SUPPORT ARRANGEMENT FOR COVERING ELEMENTS OF A BUILDING

RELATED APPLICATIONS

This application is a U.S. application under 35 U.S.C. § 119 claiming benefit of and priority to GB Application No. 2311492.9, filed on Jul. 26, 2023, the contents of which are hereby incorporated by reference in their entirety for all purposes.

FIELD OF INVENTION

The present invention relates to an improved arrangement for supporting covering elements of a building.

DESCRIPTION OF PRIOR ART

In construction, there has been an increasing trend towards the use of masonry slips, such as brick slips, which are often bonded to backing boards such as steel, composites or fibre cement boards, and then mounted on a face or soffit of a building. Such arrangements can be used, for example, in cladding panels or lintels to form parts of the fascia or soffit of a building or as underslung soffits designed to be mechanically fixed to masonry support structures bolted to the internal structure of a cavity wall. Masonry slip arrangements can be prefabricated before transporting to a site for installation and this reduces the amount of onsite time required to construct a building. Additionally, masonry slips arranged as ornate features, such as arched lintels, replaces onsite crafting of such ornate features, which can often be time consuming and require a high level of skill. Construction companies can produce entire building facades and sidings, composed of a plurality of masonry slip units, within a factory in a quality-controlled setting before transporting and assembling on site.

The known support arrangement S according to the prior art has a backing board BB formed from fibre cement board, composite or steel and a supporting structure SS with a plurality of separate support members. In particular, as shown in FIGS. 1 and 2, the supporting structure SS is formed from three identical elongate support members SM1 and two identical support members SM2 having a shorter length than the three identical support members SM1. The supporting structure SS may be alternatively arranged according to specific design requirements of the support arrangement S. In the illustrated example, each of the support members SM1, SM2 have a flat portion and a reinforcing flange that extends from the flat portion perpendicularly to the flat portion.

Each of the support members SM1 and SM2 are fixed to the backing board BB. In particular, each of the support members are provided with apertures for receiving bolts that extend into the backing board BB.

Moreover, the known support arrangement S has an attachment channel A to enable the support arrangement S to be attached to a building or building component. The support members SM1, SM2 each extend perpendicularly from the attachment channel A and the latter is attached to the supporting structure SS defined by the support members SM1 and SM2. In particular, the attachment channel A is welded to the support members SM1 and SM2 and these latter are mechanically fixed (riveted) to the backing board BB. Therefore, the separate support members SM1, SM2 are interconnected via the elongate attachment channel A that extends between the support members SM1, SM2 and the attachment channel A is attached indirectly to the backing board by means of the support members SM1, SM2.

Moreover, both the support members SM1, SM2 and the attachment channel A are often both formed from steel, so that this arrangement is quite expensive to manufacture.

Covering elements C such as brick slips are fixed by grout/bonding method and/or by mechanical fixing to the backing board BB. In particular, as shown in FIG. 2, the backing board BB is shaped to form a soffit surface having three rows Ra, Rb, Rc of brick slips wherein the middle row R2 is offset relative to the top Ra and bottom Rc row to replicate the appearance of a traditional brick bond.

Even if highly utilized, the known support arrangement S according to FIGS. 1 and 2 does not result in a fully optimized use of materials for its production and this is now a challenging aspect considering the rising cost of materials, the shortage of material availability, the need of waste reducing and energy consumption, in particular for environmental sustainability.

OBJECTS OF THE INVENTION

It is an object of the present invention to prevent or mitigate the problems of known solutions, thus providing an arrangement for the support of covering elements that reduces the quantity of material required for its production, while maintaining a suitable and required structural rigidity.

It is an object of the present invention to obviate or mitigate the use of steel (or other metallic materials) in respect of the known solutions, while maintaining a suitable and required structural rigidity.

Another object of the present invention is to provide a support arrangement for covering elements having high structural rigidity.

Another object of the present invention is to provide a support arrangement for covering elements of reduced cost construction.

Another object of the present invention is to provide a support arrangement for covering elements of easier and quicker installation.

Another object of the present invention is to provide a support arrangement for covering elements of reduced weight.

Another object of the present invention is to provide a support arrangement for covering elements that is highly eco-friendly.

Another object of the present invention is to provide a support arrangement for covering elements that has an alternative and improved characterisation and design, in both constructional and functional terms, compared with the known ones.

SUMMARY

According to a first aspect of the invention there is provided a support arrangement for supporting covering elements on a soffit and/or a fascia of a building, the support arrangement comprising a backing member for receiving covering elements and an attachment means extending longitudinally along the length of the backing member for attaching the support arrangement to a building or a building component such that it forms a part of the building and wherein no support gussets are provided spaced apart along the length of the support arrangement.

Advantageously, this allows the production of a support arrangement that is less expensive to manufacture and that has also a lighter weight, thus being easy to manage and to install.

The supporting arrangement does not comprise a plurality of separate vertical support gussets. There are no support gussets spaced apart along a length of, meaning longitudinally spaced apart in respect of, the support arrangement. There are no support gussets extending depthwise, meaning perpendicularly to the length of the support arrangement, across the support arrangement. The supporting structure is a supporting structure of the support arrangement. The supporting structure is for supporting covering elements on a soffit and/or fascia of a building in use. In particular, by supporting structure we mean a structural configuration of components of the support arrangement which transfer the load of the covering elements to the building or building component.

In the support arrangement there are no support gussets extending from the attachment means or the backing member.

In the support arrangement there are no support gussets intermediate of the attachment means and the backing member.

