CONSTRUCTION OF AN ARCH

Abstract

A frame for retaining one or more masonry slips is provided. The one or more masonry slips each have at least two slots formed on at least two sides thereof. The frame includes a supporting structure including a back plate, and is configured to house two or more masonry slips, and two or more face rails positioned on the back plate of the supporting structure. Each face rail is configured to house at least one masonry sup, and includes a projection directed away from the back plate of the supporting structure, and a retaining element positioned at the end of the projection so that the retaining element is approximately parallel to the back plate of the supporting structure, and the retaining element is configured to be positioned within one of the two slots formed on the sides of the masonry slip.

Description

FIELD OF INVENTION

The present application is in the field of construction, and specifically the construction of arches, and more specifically for the construction of arches using modern building techniques. Set out herein are both an apparatus for forming an archway as well as a method of assembly.

BACKGROUND

A common building construction is that of a main structure which is produced using the latest building technology and materials, surrounded on the outside by a cladding, perhaps made of more traditional materials like bricks. The benefits of this structure are that the main building can be built from any number of new materials and therefore fulfil all building regulations as these develop, while the cladding forms an outer wall that can be made more aesthetically pleasing. Such a structure typically includes a cavity between the main building and the cladding, wherein this cavity not only increases insulation of the building from the external elements and environment, but also allows greater flexibility when constructing the main building structure.

There is a particular difficulty however with certain building designs being constructed in this manner. Namely one such design is that of an arch construction. Arches are used in buildings to enlarge entrances, allow more light into enclosed spaces, or to mimic older style building design such as large arches used as entrances at coaching inns. There is therefore a need to be able to create such building designs through the use of the cladding based construction. The present invention seeks to address these problems and provides both an apparatus for construction of the arch as well as a method of assembly.

SUMMARY

Aspects of the invention are set out in the independent claims. Optional features are set out in the dependent claims.

According to a first aspect there is provided a frame for retaining one or more masonry slips, the one or more masonry slips each having at least two slots formed on at least two sides thereof, respectively, the frame comprising a supporting structure comprising a back plate, wherein the supporting structure is configured to house two or more masonry slips, two or more face rails positioned on the back plate of the supporting structure wherein each face rail is configured to house at least one masonry slip, each face rail comprising a projection directed away from the back plate of the supporting structure, and further comprising a retaining element positioned at the end of the projection and such that the retaining element is approximately parallel to the back plate of the supporting structure, wherein the retaining element is configured to be positioned within one of the two slots formed on the sides of the masonry slip.

This has the advantage of enabling an archway to be formed using a cladding type construction.

A further optional feature comprises a spacer element configured to be positioned within a slot of a first masonry slip housed by the first face rail, and within a slot of a second masonry slip housed by the second face rail, such that the spacer element maintains a set gap between the first masonry slip and the second masonry slip. This is particularly advantageous as the spacer element mechanically holds the masonry slip and stops it from rotating in situ and therefore moving from its intended position. Such movements may be hazardous so this greatly improves the design.

According to a further aspect there is provided method of assembling the frame of the first aspect, the method of assembly comprising fabricating a supporting structure comprising a back plate and at least two face rails, installing a first masonry slip into a first face rail by rotating the first masonry slip such that the first masonry slip passes via the projection of the first face rail, installing a second masonry slip into the second face rail by rotating the second masonry slip such that it passes via the projection of the second face rail, wherein the slot on the side of each masonry slip is positioned level with the retaining element of the corresponding face rail parallel to the back plate, positioning the retaining elements within the corresponding slot on the side of the corresponding masonry slip.

Optionally, the method of assembly further comprising the steps of inserting a first spacer element into the side of the masonry slip, whilst allowing enough room for the adjacent masonry slip to subsequently be installed, and once the adjacent masonry slip is installed rotating the spacer element such that the spacer element is in contact with both the first and the second masonry slips, preventing the masonry slips form being rotated in the opposite direction to which they were installed. Advantageously this may hold the masonry slips effectively.

Optionally, wherein the spacer elements are washers, and the method of assembly further comprising the steps of fixing the spacer elements to the back plate, wherein the backing plate comprises pre-cut holts in locations aligned with centres of joints between adjacent masonry slips. Advantageously this may offer a low cost solution.

BRIEF DESCRIPTION OF FIGURES

FIG. 1 shows a supporting structure consisting of stainless-steel arch lintel, back plate and underside plate with a frontal view.

FIG. 2 shows the supporting structure of FIG. 1, from a side view.

