view of a finished wall section.

DETAILED DESCRIPTION

[0050] Various apparatuses or methods will be described below to provide an example of embodiment of each claimed invention. No embodiment described below limits any claimed invention and any claimed invention may cover apparatuses or methods that are not described below. The claimed inventions are not limited to apparatuses or methods having all of the features of any one apparatus or method described below or to features common to multiple or all of the apparatuses described below. It is possible that an apparatus or method described below is not an embodiment of any claimed invention. The applicant(s), inventor(s) and/or owner(s) reserve all rights in any invention disclosed in an apparatus or method described below that is not claimed in this document and do not abandon, disclaim or dedicate to the public any such invention by its disclosure in this document.

[0051] Applicant's teachings relate to apparatuses and methods for installing cladding to structures, such as, for example, a building. In particular, applicant provides a foundation apparatus configured to be secured to a structure, such as, for example, a building, and a base profile that is configured to be secured to the foundation apparatus and which supports selected cladding. The foundation apparatuses and base profiles provide a support structure enabling a desired area to be cladded on the structure.

[0052] Referring to FIGS. 1A and 1 B, a foundation apparatus 100 is shown secured to a surface 102. The surface 102 can be a provided on a structure, such as, for example but not limited to, a building. The building may have a skeletal building structure generally comprising a plurality of consecutive vertically spaced floor slabs, or at least a floor slab and a similar structure to form the ceiling/roof of the building. The surface 102 can therefore be a horizontal surface of a floor slab, either on the upper or lower side. [0053] In accordance with various embodiments of applicant's teachings, the foundation apparatus 100 includes a body defined by a supporting surface 104, a bottom surface 106 and a top surface 108. The bottom surface 106 abuts the supporting surface 104. The supporting surface 104 can be generally orthogonal to the bottom surface 106. The bottom surface 106 engages the surface 102. Although not shown, a thermal break can be provided between the bottom surface 106 and the surface 102. The top surface 108 generally opposing the bottom surface 106. The top surface 108 can be sloped relative to the bottom surface 106, so that the top and bottom surfaces 108, 106 generally converge in a direction away from the supporting surface 104, providing a structurally rigid configuration.

[0054] The top surface 108 of the foundation apparatus 100 can include a plurality of first ridges 110. A first channel 112 is provided extending between the top and bottom surfaces 108, 106 for receiving a connection member 114 fixed to the surface 102. The connection member 114 can be, for example but not limited to, a bolt or threaded rod fixed to the surface 102. The plurality of first ridges 110 on the top surface 108 generally surround the first channel 112. The first channel 112 can be elongate enabling adjustable positioning of the foundation apparatus 100 relative to the surface 102.

[0055] At least one reinforcing web support 116 can be provided between the bottom and top surfaces 106, 108, further improving the structural rigidity of the foundation apparatus 100.

[0056] Further illustrated are a nut 118 and a washer member 119, the nut 118 and the washer member 119 used in combination to secure the foundation apparatus 100 to the connection member 114. The washer member 119 includes a bottom surface having a plurality of second ridges 120 complementary to the first ridges 110 of the top surface 108. The first and second ridges 110, 120 are engageable to fix the nut 118 in position relative to the foundation apparatus 100, thereby maintaining the support surface 104 a fixed distance relative to the connection member 114. The second ridges 120 of the washer member 119 are sloped corresponding to the slope of the top surface 108. Although not shown, a thermal break can be provided between the nut 118 and the connection member 114. The nut 118 is tightened against the connection member 114 until the foundation apparatus 100 is suitably secured to the surface 102.

[0057] The supporting surface 104 can include a second channel 122 for securing a base profile (described below) to the supporting surface 104 with a fastening mechanism, for example, a bolt. The second channel 122 can be elongate in a horizontal direction to enable adjustable positioning of the foundation apparatus 100 relative to the base profile.

[0058] Referring to FIGS. 2A and 2B, a base profile 124 is provided for use with the foundation apparatus 100. In particular, the base profile 124 is adapted to be secured to the supporting surface 104 of the foundation apparatus 100. The base profile 124 includes an inner flange surface 126 and an outer flange surface 128.