In the support arrangement there are no support gussets located longitudinally proximal in respect of the backing member.

In the support arrangement there are no support gussets attached/fixed to the attachment means or the backing member.

Preferably, the support arrangement comprises a backing member that is operable to receive covering elements.

The attachment means comprises an attachment member.

The attachment member is configured as a channel.

Ideally, the attachment means has a longitudinal development with a U-shaped cross section.

Ideally, the attachment member comprises an attachment channel having a base and two mutually opposing sidewalls that extend perpendicularly from the base, and an opening that is defined between the opposing sidewalls and faces the base.

Preferably, the attachment means is operable to receive directly the one or more backing members. By receive directly, we mean that the one or more backing members and the attachment means are in contact with one another in the support arrangement in use.

Preferably, the attachment means spans at least two covering elements.

Preferably, the attachment means is configured and intended to be associated to at least two covering elements.

Ideally, the backing member comprises at least one backing board.

Ideally, the backing board is configured to span at least two covering elements. Advantageously, the backing board acts as a means for connecting together at least two covering elements.

Ideally, the backing member may also act as a structural supporting element. The support structure may comprise the backing member. When we say that the backing member may also act as a structural supporting element, and that the support structure may comprise the backing member, we mean that it may act as a structural supporting element in addition to the attachment means. We mean that the backing member itself helps to support the covering elements on a soffit and/or a fascia of a building in use. The backing member helps support the covering elements by providing rigidity and/or stability to the support arrangement by transferring the load of the covering elements in use to the attachment means which is itself supported on a structure of a building.

Ideally, the supporting structure of the support arrangement is defined only by the attachment means and by the backing member. By this we mean that in use, the attachment means and the backing member are sufficient to support the covering elements on a soffit and/or a fascia of a building without a further structural component for stabilising and/or rigidifying the support arrangement, in particular without support gussets for stabilising and/or rigidifying the support arrangement.

Ideally, the support arrangement comprises a support framework.

Ideally, the support framework comprises the attachment means, wherein the backing member and covering elements are fixed to the attachment means in use, and the attachment means is engageable with fixings of a mount for mounting the support arrangement on a building.

Advantageously, the attachment means alone defines the support framework to which the backing board and/or covering elements is/are fixed in use, and it is engageable with fixings of a mount for mounting the support arrangement on a building.

Ideally, the backing member is formed at least partially from non-metallic material.

Preferably, the backing member may be a metal or metal alloy or steel backing board.

Preferably, the backing member is fixed only to the attachment means.

Preferably, the backing board is fixed only to the attachment means.

Preferably, the attachment means is fixed directly to the backing member.

Preferably, the attachment means is fastened by bonding and/or by mechanical fixing to the backing member. The bonding may be adhesive bonding.

Preferably, the backing member is formed at least partially from cementitious and/or composite material. Advantageously, cementitious or composite backing members are more easily drilled than steel and can more readily and easily receive mechanical fixes such as screws. Therefore, covering elements, such as masonry slips, can more readily be mechanically fixed to a cementitious or composite backing member and this discourages the use of copious amounts of epoxy resin. The reliance on adhesives, such as certain epoxy resins, which can emit toxic fumes when burnt, is thereby mitigated by use of a cementitious or composite backing member to which covering elements can be easily mechanically fixed. Further advantageously, cementitious or composite materials used in construction are typically fireproof and are generally less expensive and are of lighter weight than steel or other purely metallic building materials.

Preferably, the support arrangement, most preferably the backing member, is non-combustible.

Ideally, the backing member is entirely formed from cementitious or composite material.

Preferably, the backing member is formed from a material being a combination of cement and reinforcing fibres.

Ideally, the backing member is formed at least partially from mineral particle board such as magnesium oxide particle board, concrete, fiber-reinforced polymers, FRPs (including wood comprising cellulose fibers in a lignin and hemicellulose matrix), carbon-fiber reinforced plastic (CFRP) or glass-reinforced plastic (GRP), thermoplastic composite (short fiber thermoplastics, long fiber thermoplastics or long fiber-reinforced thermoplastics), thermoset composite, and/or aramid fibre and carbon fibre in an epoxy resin matrix.

Preferably, the backing member is formed at least partially from calcium-silicate based fibre cement. Advantageously, calcium silicate fibre cement is flexible, strong, water resistant and has high levels of dimensional stability.

Preferably, the backing member comprises one or more backing boards.

Preferably, the backing member comprises a first board portion and a second board portion.

Ideally, the first board portion is a fascia-forming face while the second board portion is a soffit-forming face, or vice-versa.

Preferably, the first board portion and the second board portion are planar with their planes extending orthogonally with each other.

Preferably, the first board portion has a first inner edge intended to be closer to a corresponding second inner edge of the second board portion, while the first outer edge is the edge opposite to the first inner edge in/of the first board portion and the second outer edge is the edge opposite to the second inner edge in/of the second board portion.

Preferably, the inner edge of the second board portion abuts against the inner face of the first board portion, or vice-versa. Ideally, the inner edge of the second board portion is bonded to the inner face of the first board portion, or vice-versa.

Preferably, the inner edge of the first board portion is intended to be spaced by the facing inner surface of the covering elements. Ideally, the inner edge of the first board portion is not bonded to the covering elements.

Preferably, the outer edge of the first or second board portion of the backing member is intended to be flush with an end of the covering element.

Preferably, the outer edge of the first or second board portion of the backing member is intended to extend over the corresponding end of the covering element.