FIG. 3 shows a frame comprising face rails and soffit rails attached to the supporting structure of FIG. 1, FIG. 3 shows a frontal view.

FIG. 4 shows a side view of the frame of FIG. 3 in a side view

FIG. 5 shows an enlarged perspective view of a portion of the frame of FIG. 3, wherein that portion is in the centre of the frame in FIG. 3.

FIG. 6 shows a masonry slip.

FIG. 7 shows the masonry slips being rotated so that they pass via the projecting legs of the Face Rails.

FIG. 8 shows the masonry slips in situ after being positioned within the face rails.

FIG. 9 shows the spacer element being inserted into the side of a masonry slip.

FIG. 10 shows an alternate form of spacer element being inserted in the side of the masonry slip.

FIG. 11 shows a frame with the face rail, masonry slips and spacer elements all attached.

FIG. 12 shows a frame with the face rail, masonry slips and spacer elements all attached, with a different form of spacer element shown.

FIGS. 13 and 14 show the frames of FIGS. 11 and 12 in cross section.

DETAILED DESCRIPTION

There is described herein a frame for retaining one or more masonry slips, the one or more masonry slips each having at least two slots formed on at least two sides thereof, respectively, the frame comprising a supporting structure comprising a back plate, wherein the supporting structure is configured to house two or more masonry slips, two or more face rails positioned on the back plate of the supporting structure wherein each face rail is configured to house at least one masonry slip, each face rail comprising a projection directed away from the back plate of the supporting structure, and further comprising a retaining element positioned at the end of the projection and such that the retaining element is approximately parallel to the back plate of the supporting structure, wherein the retaining element is configured to be positioned within one of the two slots formed on the sides of the masonry slip. This has the advantage of enabling an archway to be formed using a cladding type construction.

A further optional feature comprises a spacer element configured to be positioned within a slot of a first masonry slip housed by the first face rail, and within a slot of a second masonry slip housed by the second face rail, such that the spacer element maintains a set gap between the first masonry slip and the second masonry slip. This is particularly advantageous as the spacer element mechanically holds the masonry slip and stops it from rotating in situ and therefore moving from its intended position. Such movements may be hazardous so this greatly improves the design.

FIG. 1 shows an archway 10 spanning a gap between a proximal and distal end portions. The archway shown holds its own weight—moreover arches may have to hold both their own weight as well as the weight of some or all of an auxiliary structure positioned above the arch.

FIG. 2 shows a cross section of the arch 10 of FIG. 1. This shows that the arch 10 may be formed by a supporting structure such as a fabricated section, or steel girder or the like functioning as a lintel. The cross section may be hollow, or may comprise a fabricated section, or steel girder that is not hollow.

As can be seen in the cross section whilst the cross section is broadly rectangular there is a lip 16 at the top extending from the frontal surface (referred to as the back plate) 12. When installed masonry slips may be substantially flush with the edge of this lip. Alternatively, they may extend beyond the lip. The lip is perpendicular with the back plate 12 of the supporting structure. The back plate 12 is the face of the arch facing outward from the building. The underside plate 14 is also shown.

FIG. 3 shows a frame 10 comprising face rails 20 and soffit rails 30 attached to the supporting structure of FIG. 1. FIG. 3 shows a frontal view. The face rails 20 each comprise at least one projection 22 directed away from the back plate 12 of the supporting structure. The projection 22 comprises a retaining element 24 positioned at the end of the projection 22 and such that the retaining element 24 is approximately parallel to the back plate 12 of the supporting structure. In FIG. 3 the retaining elements 24 can be seen as hemispherical shapes on the face rails 20. The retaining elements 24 may be any shape. The projection 22 themselves are hidden by the retaining elements 24. The projection is perpendicular to the plan of the page in FIG. 3 and would point directly out of the page. The projection 22 provides a separation distance between the face rail 20 and the retaining element 24 in which a masonry slip 40 can be positioned. It is noted that in FIG. 3 each face rail 20 comprises two projections 22 and retaining elements 24. It is noted however than any number of projections 22 and retaining elements 24 may be used. It is also noted that multiple retaining elements 24 may emanate from a single projection 22.

FIG. 3 also shows the soffit rails 30. The soffit rails 30 are attached to the underside plate 14. The underside plate 14 is shown as being the underside of the arch 10. Each soffit rail 30 comprises two projections 32 extending away from the underside plate 14 of the supporting structure 10. The projections 32 in each pair are spaced apart from each other. Each soffit rail 30 further comprises a retaining element 34 extending from the end of each projection 32 such that the retaining elements 34 are substantially parallel to the underside plate 14 of the supporting structure 10. The retaining elements 34 are attached to the projections 32. In each pair there is a first projection 32 with an associated retaining element 34, and a second projection 32 with an associated retaining element 34. The first and second retaining element 34 extend towards each other such that each soffit rail 30 and pair of projections 32 can form a slot for a masonry slip 40 such that in use the masonry slip 40 may be held by the soffit rail 32.

