Abstract: A manufacturing assembly and method produce a wire mesh including a plurality of longitudinal members and a monolithic transverse member secured to the plurality of longitudinal members. The monolithic transverse member includes a plurality of transverse portions that define a first cross-sectional shape, and further includes a plurality of longitudinal portions that define a second cross-sectional shape different than the first cross-sectional shape.

Abstract: A turret roll forming machine includes at least one turret assembly carrying multiple rows of tooling (e.g., forming rollers), rotatable about an axis to selectively align rows of tooling with an input or output. A transmission is accessible from an exterior of the turret assembly without disassembling of the turret assembly to perform a changeover of roll tooling and/or maintenance on gears, bearings, or shafts of the transmission. Thus, a chain drive may be employed, advantageously accommodating differing rotational speeds for top and bottom forming rollers of each pair of forming rollers, e.g. to reduce roll scuffing. Pairs of forming rollers may be provided as cassettes, which are removably coupleable to the turret assembly allowing quick and easy reconfiguration and/or servicing, minimizing negative effects of changeover. The turret assembly may be a unitary structure (e.g., a weldment) improving rigidity and increasing accuracy of roll forming operations.

Abstract: A rotary slitting blade for fabricating expanded metal products includes opposed end surfaces and an outer circumferential surface extending from one of the end surfaces to the other of the end surfaces. A plurality of notches are formed in each of the end surfaces. The notches include curved surfaces having convex curvatures that smoothly transition into one of the end surfaces and/or the outer circumferential surface. The rotary slitting blade improves the quality of a resulting expanded metal product by reducing or eliminating tears, cracks, and fractures in the expanded metal product.

Abstract: A manufacturing assembly and method produce a wire mesh including a plurality of longitudinal members and a monolithic transverse member secured to the plurality of longitudinal members. The monolithic transverse member includes a plurality of transverse portions that define a first cross-sectional shape, and further includes a plurality of longitudinal portions that define a second cross-sectional shape different than the first cross-sectional shape.

Abstract: A stud such as a light-weight metal stud can include a first elongated channel member and a second elongated channel member coupled to the first elongated channel member by a wire matrix, where ends of the wire matrix are located at ends of the first and second channel members. A pitch of the wire matrix can vary over the length of the stud. Two or more such studs can have different lengths where a difference in the lengths is not a multiple of the pitch.

Abstract: A rotary slitting blade for fabricating expanded metal products includes opposed end surfaces and an outer circumferential surface extending from one of the end surfaces to the other of the end surfaces. A plurality of notches are formed in each of the end surfaces. The notches include curved surfaces having convex curvatures that smoothly transition into one of the end surfaces and/or the outer circumferential surface. The rotary slitting blade improves the quality of a resulting expanded metal product by reducing or eliminating tears, cracks, and fractures in the expanded metal product.

Abstract: A stud such as a light-weight metal stud can include a first elongated channel member and a second elongated channel member coupled to the first elongated channel member by a wire matrix, where ends of the wire matrix are located at ends of the first and second channel members. A pitch of the wire matrix can vary over the length of the stud. Two or more such studs can have different lengths where a difference in the lengths is not a multiple of the pitch.

Abstract: The present invention provides for a welded wire lath device having a plurality of longitudinal wires extending along a plane and in a longitudinal direction, a plurality of tension release devices disposed on the plurality of longitudinal wires, a plurality of transverse wires extending along the plane in a transverse direction; and a plurality of weld connections at each intersection point between the plurality of longitudinal wires and the plurality of transverse wires. Each of the plurality of tension release devices are randomly spaced along the plurality of parallel longitudinal wires. The longitudinal wires, including each of the plurality of tension release devices, have a rectilinear cross-section. The present invention also provides for a structural assembly, and related method, having the welded wire lath device attached to a structural support such as a wall or ceiling and having a cementitious material embedded within the welded wire lath device.

Abstract: A light-weight metal framing member includes a metal stud and reinforcement plate(s), and method to produce a light-weight metal framing member may include forming a pair of channel members each having a respective major face having a respective first edge, and reinforcing such with one or more reinforcement plates, preferably at opposed ends thereof. Each member includes first and second flanges extending along the respective major face. A wire matrix includes a pair of wires each having apexes alternatively physically attached to the pair of channel members. The wire matrix forms longitudinal passages to support utility lines and position the lines away from the pair of channel members. The apexes are secured to flanges of the pair of channel members to strengthen the stud and reduce weight.

Abstract: An expanded metal lath may be formed by slitting a metal sheet or strip in a defined pattern and subjecting the sheet or coil to a tensile force sufficient to cause the slits to form a plurality of openings. The web bands forming the plurality of openings can include a heavier web bands in areas where fasteners will be used to affix the expanded metal lath to a substrate and lighter web bands in other areas where fasteners will not be used. The expanded metal lath can include stabilizers or selvedge wires at opposed lateral or longitudinal edges to protect the expanded metal lath during shipping and installation. The expanded metal lath may include furring elements integrally formed with the web bands to raise the expanded metal lath off an underlying surface.