Ideally, the outer edge of the first is intended to extend over the corresponding end of the covering element, while the outer edge of the second board portion is intended to be flush with the edge of the covering element.

Preferably, the first or second board portion of the backing member spans at least two covering elements.

Preferably, the base of the attachment channel is fixed to the second board portion or to the first board portion of the backing member.

Preferably, one sidewall of the attachment channel is fixed to the first board portion or to the second board portion of the backing member.

Ideally, the base and one sidewall of the attachment channel are fixed to different portions of the backing member.

Preferably, the first board portion and the second board portion of the backing member are made as a single body/piece that is L-shaped.

Preferably, the first board portion and the second board portion of the backing member are made as two distinct bodies/pieces that, in the support arrangement, are intended to be attached to each other.

Preferably, the first board portion and the second board portion of the backing member are made as two distinct bodies/pieces that, in the support arrangement, are intended to contact each other. The first and second board portions contact each other when they are attached to each other.

Preferably, the longitudinal extension of the attachment channel is less than the longitudinal extension of the backing board.

Preferably, the attachment channel has a longitudinal extension so as to span at least two covering elements.

Preferably, the backing member has a longitudinal extension so as to span at least two covering elements.

Ideally, the attachment channel comprises external and internal sidewalls, wherein the external sidewall is located between the internal sidewall and the fascia-forming face of the backing member when the attachment channel is fixed to the backing member in use.

Preferably, the attachment channel comprises at/on its base first means for fixing to the backing member and further comprises at/on the external sidewall second means for fixing to the backing member. The external sidewall may be fixed to the first board portion or to the second board portion of the backing member. The external sidewall may be in contact with the first board portion or with the second board portion of the backing member. The external sidewall may be in contact with the first board portion when the external sidewall is fixed to the first board portion of the backing member.

The external sidewall may be in contact with the second board portion of the backing member when the external sidewall is fixed to the second board portion of the backing member.

The external sidewall may be in contact with the first board portion when the base of the attachment channel is fixed to the second board portion of the backing member.

The external sidewall may be in contact with the second board portion of the backing member when the base of the attachment channel is fixed to the first board portion of the backing member.

Ideally, the mutually opposing sidewalls of the attachment channel are parallel to one another.

Ideally, the attachment channel is parallel with the first board portion and/or the second board portion when the attachment means is fixed to the backing member. By this we mean that the attachment channel is parallel to one or more surface of the first board portion and/or second board portion.

Ideally, the external sidewall is parallel with the first board portion and/or the second board portion when the attachment means is fixed to the backing member.

Ideally, the mutually opposing sidewalls of the attachment channel are planar.

Ideally, the external sidewall is in planar-abutting contact with a planar surface of the first board portion or the second board portion when the attachment means is fixed to the backing member in use.

Ideally, the base of the attachment channel is parallel with the first board portion and/or the second board portion when the attachment means is fixed to the backing member. The base of the attachment channel is planar. The base is in planar-abutting contact with a planar surface of the first board portion or the second board portion when the attachment means is fixed to the backing member in use.

Ideally, the first fixing means at/on the base of the attachment channel comprises a second set of through openings that are spaced apart along the longitudinal extension of the attachment channel and that are intended for mechanical fixing the attachment channel to the first or to the second board portion of the backing member.

Ideally, the second fixing means at/on at least one sidewall of the attachment channel comprises a second set of through openings that are spaced apart along the longitudinal extension of the attachment channel and that are intended for mechanical fixing the attachment channel to the first or to the second board portion of the backing member.

Preferably, the supporting structure is a supporting frame consisting only of the attachment channel and to which the backing member is fixable or fixed. The supporting frame is a supporting framework.

The backing member is supportable only by the attachment means. By this we mean that the backing member may be supported in use only by the attachment means and no additional external supporting means. By external supporting means we mean supporting means not arising from the material properties of the backing member itself, i.e., supporting means applied to the backing means.

Ideally, the backing member of the supporting structure is made of metallic material, preferably of steel.

Ideally, the supporting structure does not comprise a plurality of spaced apart support members.

Preferably, if the backing member is a steel backing board, the attachment means is fixed directly by welding to the backing member.

Preferably, the backing member is fixed to the attachment channel by adhesive. Ideally, the adhesive is a resin chosen so as to not emit harmful toxins when burnt.

Preferably, the backing member is fixed to the attachment channel by fixing means such as a screw and washer, pop rivet, spring clip, or any suitable fixing means.

Preferably, the backing member is fixed to the attachment channel by adhesive and/or by mechanical fixing means.

Ideally, in use, the fixing means are located in spacings between covering elements and not between the covering element and backing member.

Advantageously, the fixing means does not interfere with the placement of covering elements on the backing member.

Advantageously, due to the presence of an attachment means and/or the backing member acting as a supporting structure and spanning the extension of the backing member for at least two covering elements and due to the absence of a plurality of the elongated support members extending perpendicularly from the attachment means, fixing means for fixing the backing member to the attachment means can be located between covering elements in use and not between a covering element and the backing member. Each covering element thereby sits flush against the backing member and the attachment of the covering element to the backing member is not affected by the location of the fixings.

Advantageously, the support framework defined by the attachment means and/or by the backing member can be designed and manufactured in a factory, thereby minimising onsite construction times.

Advantageously, the fixing of the support framework, that is defined only by the attachment means attached to the backing board can be manufactured in a factory, thereby minimising onsite construction times.

Preferably, the attachment means is adapted to receive mechanical fixings such as screws or bolts.