[0059] The inner flange surface 126 is adapted to be secured to the supporting surface 104 of the foundation apparatus 100. The inner flange surface 126 comprises first and second inner flange surfaces, which are separated by a slot 130. [0060] The outer flange surface 128 is spaced apart from the inner flange surface 126, with the inner and outer flange surfaces 126, 128 being generally opposing and parallel. The outer flange surface 128 provides a surface for supporting selected cladding secured thereto. The outer flange surface 128 comprises first and second outer flange surfaces, which are separated by a gap 132. The gap 132 is defined by first and second sidewalls 134, 136.

[0061] The base profile 124 further includes a web 138 connecting the inner and outer flange surfaces 126, 128. The web 138 can be generally orthogonal to the inner and outer flange surfaces 126, 128. The first and second sidewalls 134, 136 space apart the web 138 from the outer flange surface 128. The web 138 can also include a plurality of apertures 140 for reducing the weight of the base profile 124.

[0062] It should be appreciated that the base profile 124 can have a generally uniform cross-section in a longitudinal direction. The base profile 124 can be extruded aluminum, for example.

[0063] Referring to FIGS. 3A and 3B, a rod 142 can be implemented for securing the base profile 124 to the foundation apparatus 100. The rod 142 is sized to be received in the slot 130. The rod 142 can extend beyond an end of the base profile 124, and may therefore be used for longitudinally aligning adjacent base profiles 100. The rod 142 and the slot 130 of the base profile 124 can have complementary dovetail cross-sections for retaining the rod 142 within the slot 130.

[0064] Furthermore, the rod 142 can include threads 144 for receiving a fastening mechanism (for example, a bolt) provided through the second channel 122 of the supporting surface 104 of the foundation apparatus 100 for securing the base profile 124 to the foundation apparatus 100. The slot 130 of the base profile 124 can also include a recess 146 for receiving an end of the fastening mechanism provided through the second channel 122 of the supporting surface 104 of the foundation apparatus 100.

[0065] Referring to FIG. 4, a first base profile 100 can be secured to a foundation apparatus 100 by inserting the rod 142 into the slot 130 of the base profile 124, and aligning the second channel 122 of the foundation apparatus 100 (shown already secured to the surface 102) with the threads 144 of the rod 142 and the recess 146 of the base profile 100. A fastening mechanism (for example, a bolt) can then be inserted through the second channel 122 and received by the threads 144. The fastening mechanism can then be tightened a desired amount to draw the rod 142 against the base profile 124. The rod 142 is retained within the slot 130 according to the dovetail cross-section, and therefore tightening the fastening mechanism will also draw the inner flange surface 126 of the base profile 124 to bear against the supporting surface 104 of the foundation apparatus 100.

[0066] As shown in FIGS. 4 and 5, a spacer 148 can be provided for spacing apart adjacent base profiles 124 aligned by the rod 142. The spacer 148 can be generally ring shaped and be sized to fit over the rod 142 and positioned appropriately along the rod 142. The spacer 148 can be formed of a plastic material to provide a thermal break between adjacent longitudinally base profiles 124. [0067] As shown in FIGS. 5 and 6, a second base profile 124 can then be positioned above the first base profile 124, with the rod 142 inserted into the slot 130 of the second base profile 124. The first and second base profiles 124 are thereby aligned longitudinally by the rod 142. The other end (i.e. the upper end) of the second base profile 100 can then be secured to a subsequent foundation apparatus 100, e.g., provided on a subsequent floor slab, in the same manner as described for the first base profile 124.

[0068] It should be appreciated that the terms upper, lower, top, bottom, inner, outer, etc., are used in this disclosure for the sake of clarity and relate to the position of the foundation apparatus 100 and base profile 124 when in an installed orientation in accordance with the specific examples illustrated. In particular, the terms front/outer refer to a direction generally away from the surface of the structure being cladded, while the terms rear/inner refer to a direction generally toward the surface of the structure being cladded. Applicant's teachings are not intended to be limited to particular orientations of the foundation apparatuses 100 and/or base profiles 124, and that various orientations are possible within applicant's teachings.