FIG. 4 shows a side view of the frame of FIG. 3 in a side view. The face rail 20 on the back plate 12 of the supporting frame 10 is seen in FIG. 4. The projections 22 are perpendicular to the back plate 12. The projection 32 of the soffit rail 30 is also seen. The projection 32 of the soffit rail 30 is perpendicular to the underside plate 14 of the supporting structure 10.

FIG. 5 shows an enlarged perspective view of a portion of the frame of FIG. 3, wherein that portion is in the centre of the frame 10 in FIG. 3. This shows the face rails 20, projections 22 and retaining elements 24 as described above. It also shows the soffit rails 30, projections 32 and retaining elements 34 as described above. It is noted that in this example each face rail 30 comprises projections 22 on just one side, whereas soffit rails 30 comprise projections 32 on both the left and right hand sides.

FIG. 6 shows a masonry slip 40. The masonry slip shown is in an L-shape—however many other shapes may be use. The greater length 42 of the masonry slip 40 may fit within a face rail 20, whilst the shorter length 44 may fit within the soffit rail 30. Alternatively the opposite configuration may be used with the greater length 42 fitting within the soffit rail 30. Alternatively, both lengths of the masonry slip 40 may be the same length and merely referred to as first and second lengths. They may then be used interchangeably between the face 20 and soffit 30 rails. Indentations 46 are shown on both sides of the masonry slip 40. The retaining elements 24, 34 may fit within the indentations. It is noted that the indentations on the greater length 42 of the masonry slip 40 may be on only one side, however for flexibility of use it may be advantageous for indentations 42 to be positioned on both sides as shown.

FIG. 7 shows the masonry slips 40 being rotated 50 so that they pass via the projections 24 of the Face Rails 20. The masonry slip 40 is therefore positioned as shown such that when the indentation 46 in the side of the masonry slip 40 is level with the retaining element 24 of the face rail 20 parallel to the backing plate 12 this is rotated the opposite way 52 (shown in FIG. 8) so that the retaining element 24 sits within the indentation 46. It is noted that indentation and slot may be used interchangeably.

FIG. 8 shows the masonry slips 40 in situ after being positioned within the face rails 20. This shows that the retaining elements 24 are positioned within the indentation 46 of the masonry slip 40.

FIG. 9 shows the spacer element 60 being inserted into the side of a masonry slip. It is essential that the masonry slips 40 are securely fastened to the supporting structure 10. In some instances, the use of the face rails 20 will be enough. In other instances, the optional soffit rails 30 may also be used. In the embodiment shown in FIG. 9 additional spacer elements 60 are being installed such that the masonry slips 40 are even more secure. Various forms of masonry slip 40 may be used. For example, those in FIG. 9 are shown as being rectangular in profile (which includes an L-shape as shown above). In this example the spacer element 60 may comprise a clip like structure comprising a central body portion and two arms 62 extending from either side of the body portion, the arms 62 extending towards the centre of the body portion and towards each other, optionally wherein central body portion of the spacer element is substantially flat. In FIG. 9 these are positioned between a first masonry slip and a second masonry slip.

FIG. 10 shows an alternate form of spacer element 70 being inserted in the side of the masonry slip 40. The spacer element of FIG. 10 comprises a washer like structure, optionally wherein the spacer element comprises a central body with two projections. The first projection 72 emanates from a proximal end of the central body upwards, and the second projection 74 emanates from a distal end of the central body downwards, further optionally wherein the projections are rounded and atraumatic. In this embodiment the washer is predominantly flat.

In both FIG. 9 and FIG. 10 the spacer elements are inserted into the indentation 46 of the masonry slip 40 to be installed. During installation enough space is kept for the adjacent masonry slip 40 to subsequently be installed.

FIG. 11 shows a frame with the face rail 20, soffit rails 30, masonry slips 40 and spacer elements 60 all attached. This shows the angled spacer elements, and the retaining elements, retaining the masonry slip. The process shown in FIGS. 9 and 10 has been repeated such that all masonry slips in the arch are installed.

After all of the masonry slips were installed the spacers 60 were then rotated to contact the adjacent masonry slip 40 so that the spacer elements 60 prevent the masonry slips from rotating in the opposite direction to the direction in which they were installed. This effectively freezes the masonry slips 40 in place. Optional further adhesive may be used to cement the location of the masonry slips further.