Advantageously, this enables the backing member/board to be mechanically fixed to the attachment means.

Preferably, when mounted on a building or building component, at least a part of the support arrangement forms at least a part of a soffit of the building.

Advantageously, the support arrangement can be fixed to a building or building component at least partially via the attachment means.

Ideally, the attachment means is operable to mount or mechanically fix the support arrangement to a building component, or to hang the support arrangement from a building component.

Preferably, the attachment means is operable to mount or mechanically fix the support arrangement to a building component such that at least a majority of the support arrangement is suspended vertically below the building component.

Ideally, the attachment means is an elongate attachment means.

Ideally, the attachment means is operable to receive fixing means. Ideally, the attachment means comprises apertures sized to receive fixings such as screws or bolts. Ideally, the attachment channel comprises apertures in a body of one or both of the sidewalls distributed longitudinally therein.

Preferably, the attachment means is operable to retain the support arrangement at or about a face of a building.

Preferably, the attachment means is operable to mount the support arrangement on a building such that at least part of the support arrangement forms at least a part of a building soffit.

Advantageously, the support arrangement may be used to form at least part of the fascia of a building.

Advantageously, the support arrangement may be used to form at least part of the soffit of a building.

Ideally and advantageously, the attachment means and backing member is functional as the only support member and defines alone the supporting structure.

Preferably, the attachment means can be arranged defining a virtual plane to which a backing member/board can be mounted.

Ideally, the attachment means is located to the rear of the fascia-forming face.

Preferably, the attachment means is located proximal an upper portion of the fascia-forming face. By “upper portion” we mean the uppermost portion of the fascia-forming face when the support arrangement is set upright as it would be orientated when installed on a building.

Ideally, the top of the attachment means is flush or near flush with the top of the fascia-forming face. By this we mean when the support arrangement is orientated as it would be when fitted on a building.

Preferably, the attachment means is located at a position relative to the fascia-forming face and/or the soffit-forming face such that when the support arrangement is fitted to a masonry support surface, the covering elements on the support arrangement form a continuous surface with masonry that is disposed and supported on the masonry support surface.

Ideally, the attachment means is formed at least partially from metal, most preferably at least partially from steel.

Preferably, the attachment means comprises an attachment channel that is operable to receive fixing means such as a nut and bolt.

Alternatively, the attachment means comprises fixing means operable to engage with a building component.

Alternatively, the attachment means comprises a means to hang the support arrangement from a building or building component.

Alternatively again, the attachment means comprises an interlocking arrangement to enable the attachment means to interlock with a corresponding arrangement on a building component.

Ideally, the attachment means comprises an elongate attachment channel.

Advantageously, the location of the support arrangement relative to the building component to which it is fixable can be adjusted along the longitudinal axis of the elongate attachment channel before torqueing the fixings.

Ideally, the attachment means comprises one or more fixing elements that are operable to fixedly engage with fixing means such as nuts or bolts.

Ideally, the fixing element(s) is/are movable relative to the attachment channel.

Advantageously, as the fixing elements are movable relative to the attachment channel, the position of support arrangement can be adjusted before fixing the support arrangement to a mount.

Ideally, the attachment channel and fixing elements are orientated such that the support arrangement can be fixed to a building component by vertically engaging the fixing elements with fixing means such as nuts or bolts.

In one embodiment, the fixing element is a male fixing element such as a bolt or screw that protrudes from the attachment channel to engage with a female fixing element such as a nut.

Alternatively, the fixing element is a female fixing element such as a nut that can receive a male fixing element that extends to the female fixing element of the attachment means.

Preferably, the female fixing element is a nut or machined block having an aperture to receive and fixedly engage with a fixing means such as a bolt.

Ideally, the fixing element is a spring nut.

Preferably, the attachment means comprises a retaining means to retain at least one fixing element within the attachment channel.

Ideally, the attachment channel is shaped to movably retain the fixing element(s) within the attachment channel.

Preferably, the retaining means comprises a retaining lip that extends over an opening in the attachment channel to movably retain the fixing element(s) therein.

The attachment means may comprise a plurality of attachment members. The attachment members may each be configured as channels. The attachment members may each have a longitudinal development with a U-shaped cross section. The attachment members may each comprise an attachment channel having a base and two mutually opposing sidewalls that extend perpendicularly from the base, and an opening that is defined between the opposing sidewalls and faces the base. The attachment members may be generally spaced apart over a depth of the one or more backing members and/or generally spaced apart over a length of the one or more backing members. The attachment members may extend longitudinally in respect of the one or more backing members and/or may extend in a depthwise direction in respect of the one or more backing members.

The one or more attachment members and the backing member may be separately formed bodies which are attached to one another in the support arrangement. The plurality of attachment members may be independently attached to the backing member in the support arrangement.

Advantageously, the plurality of attachment members can be used to distribute the stress on the one or more backing members. This prevents the structural capacity of the one or more backing members being reached as a result of the weight of the covering elements being supported thereon in use and/or the self-weight of the one or more backing members. Advantageously, this provides a more rigid and stable support arrangement. This is particularly important where the depth of the support arrangement, defined as the width of the second board portion, increases so as to cause a greater load due to the self-weight of the backing member and/or the covering elements thereon in use.

The attachment members may comprise a first attachment member according to any of the preceding statements of invention and one or more further attachment members displaced from the first attachment member in a depth-wise direction of the supporting arrangement.

Ideally, the attachment members may extend in a direction intermediate of longitudinally and depthwise in respect of the one or more backing members.