[0069] A plurality of the foundation apparatuses 100 can be installed onto the surface 102 of a floor slab and spaced apart at regular intervals. The foundation apparatuses 100 are installed after a desired number of connection members 114 are installed onto the surface 102 of the floor slab, the connection members 114 marking the desired locations of the foundation apparatuses 100. A plurality of the foundation apparatuses 100 can also be installed onto the surface 102 of a consecutive floor slab and spaced apart at the same regular intervals. The foundation apparatuses 100 can be vertically aligned between the consecutive floor slabs.

[0070] The base profiles 124 can then be secured to the supporting surfaces 104 of the foundation apparatuses 100 so that the base profiles 124 extend vertically to span between two or more of the foundation apparatuses 100 on consecutive floor slabs. Once installed, the base profiles 124 can be generally parallel and spaced apart horizontally. The steps of fixing the foundation apparatuses 100 and the base profiles 124 as described herein are repeated until the skeletal building structure that requires cladding is covered. [0071] Furthermore, the base profiles 124 present the outer flange surfaces 128 facing outwardly from the structure. The outer flange surfaces 128 of the base profiles 124 provide a support surface for securing selected cladding.

[0072] The installation of the foundation apparatuses 100 and the 124 can be proceeded generally from inside of the building structure.

[0073] Aspects of the applicant's teachings having regard to the foundation apparatus 100 and base profile 124 may be further understood in light of the following example, which should not be construed as limiting the scope of the present teachings in any way. [0074] In an example of applicant's teachings, the selected cladding is provided in the form of panels 150 as illustrated in FIGS. 7A to 7E. The panels 150 have an outer surface 152 that can be formed of metal. For some embodiments of applicant's teachings, the outer surface 152 is flanged forming upper and lower edges 154, 156. The panels 150 also have first and second supporting elements 158, 160 extending along the upper and lower edges 154, 156, respectively. The second supporting element 160 is adapted to receive in friction fit the first supporting element 158. Stiffening members 162 can also be provided extending between the first and second supporting elements 158, 160.

[0075] Referring to FIGS. 8A to 9B, in accordance with the method of this example, the first supporting element 158 of the panel 150 is secured at both ends to the outer flange surface 128 of the base profiles 124, thereby securing the panels 150 to the surface 102 of the structure. The base profiles 124 are horizontally spaced apart a distance corresponding to a width of the panels 150. In general, the first supporting element 158 of the panel 150 is secured to the outer flange surface 128 of the base profiles by, for example, but not limited to, rivets, bolts, or screws. The first supporting element 158 of the panel 150 is secured at both ends to the outer flange surface 128 of the base profiles 124 to form a course of cladding that presents the first supporting element 158 along the upper edges 154 of the selected cladding in that course. This course can form a base course of the cladding. The first course of cladding can be horizontally leveled before it is fixed to the base profiles 124. [0076] It should be appreciated that the gap 132 defined by the sidewalls 134, 136 of the base profiles 124 allows the panels 150 room to expand/contract, for example, due to temperature fluctuations.

[0077] A subsequent course of cladding is fixed to the below course as follows, and with reference to FIGS. 10 to 13B. The second supporting element 160 along the lower edge 156 of a panel 150 of the subsequent course is fixed to the first supporting element 158 along the upper edge 154 of the below or previous course by inserting the webs of the first supporting element 158 within the slots of the second supporting element 160. The assembled first and second supporting profiles 158, 160 when joined together are unitarily fixed to the outer flange surface 128 of the base profile 124. The first supporting element 158 of the panel 150 of the subsequent course can then be secured at both ends to the outer flange surface 128 of the base profiles 124.

[0078] The process can be repeated until the desired number of courses of selected cladding has been installed on the building structure.

[0079] Once the panels of cladding 150 have been installed to the desired area of the structure, insulating material can then be applied to the inside of the cladding. As shown in FIGS. 8B, 9B and 10, an insulation supporting profile 162 can be provided fixed to the first supporting element 158 so that the insulation supporting profile 162 presents a surface adapted to receive insulating material to form a first layer of insulation. The thickness of insulating material in the first layer of insulation would correspond to the extent of the surface provided by the insulation supporting profiles 162.