FIG. 12 shows a frame with the face rails 20, soffit rails 30, masonry slips 40, and spacer elements 70 all attached, with a different form of spacer element shown. The washer like spacer element in shown in FIG. 12.

FIGS. 13 and 14 show the frames of FIGS. 11 and 12 in cross section. FIG. 13 shows that both the retaining element 24, 34 and the spacer element 60 are positioned in the indentation 46 of the masonry slip 40. FIG. 14 additionally shows that for elements were washer like spacer elements 70 are used some type of further adhesive may be used to anchor the spacer element. In FIG. 14 a self-tapping screw 80 is used to anchor the spacer element through a pre-cut hole in the face rail (shown as a circle on the face of the face rail in many of the previous Figures). However other types of anchoring may be used as would be well known to the person skilled in the art.

An archway may therefore be manufactured using the frame described above. A building incorporating such an archway and/or frame may also be manufactured.

As is shown in the preceding Figures the arch 10 may be assembled fabricating a supporting structure comprising a back plate 12 and at least two face rails 20. The supporting structure 10 may also comprise at least one soffit rail 30, but this is an optional feature. A first masonry slip 40 may be installed into a first face rail 20 by rotating the first masonry slip 40 such that the first masonry slip passes via the projection 22 of the first face rail 20 (as is shown in FIG. 7). A second masonry slip 40 may then be installed by rotating the second masonry slip 40 such that it passes via the projection 22 of the second face rail 20. The indentation 46 on the side of each masonry slip is positioned level with the retaining element 24 of the corresponding face rail 20 parallel to the back plate 14. The retaining elements 24 may then be positioned within the corresponding indentation 46 on the side of the corresponding masonry slip.

It is noted that use of the spacer elements 60, 70 is entirely optional. If spacer elements are used they may be installed by inserting a first spacer element 60, 70 into the side of the masonry slip, whilst allowing enough room for the adjacent masonry slip 40 to subsequently be installed. Once the adjacent masonry slip 40 is installed the spacer element may be rotated such that the spacer element 60, 70 is in contact with both the first and the second masonry slips, preventing the masonry slips from being rotated in the opposite direction to which they were installed.

As noted above in relation to FIG. 14 when the spacer elements are washers 70, a further step of assembly may include fixing the spacer elements 70 to the back plate 12, wherein the backing plate comprises pre-cut holes in locations aligned with centres of joints between adjacent masonry slips. The holes may alternatively be cut on the face rails 20.

As previously noted one additional optional step in fabricating the supporting structure may comprise soffit rails 30 to the underside plate 14 of the supporting structure 10.

In each of the above concepts, the material making up the elements is of a non-flammable nature. This appropriately reduces any fire concerns in modern buildings. Most preferably, the material for each of these elements is stainless steel, as this does not rust and has a very high melting point and is considered to be a safe material choice. The masonry slips may be manufactured from an alternative material, or have a veneer of another material placed on them for aesthetic purposes. Furthermore, it will be clear that the individual elements of each of the options can be appropriately combined with other.

Claims

1-25. (canceled)

26. A frame for retaining one or more masonry slips, the one or more masonry slips each having at least two slots formed on at least two sides thereof, respectively, the frame comprising: a supporting structure comprising a back plate, wherein the supporting structure is configured to house two or more masonry slips;two or more face rails positioned on the back plate of the supporting structure, wherein each face rail is configured to house at least one masonry slip, each face rail comprising a projection directed away from the back plate of the supporting structure, and a retaining element positioned at the end of the projection and so that the retaining element is approximately parallel to the back plate of the supporting structure, wherein the retaining element is configured to be positioned within one of the two slots formed on the sides of the masonry slip.

27. The frame of claim 26, further comprising a spacer element configured to be positioned within a slot of a first masonry slip housed by the first face rail, and within a slot of a second masonry slip housed by the second face rail, so that the spacer element maintains a set gap between the first masonry slip and the second masonry slip.

28. The frame of claim 26, wherein the supporting structure comprises an underside plate on an underside of the supporting structure beneath the back plate.

29. The frame of claim 26, further comprising two or more soffit rails positioned on an underside plate of the supporting structure, wherein each soffit rail comprises two projections extending away from the underside plate of the supporting structure spaced apart from each other, each soffit rail further comprising a retaining element extending from the end of each projection so that the retaining elements are substantially parallel to the underside plate of the supporting structure, the first and second retaining elements extending towards each other so that each can fit within a slot of a masonry slip so that the masonry slip is held by the soffit rail.