The attachment members may extend over the one or more backing members in a parallel and/or orthogonal manner of the attachment members.

The attachment members may extend longitudinally in respect of the one or more backing members.

The attachment members may extend transversely in respect of the one or more backing members. Ideally, wherein the fixing element is a spring nut, the spring biases the nut against the retaining means.

Ideally, the covering elements that can be fitted to the backing member/board are masonry slips such as brick, block or stone slips, or composite slips such as glass-reinforced plastic slips.

Ideally, the covering elements are mechanically fixed and/or adhesively bonded to the backing member/board.

In one embodiment, the covering elements are fixed to the backing member/board solely by a mechanical fix and not via adhering, gluing or bonding the covering elements to the backing member/board.

Ideally, the support arrangement is prefabricated. By prefabricated we mean it is manufactured, for example, in a factory, before being transported to a site for installation.

Preferably, the backing member is shaped to interlock with backing members of adjacent support arrangements such that a continuous surface is formed.

Ideally, the backing member is shaped to correspond to a brickwork pattern, such as stretcher, stack, header, English or Flemish brick bond, so that covering elements may be applied to the backing member to generate said brickwork pattern.

Ideally, a clipping means is provided to clip one or more end bricks to the support arrangement.

Preferably, a clipping means is provided to clip one or more end bricks to the backing member.

Ideally, the clipping means comprises a metal bracket having a first portion configured to be fastened to a covering element and a second portion configured to be fastened to the backing member.

Ideally, the clipping means comprises a metal bracket that is substantially C-shaped.

Preferably, the clipping means comprises a metal bracket having:

- a first portion configured to be inserted into a seat defined in an end brick,
- a second portion configured to be mechanically fastened to the backing member, and
- a third portion connecting the first portion to the second portion and having an extension wider that the thickness of the backing board.

Ideally, a connecting means is provided to connect one or more adjacent bricks to the support arrangement.

Ideally, a connecting means is provided to connect one or more adjacent bricks to each other at their respective inner facing sides. Preferably, a connecting means is provided to connect two adjacent bricks to the backing member.

According to a second aspect of the invention there is provided a building assembly comprising covering elements and a support arrangement for supporting covering elements on a soffit of a building, the support arrangement comprising an attachment means for attaching the support arrangement to a building or a building component such that it forms a part of the building and a backing member where no support gussets are provided spaced apart along the length of the support arrangement. The support arrangement of the building assembly is for supporting covering elements on a soffit and/or a fascia of a building. The support arrangement comprising a backing member for receiving covering elements and an attachment means extending longitudinally along the length of the backing member.

Ideally, the building assembly further comprising a mount for the support arrangement, the mount being adapted to be installed as part of a building.

Ideally, the building assembly is a lintel or soffit building assembly.

Ideally, the building assembly is prefabricated.

According to a third aspect of the invention there is provided a method of constructing a support arrangement for cover-elements of a soffit of a building, the method comprising the steps of forming a supporting structure that is made only by an attachment means for attaching the support arrangement to a building or a building component such that it forms a part of the building and a backing member. This means that the supporting structure is made only by the attachment means and the backing member and is for attaching the support arrangement to the building or a building component such that it forms a part of the building and a backing member. In particular and advantageously, the supporting structure does not comprise support gussets spaced apart along the length of the support arrangement.

According to a fourth aspect of the invention, there is provided a method of constructing a support arrangement for supporting covering elements on a soffit and/or fascia of a building, the support arrangement comprising a backing member for receiving covering elements and an attachment means extending longitudinally along the length of the backing member for attaching the support arrangement to a building or building component such that it forms a part of the building and wherein no support gussets are provided spaced apart along the length of the support arrangement.

Ideally, the method comprising the step of providing a backing member and fixing the attachment means directly to the backing member.

Ideally, the backing member is a cementitious/composite backing member.

Advantageously, the attachment means comprises an attachment channel which can be fixed to the backing member in a single step.

Ideally, the method does not comprise the step of connecting a plurality of supporting gussets to form a supporting frame to which a backing member can be fixed. The supporting frame is a supporting framework for providing support to the backing member for rigidifying the backing member in use.

Preferably, the method comprising the step of mounting the backing member directly to the attachment means via fixing means such as screws or bolts.

Ideally, the method comprising the step of bonding one or more covering elements to the backing member using adhesives.

Preferably, the method comprising the step of mechanically fixing one or more covering elements to the backing member. Ideally, the covering elements are further fixed to the backing member by clipping means. Ideally, the clipping means comprises metal brackets having a first portion configured to be fastened to a covering element and a second portion configured to be fastened to the backing member.

Preferably, the method comprising the step of fixing one or more covering elements directly to the attachment means. Ideally, the covering elements are bonded directly to the attachment means using adhesives. Ideally, the covering elements are bonded directly to the attachment means by mechanically fixing means.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will now be described with reference to the accompanying drawings, which shows only three embodiments of a support arrangement according to the invention, and only one embodiment of a mount for a support arrangement according to the invention by way of example only.

FIG. 1 is a isometric view of the support arrangement according to prior art,

FIG. 2 shows a top plan view of the support arrangement of FIG. 2,

FIG. 3 is a isometric view of a support arrangement according to the invention for supporting a series of L-shaped brick slips,

FIG. 4 is a side view of the support arrangement of FIG. 3 in a version intended to support both a series of L-shaped brick slips and rectangular brick slips,

FIG. 5 is a back view of the support arrangement of FIG. 4,

FIG. 5A is an enlarged view of a detail of FIG. 5,

FIG. 6 is a top plan view of the support arrangement of FIG. 4,

FIG. 7 is a side view of a support arrangement according to the invention,

FIG. 8 is a top plan view of the support arrangement of FIG. 7.