[0080] Referring to FIGS. 14 and 15, a second layer of insulation 164 can be provided internally of the panels 150. In particular, the second layer of insulation can be provided generally bounded between the base profiles 124, but not extending internally of the inner flange surfaces 126 of the base profiles 124.

[0081] Furthermore, with reference to FIGS. 16A and 16B, flooring insulation 166 can be provided to cover the surface 102 of the floor slab, concealing the foundation apparatuses 100. Gap insulation 168 can be provided to fill the gap between the floor slab and the inner flange surfaces 126 of the base profiles 124. The gap insulation 168 can be secured by a flange member 170. [0082] Referring to FIGS. 17 to 19, a retaining wall 172 can then be installed internally of the second layer of insulation 164. The retaining wall 172 can be secured to the inner flange surfaces 126 of the base profiles 124. Flanges 174 can be secured to the retaining wall 172 and/or the inner flange surfaces 126 of the base profiles 124, the flanges 174 for supporting a layer of masonry 176. After the layer of masonry 176 is set, a final interior wall and floor surface 178, 180 can be installed.

[0083] Although this particular example relates to the use of the support structure formed by the foundation apparatuses 100 and base profiles 124 to install panels 150, it should be understood that the applicant's teachings should not be limited to any particular type or mechanism of selected cladding.

[0084] While the applicant's teachings are described in conjunction with various embodiments, it is not intended that the applicant's teachings be limited to such embodiments. On the contrary, the applicant's teachings encompass various alternatives, modifications, and equivalents, as will be appreciated by those of skill in the art.

Claims

CLAIMSI claim:

1. A cladding support system comprising: a) at least one foundation apparatus for attachment to a floor slab, the foundation apparatus including a body including a supporting surface, a bottom surface for engaging the floor slab, a top surface, and a first channel extending between the top and bottom surfaces for receiving a connection member fixed to the floor slab; and b) at least one base profile, the base profile including an inner flange surface adapted to be secured to the supporting surface of the foundation apparatus, and an outer flange surface spaced apart from the inner flange surface, the inner and outer flange surfaces being generally opposing and parallel, the outer flange surface for supporting selected cladding to be secured thereto.

2. The system of claim 1 , wherein the supporting surface is generally orthogonal relative to the bottom surface, and wherein the top surface is sloped relative to the bottom surface.

3. The system of claim 2, wherein the top and bottom surfaces of the body are connected to the supporting surface and generally converge in a direction away from the supporting surface.

4. The system of claim 3, wherein the top surface includes a plurality of first ridges surrounding the first channel, and further comprising, in combination, a nut and a washer member for securing the body to the connection member, the washer member including a bottom surface having a plurality of second ridges complementary to the first ridges of the top surface of the body, the first and second ridges engageable to fix the nut in position relative to the body.

5. The system of claim 4, wherein the bottom surface of the washer member is sloped corresponding to the top surface of the body.

6. The system of any one of claims 1 to 5, wherein the body includes at least one reinforcing web support provided between the bottom and top surfaces.

7. The system of any one of claims 1 to 6, wherein the channel is elongate enabling adjustable positioning of the foundation apparatus relative to the floor slab.

8. The system of any one of claims 1 to 7, wherein the supporting surface comprises a second channel for securing the base profile to the supporting surface with a fastening mechanism.

9. The system of claim 8, wherein the second channel is elongate enabling adjustable positioning of the foundation apparatus relative to the base profile.

10. The system of any one of claims 1 to 9, wherein the base profile comprises a web, wherein the web connects the inner and outer flange surfaces, and wherein the web is generally orthogonal to the inner and outer flange surfaces.

11. The system of claim 10, wherein the inner flange surface comprises first and second inner flange surfaces, and wherein the first and second inner flange surfaces are separated by a slot.

12. The system of claim 11 , further comprising a rod sized to be received in the slot, the rod for longitudinally aligning adjacent base profiles.

13. The system of claim 12, wherein the slot and the rod have complementary dovetail cross-sections for retaining the rod with the slot.