30. The frame of claim 27, wherein the spacer element comprises a clip like structure comprising a central body portion and two arms extending from either side of the body portion, the arms extending towards the centre of the body portion and towards each other, and wherein central body portion of the spacer element is substantially flat.

31. The frame of claim 27, wherein the spacer element comprising a washer like structure, and wherein the spacer element comprises a central body with two projections, and a first projection of the two projections emanates from a proximal end of the central body upwards, and a second projection of the two projections emanates from a distal end of the central body downwards, and wherein the projections are rounded and atraumatic.

32. The frame of claim 26, wherein the supporting structure is a curved supporting structure, and wherein the curved supporting structure forms an arch.

33. The frame of claim 27, wherein the frame comprises a second spacer element positioned between the first masonry slip and the second masonry slip, and wherein the first spacer element is positioned above the second spacer element.

34. The frame of claim 33, wherein the first spacer element is substantially the same size as the second spacer element, and wherein the first spacer element is larger than the second spacer element so that when the masonry slips are fitted the gap between the masonry slips is larger at the top than the bottom of the join between the first and second masonry slips, and wherein the masonry slips are L-shaped.

35. The frame of claim 26, the frame comprising a weight bearing support sheet; and/or wherein the frame is constructed from steel; and/orwherein the supporting structure is a lintel structure.

36. The frame of claim 27, wherein the spacer element either: is configured to be disposed between a first face rail and a second face rail, or wherein the spacer element forms part of a first face rail.

37. The frame of claim 26, wherein each face rail extends approximately perpendicularly away from the back plate; and/or wherein the retaining element extends approximately perpendicularly to the projection.

38. An archway comprising: a frame for retaining one or more masonry slips, the one or more masonry slips each having at least two slots formed on at least two sides thereof, the frame comprising:a supporting structure comprising a back plate, wherein the supporting structure is configured to house two or more masonry slips;two or more face rails positioned on the back plate of the supporting structure, wherein each face rail is configured to house at least one masonry slip, each face rail comprising a projection directed away from the back plate of the supporting structure, and a retaining element positioned at the end of the projection and so that the retaining element is approximately parallel to the back plate of the supporting structure, and wherein the retaining element is configured to be positioned within one of the two slots formed on the sides of the masonry slip.

39. A building comprising: a frame for retaining one or more masonry slips, the one or more masonry slips each having at least two slots formed on at least two sides thereof, respectively, the frame comprising:a supporting structure comprising a back plate, wherein the supporting structure is configured to house two or more masonry slips;two or more face rails positioned on the back plate of the supporting structure, wherein each face rail is configured to house at least one masonry slip, each face rail comprising a projection directed away from the back plate of the supporting structure, and further comprising a retaining element positioned at the end of the projection and so that the retaining element is approximately parallel to the back plate of the supporting structure, and wherein the retaining element is configured to be positioned within one of the two slots formed on the sides of the masonry slip.

40. The building of claim 39, comprising an archway formed from the frame.

41. A method of assembling the frame of claim 26, the method of assembly comprising the steps of: fabricating a supporting structure comprising a back plate and at least two face rails;installing a first masonry slip into a first face rail by rotating the first masonry slip so that the first masonry slip passes via the projection of the first face rail;installing a second masonry slip into the second face rail by rotating the second masonry slip so that it passes via the projection of the second face rail;wherein the slot on the side of each masonry slip is positioned level with the retaining element of the corresponding face rail parallel to the back plate;positioning the retaining elements within the corresponding slot on the side of the corresponding masonry slip.

42. The method of assembly of claim 41, further comprising the steps of: inserting a first spacer element into the side of the masonry slip, while allowing enough room for the adjacent masonry slip to subsequently be installed;wherein once the adjacent masonry slip is installed rotating the spacer element so that the spacer element is in contact with both the first and the second masonry slips, preventing the masonry slips form being rotated in the opposite direction to which they were installed.

43. The method of assembly of claim 41, wherein the spacer elements are washers, and further comprising the steps of: fixing the spacer elements to the back plate, wherein the backing plate comprises pre-cut holts in locations aligned with centres of joints between adjacent masonry slips.

44. The method of assembly of claim 41, further comprising fabricating an underside plate as part of the supporting structure, and welding soffit rails to the underside plate of the supporting structure.

45. The method of assembly of claim 41, wherein supporting structure is curved, and/or wherein the supporting structure is a lintel, and/or wherein the supporting structure is formed from stainless steel.