FIG. 9 is an isometric view a support arrangement according to the invention.

DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

In the following description of embodiments of the invention, like reference numerals are used to denote features in alternative embodiments.

In FIGS. 3 to 6 there is shown a first embodiment of a support arrangement according to the invention illustrated generally by reference numeral 1.

The support arrangement 1 is a supporting structure 1 comprising a supporting framework 2 and a backing member 3, the backing member 3 being a backing board 3 for receiving covering elements 4, 5. By the supporting structure we mean that the supporting framework 2 and the backing board 3 transfer the load of the covering elements to the building or building component. By supporting framework 2 we mean a frame which rigidifies the backing board 3. This means that the backing member 3 may also act as a structural supporting element, the backing member 3 may act as a structural supporting element in addition to the attachment means. The backing member helps support the covering elements by providing rigidity and/or stability to the support arrangement by transferring the load of the covering elements 4, 5 in use to a structure of a building.

The backing board 3 is formed from two separate sheets 60, 61 of fibre cement board although other cementitious boards are suitable, and any number of sheets may be combined to form the backing member. For example, in one preferred embodiment, the backing board 3 is formed from calcium-silicate based fibre cement. The backing member 3 may be a metal or metal alloy or steel backing board according to the invention (FIG. 7 and description thereof below).

The supporting arrangement 1 is for supporting covering elements 4, 5 on a soffit and/or a fascia of a building. The supporting arrangement 1 comprises an attachment means 10 extending longitudinally along the length of the backing board 3 for attaching the support arrangement 1 to a building or a building component such that it forms a part of the building. The support arrangement 1 comprises no support gussets spaced apart along the length of the support arrangement 1. There are no separate vertical support gussets of the supporting structure. There are no support gussets spaced apart along a length of, meaning longitudinally spaced apart in respect of, the support arrangement 1. There are no support gussets extending depthwise, meaning perpendicularly to the length of the support arrangement 1, across the support arrangement. There are no support gussets extending from the attachment means 10 or the backing board 3. There are no support gussets intermediate of the attachment means 10 and the backing member 3. There are no support gussets located longitudinally proximal in respect of the backing member 3. There are no support gussets attached/fixed to the attachment means 10 or the backing member 3.

The backing board 3 is fixed only to the attachment channel 10. The attachment channel 10 is fixed directly to the backing board 3. The attachment channel 10 is fastened by adhesive bonding 6 and by mechanical fixing to the backing board 3. Mechanical fixing includes clips 20 (see below) and further mechanical fixing in a longitudinally proximal portion of the support arrangements 1, 101, 201 (not shown). The supporting structure 1 of the support arrangement 1 is defined only by the attachment arrangement 10 and by the backing board 3. By this we mean that in use, the attachment channel 10 and the backing board 3 are sufficient to support the covering elements 4, 5 on a soffit and/or a fascia of a building without a further structural component for stabilising and/or rigidifying the support arrangement, in particular without support gussets for stabilising and/or rigidifying the support arrangement.

The backing board 3 is supportable only by the attachment arrangement 10. By this we mean that the backing board 3 is supported in use only by the attachment arrangement 10 and no additional external supporting means. By external supporting means we mean supporting means not arising from the material properties of the backing board 3 itself, i.e., supporting means applied to the backing board 3. That is to say that there are no support gussets supporting the backing board 3.

The support framework 2, 202 comprises the attachment arrangement 10, and the backing member and covering elements 4, 5 are fixed to the attachment arrangement 10 in use, and the attachment arrangement 10 is engageable with fixings of a mount for mounting the support arrangement on a building (not shown).

The attachment arrangement 10 is operable to receive directly the backing members 3, 103, 203. By receive directly, we mean that the backing members 3, 103, 203 and the attachment arrangement 10 are in contact with one another in the support arrangement 1, 101, 201 in use.

The backing board 3 comprises a first board portion 60, that is a fascia-forming face 60, a second portion 61, that is a soffit-forming face 61.

The fascia-forming face 60 and the soffit-forming face 61 are planar with their planes extending orthogonally to one another.

Covering elements are fitted onto the supporting structure of the support arrangement 1. In particular, they are fitted to the backing board 3.

In FIGS. 3 and 7 and 8 there are only a series of L-shaped brick slips 4 arranged on the backing board 3, 103, while in FIGS. 4 to 6 and 9 there are a series of L-shaped brick slips 4 and rectangular brick slips 5 arranged on the backing board 3, 203 although alternative arrangements of brick slips will be apparent to the skilled person. The backing boards 3, 102, 203 are shaped to correspond to a brickwork pattern, such as stretcher, stack, header, English or Flemish brick bond, so that covering elements, for example the slips 4, 5, may be applied to the backing member to generate said brickwork pattern.

Covering elements other than brick slips, such as composite slips, may also be used with the support arrangement 1.

The brick slips 4, 5 are adhered to the backing board 3 by adhesives 6 (see FIG. 4) and by mechanical fix however it is not necessary to adhere the brick slips 4, 5 to the backing board 3 as they can be fixed via a mechanical fix. There are numerous known ways to mechanically fix a brick slip to a surface.

The L-shaped brick slips 4 are disposed on both the fascia-forming face 60 and the soffit-forming face 61. Specifically, the longer portion of the L-shape extends along the soffit-forming face 61, with the short portion on the fascia-forming face 60, or vice-versa. The rectangular brick slips 5 are disposed on the soffit forming face 61 or fascia forming face 60 only.