14. The system of any one of claims 12 or 13, wherein the rod comprises threads adapted to receive a fastening mechanism provided through the second channel of the foundation apparatus for securing the base profile to the foundation apparatus.

15. The system of claim 14, wherein the slot of the base profile comprises a recess for receiving an end of the fastening mechanism provided through the second channel of the foundation apparatus.

16. The system of any one of claims 12 to 15, further comprising a spacer for spacing apart adjacent base profiles aligned by the rod.

17. The system of any one of claims 10 to 16, wherein the outer flange surface comprises first and second outer flange surfaces, and wherein the first and second outer flange surfaces are separated by a gap.

18. The system of claim 17, wherein the gap is defined by first and second sidewalls, and wherein the first and second sidewalls space apart the first and second outer flange surfaces from the web.

19. The system of any one of claims 10 to 18, wherein the web comprises a plurality of apertures.

20. A foundation apparatus for use with a base profile to secure the base profile to a floor slab, the foundation apparatus comprising a body, the body including a supporting surface for supporting a base profile secured thereto, a bottom surface for engaging the floor slab, a top surface, and a first channel extending between the top and bottom surfaces for receiving a connection member fixed to the floor slab.

21. The apparatus of claim 20, wherein the supporting surface is generally orthogonal to the bottom surface, and wherein the top surface is sloped relative to the bottom surface.

22. The apparatus of claim 21 , wherein the top and bottom surfaces of the body generally converge in a direction away from the supporting surface.

23. The apparatus of claim 22, wherein the top surface includes a plurality of first ridges surrounding the first channel, and further comprising, in combination, a nut and a washer member for securing the body to the connection member, the washer member including a bottom surface having a plurality of second ridges complementary to the first ridges of the top surface of the body, the first and second ridges engageable to fix the nut in position relative to the body.

24. The apparatus of claim 23, wherein the bottom surface of the washer member is sloped corresponding to the top surface of the body.

25. The apparatus of any one of claims 20 to 24, wherein the body includes at least one reinforcing web support provided between the bottom and top surfaces.

26. The apparatus of any one of claims 20 to 25, wherein the channel is elongate enabling adjustable positioning of the foundation apparatus relative to the floor slab.

27. The apparatus of any one of claims 20 to 26, wherein the supporting surface comprises a second channel for securing the base profile to the supporting surface with a fastening mechanism.

28. The apparatus of claim 27, wherein the second channel is elongate enabling adjustable positioning of the foundation apparatus relative to the base profile.

29. In combination, the apparatus of any one of claims 20 to 28 and a base profile, the base profile comprising: a) an inner flange surface adapted to be secured to the supporting surface of the foundation apparatus; and b) an outer flange surface spaced apart from the inner flange surface, the inner and outer flange surfaces being generally opposing and parallel, the outer flange surface for supporting selected cladding to be secured thereto.

30. The combination of claim 29, wherein the base profile comprises a web, wherein the web connects the inner and outer flange surfaces, and wherein the web is generally orthogonal to the inner and outer flange surfaces.

31. The combination of claim 30, wherein the inner flange surface comprises first and second inner flange surfaces, and wherein the first and second inner flange surfaces are separated by a slot.

32. The combination of claim 31 , further comprising a rod sized to be received in the slot, the rod for longitudinally aligning adjacent base profiles.

33. The combination of claim 32, wherein the slot and the rod have complementary dovetail cross-sections for retaining the rod within the slot.

34. The combination of claim 33, wherein the rod comprises threads adapted to receive a fastening mechanism extending through the second channel of the foundation apparatus to secure the base profile to the foundation apparatus.

35. The combination of claim 34, wherein the slot comprises a recess for receiving an end of the fastening mechanism extending through the rod.

36. The combination of any one of claims 32 to 35, further comprising a spacer for spacing apart adjacent base profiles aligned by the rod.

37. The combination of any one of claims 30 to 36, wherein the outer flange surface comprises first and second outer flange surfaces, and wherein the first and second outer flange surfaces are separated by a gap.

38. The combination of claim 37, wherein the gap is defined by first and second sidewalls, and wherein the first and second sidewalls space apart the first and second outer flange surfaces from the web.