Abstract: A light-weight metal framing member includes a metal stud and reinforcement plate(s), and method to produce a light-weight metal framing member may include forming a pair of channel members each having a respective major face having a respective first edge, and reinforcing such with one or more reinforcement plates, preferably at opposed ends thereof. Each member includes first and second flanges extending along the respective major face. A wire matrix includes a pair of wires each having apexes alternatively physically attached to the pair of channel members. The wire matrix forms longitudinal passages to support utility lines and position the lines away from the pair of channel members. The apexes are secured to flanges of the pair of channel members to strengthen the stud and reduce weight.

Abstract: An expanded metal lath may be formed by slitting a metal sheet or strip in a defined pattern and subjecting the sheet or coil to a tensile force sufficient to cause the slits to form a plurality of openings. The web bands forming the plurality of openings can include a heavier web bands in areas where fasteners will be used to affix the expanded metal lath to a substrate and lighter web bands in other areas where fasteners will not be used. The expanded metal lath can include stabilizers or selvedge wires at opposed lateral or longitudinal edges to protect the expanded metal lath during shipping and installation. The expanded metal lath may include furring elements integrally formed with the web bands to raise the expanded metal lath off an underlying surface.

Abstract: Reinforcing inserts reinforce a frame member, such as a manufactured or metal stud. A reinforcing insert may be inserted into a stud, for example into the interior region between two elongated channel members of the stud to support one or more elements of the stud, thereby reinforcing the stud. The reinforcing insert may be received into one or both ends of the stud. The reinforcing insert may be shaped to engage (e.g., frictional or interference fit) in the interior of the stud. A length and other dimensions or properties of the reinforcing insert may be sized in accordance with the properties of the stud to be reinforced. The reinforcing insert may be tapered at one end, may include recesses to accommodate intrusive fasteners and/or include lightening apertures or pockets.

Abstract: Various metal framing members enhance thermally insulative characteristics of a wall. Framing members include a metal stud with a web portion having through-holes that include at least one piece of retained material. Each of the through-holes lengthens or disrupts thermally conductive paths across the framing member, forming convoluted or serpentine thermal paths. The through-holes are arranged in a pattern that defines a truss structure that includes a number of straight-line web sections that extend uninterruptedly diagonally across a width of the web portion. Framing members include tracks, to hold metal studs, each with a web portion with through-holes that lengthen or disrupt thermally conductive paths. The framing members may be the result of a continuous manufacturing processing, formed of a unitary singular piece of material (e.g., galvanized metal). Thermally insulative gaskets or membranes may insulate the tracks from adjacent structure or surfaces. Structures may be provided as a kit.

Abstract: A lath and method to produce a lath may include furring strand wires with furring bends, transverse wires joined to the furring strand wires to not overlap a furring bend, and a stabilization wire arranged along a serpentine path and joined to the transverse wires.

Abstract: A lath and method to produce a lath may include furring strand wires with furring bends, transverse wires joined to the furring strand wires to not overlap a furring bend, and a stabilization wire arranged along a serpentine path and joined to the transverse wires.

Abstract: A light-weight metal stud and method to produce a light-weight metal stud may include forming a pair of channel members each having a respective major face having a respective first edge. Each member includes first and second flanges extending along the respective major face. A wire matrix includes a pair of wires each having apexes alternatively physically attached to the pair of channel members. The wire matrix forms longitudinal passages to support utility lines and position the lines away from the pair of channel members. The apexes are secured to flanges of the pair of channel members to strengthen the stud and reduce weight.

Abstract: A building includes exterior walls that form spaces which are selectively vented under control of a control system. Vents are operated to retain trapped air or exhaust trapped air to improve the energy performance of the building. Vents with selectively operable dampers may be located proximate a top of a wall or wall section of wall. Vents may also be located proximate a bottom of a wall or wall section to allow drainage of liquid and circulation of air. Various specific wall constructions provide for an air gap between layers of exterior sheathing of the exterior wall. The air gap may be in addition to a space between interior and exterior sheathing, which space may include a thermal insulation material (e.g., fiberglass batting).

Abstract: An expanded material suitable for industrial application may have a nominal tap density from 0.18 grams/cc to 1.00 grams/cc and a wall thickness greater than 1.00 microns. The expanded material may take the form of an expanded silicate, for instance perlite, obsidian, pitchstone or vermiculite. A composition may include the expanded material in a dispersion, for example a resin dispersion, for instance a latex acrylic. Such may be particularly suitable as a partial or complete substitute for another aggregate used in the composition, such as sand. The composition may be suitable in structural applications, for example as an EIFS coat. The expanded material may, or may not, include a partial or complete hydrophobic coating.

Abstract: A welded wire lathing material for mounting stucco plaster and the like onto a building frame. This lathing material comprises intersecting transverse and primary longitudinal strands substantially located in a first plane. It also comprises secondary longitudinal strands also substantially placed in first plane and closely spaced with, some of primary longitudinal strands, thus forming longitudinal slots located at predetermined spaced intervals extending across the lathing material. The slots are wider than the shaft, but narrower than the head, of fasteners predetermined for attaching the lath to building frames. The longitudinal and transverse strands are welded together where they intersect to form a rectangular mesh approximately located in the first plane.