As mentioned, the support arrangement 1 has an attachment means/arrangement 10 to enable the support arrangement 1 to be attached to a building or building component, the attachment arrangement 10 in this embodiment being an attachment member 10 being an attachment channel 10. A plurality of attachment channels of the attachment means 10 may be provided, as in FIG. 9 showing attachment channels 10a, 10b (see description below).

The attachment channel 10 and the backing board 3 are separately formed bodies which are attached to one another in the support arrangement 1.

- the attachment channel 10 has a longitudinal development with a U-shaped cross section.

The attachment channel 10 is located to the rear of the fascia-forming face 60 and it is proximal an upper portion of the fascia-forming face 60. In particular, the attachment channel 10 sits at the right angle of the L-shaped brick slips 4 that forms a part of the face of a building in use.

The top of the attachment channel 10 is flush or near flush with the top of the fascia-forming face 60. The top of the attachment channel 10 extends over the top edge of fascia-forming face 60 when the support arrangement 1 is orientated upright as it would be when fitted to a building component. The upright orientation is shown in the drawings, see especially FIG. 4 showing the top of the attachment channel 10 extending over the top edge of the backing member 60. This may not be the case, however, as shown in FIG. 7 in relation to the support arrangement 101. The skilled person will recognise that the precise placement of the support channel 10 can be modified relative to the fascia-forming face and the soffit-forming face to determine the location of the covering elements on the support arrangement 1 relative to masonry of a masonry support surface of a building or building component to which the support arrangement is attached. The channel 10 may be moved relative to the fascia-forming face and the soffit-forming face by using a thicker board 3 in the fascia-forming face 60 or the soffit-forming face 61 to provide the slips 4 and/or 5 flush with masonry of a masonry support surface of a building or building component.

The attachment arrangement 10 defines the support framework 2, 102 to which the backing board 3 and/or covering elements 4, 5 is/are fixed in use, and it is engageable with fixings of a mount for mounting the support arrangement 1, 101, 201 on a building. The attachment channel 10, or the attachment channels 10a, 10b alone define the support framework 2, 102 in the embodiments depicted.

The support arrangement 1 according to the invention does not have a plurality of separate, spaced apart, support gussets. In particular, there are no support gussets that are interconnected via the elongate attachment channel 10 and that extend perpendicularly from the elongate attachment channel 10.

In the support arrangement 1 according to the invention the attachment channel 10 is fixed directly to the backing board 3, without requiring further support members or gussets. The attachment channel 10 of support arrangement 101 is fixed directly by welding to the backing member 103.

In the support arrangement 1 according to the invention the attachment channel 10 defines alone the supporting structure/framework 2 to which the backing board 3 is directly fixed, and it is engageable with fixings of a mount for mounting the support arrangement 1 on a building.

The attachment channel 10 has a longitudinal extension so as to span all the adjacent L-shaped brick slips 4 (and all the adjacent rectangular brick slips 5 if provided) intended to be associated to the support arrangement 1.

The backing member 3 has a longitudinal extension so as to span all the adjacent L-shaped brick slips 4 (and all the adjacent rectangular brick slips 5 if provided) intended to be associated to the support arrangement 1. The backing member 3 has a longitudinal extension corresponding to the longitudinal extension of the support arrangement 1.

The longitudinal extension of the attachment channel 10 is less than the longitudinal extension of the backing board 3.

The attachment channel 10 has a base 15 with two mutually opposing sidewalls 16a, 16b (see especially FIG. 4) that extend perpendicularly from the base 15, and an opening that is mutually opposing the base 15. The attachment arrangement 10 further has a retaining arrangement to retain fixing elements movably within in the attachment arrangement 10. In this embodiment, the retaining arrangement is formed by retaining lips 11, wherein the opening has two mutually opposed retaining lips 11 that extend from the upper portion of the sidewalls 16a, 16b to project over the opening.

Fixing elements such as a nut or bolt or similar element can be inserted into the attachment channel 10 to enable the support arrangement 1 to be fixed to a building or building component. For example, a spring nut can be inserted into the attachment channel 10 and slid along the attachment channel 10 to a desired location, thereby altering the final position of the support arrangement 1 relative to a mount. The spring biases the nut towards the opening and the retaining lips 11 retain the spring and the nut within the attachment channel 10 such that a bolt can easily engage with the nut. Alternatively, a machined block (not shown) having an aperture for receiving a bolt could be used within the attachment channel 10. The orientation of the attachment channel 10 and the fixing elements is such that fixing means can be inserted vertically downwards through a building component to engage with the fixing elements thereby fixing the support arrangement 1 to a building component.

The attachment channel 10 is arranged extending along one edge portion of the backing board 3 such that fixings can attach to the edge of the backing board 3 when mounting the support arrangement 1.

The attachment channel 10 is formed from steel. In particular, the attachment channel 10 is the only steel component of the support arrangement 1.

The supporting structure 2 consists only of the attachment channel 10 and backing member 3.

The attachment channel 10 has through openings 9 for receiving rivets (not shown) that extend into the backing board 3 thereby fixing the backing board 3 to the attachment channel 10. More in detail, there are a first set of through openings 9′ defined on the base of the attachment channel 10 that are that are spaced apart along the longitudinal extension of the attachment channel and that are intended for receiving rivets for fixing the attachment channel 10 to the fascia-forming face 60. More in detail, there are a second set of through openings 9′ defined on the sidewalls of the attachment channel 10 that are that are spaced apart along the longitudinal extension of the attachment channel and that are intended for receiving bolts for fixing the attachment channel 10 to the soffit-forming face 61.