39. The combination of any one of claims 30 to 38, wherein the web comprises a plurality of apertures.

40. A structure comprising: a) a plurality of vertically spaced floor slabs; b) a plurality of foundation apparatuses, each of the foundation apparatuses including a body including a supporting surface, a bottom surface engaging one of the floor slabs, a top surface, and a first channel extending between the top and bottom surfaces receiving a connection member fixed to the one of the floor slabs; c) a plurality of base profiles, each of the base profiles including an inner flange surface secured to the supporting surface of at least one of the foundation apparatuses, and an outer flange surface spaced apart from the inner flange surface, the inner and outer flange surfaces being generally opposing and parallel; and d) at least one panel of selected cladding secured to the outer flanges of the base profiles.

41. The structure of claim 40, wherein each of the base profiles is secured to the supporting surfaces of two of the foundation apparatuses.

42. The structure of claim 41 , wherein the two of the foundation apparatuses are secured to consecutive floor slabs.

43. The structure of claim 42, wherein the two of the foundation apparatuses are generally vertically aligned.

44. The structure of any one of claims 40 to 43, wherein the panel of selected cladding is secured to the outer flanges of two of the base profiles.

45. The structure of claim 44, wherein each of the two of the base profiles are generally vertical, and wherein the two of the base profiles are spaced apart horizontally.

46. The structure of claim 45, wherein the two of the base profiles are generally parallel.

47. A method of installing cladding to a structure, the structure including at least two vertically spaced floor slabs, the method comprising: a) providing a plurality of foundation apparatuses, each of the foundation apparatuses including a support surface; b) installing at least two foundation apparatuses to each of the floor slabs, each of the foundation apparatuses presenting the support surface facing externally in relation to the structure; c) providing a plurality of base profiles, each of the base profiles including inner and outer flange surfaces; d) securing the inner flange surface of each of the base profiles to at least two of the foundation apparatuses, each of the base profiles presenting the outer flange surface facing externally in relation to the structure; and e) securing at least one panel of selected cladding to the outer flange surfaces of the base profiles.

48. The method of claim 47, wherein the foundation apparatuses are each secured to top surfaces of each of the floor slabs.

49. The method of any one of claims 47 or 48, wherein the base profiles are secured to foundation apparatuses installed on consecutive floor slabs so that the base profiles extend between the consecutive floor slabs.

50. The method of any one of claims 47 to 49, wherein the base profiles extend vertically to span at least two of the vertically spaced floor slabs.

51. The method of any one of claims 47 to 50, wherein the foundation apparatuses are installed spaced apart along each of the floor slabs so as to match a width of the panels of selected cladding.

52. The method of any one of claims 47 to 51 , further comprising installing a plurality of connection members to the floor slabs prior to the step of installing the foundation apparatuses, wherein each of the foundation apparatuses is installed on the floor slabs by securing each of the foundation apparatuses to one of the connection members.

53. The method of any one of claims 47 to 52, further comprising providing a plurality of rods for longitudinally aligning adjacent base profiles, and inserting one of the rods in a slot provided at an end of each of the base profiles, the slot adapted to receive and retain the rod.

54. The method of claim 53, further comprising securing the base profile to the foundation apparatus by receiving a fastening mechanism in threads provided by the rod, the fastening mechanism coupled to the support surface of the foundation apparatus.

55. The method of claim 54, further comprising inserting a free end of the rod in a slot provided at another end of a longitudinally adjacent base profiles.

56. The method of any one of claims 53 to 55, further comprising providing a plurality of spacers coupled to the rods between adjacent base profiles, the spacers providing a thermal break between the adjacent base profiles.

57. The method of any one of claims 47 to 56, further comprising installing insulation material in a space between the inner flange surfaces of the base profiles and interior surfaces of the panels of selected cladding.

58. The method of any one of claims 47 to 57, further comprising installing a board member on the inner flange surfaces of the base profiles.

59. The method of claim 58, further comprising installing generally horizontal flanges on the board member, wherein the board member and the horizontal flanges are adapted to receive mortar and a layer of masonry.