Advantageously, the backing board 3, 103, 203 spans the brick slips 4, 5 so that it acts as connecting member for them.

In a further possible embodiment, the backing board 3 can be made of steel. In a further possible embodiment, the support arrangement 1 has a supporting structure 2 that is defined by the attachment channel 10 and also by the backing board 3.

In use, the support arrangement 1 can be prefabricated to a desired shape and size before fitting on a building. Initially, the backing board 3 is cut to size and then the attachment channel 10 is fixed to the backing board 3. This can be any suitable fixing such as a screw and washer, pop rivet, spring clip, or any suitable fixing means. Brick slips of desired size and shape are prepared and are bonded to the backing board 3 using a grout/bonding method and/or mechanical fixings.

FIGS. 7 to 8 show a second embodiment of a support arrangement according to the invention referred to generally as reference numeral 101. The support arrangement 101 has all the features of the support arrangement 1 as described above with the only exception that there is no rectangular brick slip 5. Advantageously, this embodiment may define a lintel for bricks in order to cover the top of openings above windows. The embodiment shows part of a lintel 103 which operates in the same manner as the backing board 3 previously described. Lintel 103 comprises a fascia-forming face 160 and a soffit-forming face 161.

FIG. 9 shows a third embodiment of a support arrangement according to the invention referred to generally as reference numeral 201. The support arrangement 201 has all the features of the support arrangements 1, 101, as described above with the only exceptions that there is an L-shaped brick slip 4 and a rectangular two courses of rectangular brick slips 5, and consequently that the backing board 203 has a greater width compared to the backing boards 3, 103 of the preceding embodiments giving the support arrangement 203 greater depth compared with the previous embodiments. The support arrangement 203 also has a support framework 202 comprising two attachments channels 10a and 10b in order to maintain rigidity of the support arrangement 203 with increase depth. The attachment channels 10a, 10b are each manufactured according to the channel 10 of the previous embodiments. The attachment channel 10a is configured in the support arrangement 203 in the same manner as the channel 10 is configured in the support arrangement 3, 103 according to the previous embodiments. The attachment channel 10b is configured in the support arrangement spaced apart from the attachment channel 10a over a depth of the backing board 3. The attachment member 10b extends longitudinally in respect of the backing board. The second attachment channel 10b is displaced from the first attachment member in a depth-wise direction of the supporting arrangement. The attachment channel 10a extends over the two board portions 60, 261 of the backing board, receives both board portions 60, 261, and is secured to both board portions 60, 261, whereas the attachment channel 10b receives board portion 261 only and is secured to board portion 261 only. The channels 10a, 10b extend over the one or more board portions 60, 261 in a parallel manner. The channels 10a, 10b extend longitudinally in respect of the board portions 60, 261.

The attachment channels 10a, 10b and the backing member are separately formed bodies which are attached to one another in the support arrangement 201. The attachment channels 10a, 10b are independently attached to the backing board 203 in the support arrangement 201. The attachment channels 10a, 10b are independently attached to the second portion 261 in the support arrangement 201.

The support arrangement 1 further comprises clipping means 20 that are provided to clip one or more end bricks to the backing member 3. The clips 20 are provided to clip one or more end bricks to the support arrangement 1. The clips 20 comprise a metal bracket 20 having a first portion configured to be fastened to a covering element and a second portion configured to be fastened to the backing member. In the embodiment of FIGS. 3 to 6, because the backing member 3 is a cement backing board 3, the clips 20 can be fastened to the backing member 3 at any position along a width of a longitudinal end of the backing member 3 by drilling into the backing board 3. As shown in FIGS. 4 and 6 there are two clips 20 along each longitudinal end of the backing member 3 to clip the L-shaped slip 4 and the rectangular slip 5 to the backing member 3. Whereas in FIG. 1 there is just one end clip at each longitudinal end of the backing member 3 to clip the L-shaped slip 4 to the backing member. In the embodiment of FIG. 7 where the backing member is a metal or metal alloy or steel backing board 3, apertures may be preformed along a width of a longitudinal end of the backing member 3 for fastening the clips 20 to the backing member 3 at desired locations. The clipping means 20 comprise a metal bracket that is substantially C-shaped. The clips 20 comprise a metal bracket having: a first portion configured to be inserted into a seat defined in an end brick, a second portion configured to be mechanically fastened to the backing member, and a third portion connecting the first portion to the second portion and having an extension wider that the thickness of the backing board.

Preferably, the support arrangement 1 further has a connecting arrangement (not shown) that is provided to connect one or more adjacent bricks to the support arrangement.

In the preceding discussion of the invention, unless stated to the contrary, the disclosure of alternative values for the upper or lower limit of the permitted range of a parameter, coupled with an indication that one of the values is more highly preferred than the other, is to be construed as an implied statement that each intermediate value of the parameter, lying between the more preferred and the less preferred of the alternatives, is itself preferred to the less preferred value and also to each value lying between the less preferred value and the intermediate value.

The features disclosed in the foregoing description or the following drawings, expressed in their specific forms or in terms of a means for performing a disclosed function, or a method or a process of attaining the disclosed result, as appropriate, may separately, or in any combination of such features be utilised for realising the invention in diverse forms thereof.

SUPPORT ARRANGEMENT FOR COVERING ELEMENTS OF A BUILDING

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