Patent Application
20200318354
This application claims priority to GB1904977.4, entitled “A Support Arrangement for Covering Elements of a Building,” filed on Apr. 8, 2019, the disclosure of which is hereby incorporated by reference in its entirety.
The present invention relates to a support arrangement for supporting covering elements of a building.
In construction, there has been an increasing trend towards the use of masonry slips, such as brick slips, which are often bonded to steel backing 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. 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.
Concerns are being raised by certain sectors that the connection between the masonry slips and the steel backing board will weaken over time and the slips will come loose and fall from height. This is particularly concerning when the masonry slips form a part of a soffit and are therefore located vertically beneath the backing board, as gravity is constantly pulling the masonry slips away from the backing board. To mitigate this risk, there have been some recent improvements in how brick slips are bonded to backing boards. Typically, brick slips are bonded to steel backing boards using epoxy resins. Some backing boards also have cut-outs to receive the epoxy resin and, when the resin sets, this provides a lock between the brick slip and the backing board. A further solution is to mechanically fix each brick slip to the backing board. This typically requires drilling holes in the steel backing board so that bolts can then be fixed to the backing board via the holes to retain the slips on the board. This process is time consuming and, to save time, only minimal amounts of mechanical fixes are applied, and usually only in tandem with epoxy resins and not as a substitute.
Recent reviews of epoxy resins have suggested that some resins that are used for bonding brick slips to backing boards emit harmful toxins when burnt, and it is these toxins that can result in fatalities for occupants of a building containing such resins in the event of a fire. This is of particular concern in tall (over 18 metres) residential buildings and in the UK there are specific regulations to control the use of such resins in building components. It is expected that these regulations will be developed to further restrict usage of resins. There is therefore a need to reduce or replace the use of certain epoxy resins in these building components.
It is an object of the present invention to obviate or mitigate the problem of the use of adhesives to bond covering elements such as brick slips to supporting structures such as backing boards.
It is a further object of the invention to mitigate or obviate the problem of drilling steel backing boards to provide apertures for mechanically fixing masonry slips thereto.
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 that is operable to receive covering elements and is formed at least partially from non-metallic material, the support arrangement further comprising an attachment means for attaching the support arrangement to a building or building component such that it forms a part of the building.
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 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 support arrangement comprises a supporting structure.
Ideally, the backing member is supportable by the supporting structure.
Preferably, the backing member comprises one or more backing boards.
Preferably, the supporting structure is a supporting frame to which the backing member is fixable or fixed.
Ideally, the supporting structure comprises a plurality of spaced apart support members, the spacing between support members being traversable by the backing member.
Advantageously, using spaced apart support members instead of a continuous supporting structure can reduce the overall mass of the support arrangement.
Preferably, the backing member is fixed to the supporting structure by fixing means such as a screw and washer, pop rivet, spring clip, or any suitable 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.
Ideally, the support members are sized and/or are spaced apart at predetermined distances according to the size of the covering elements to be fitted to the support arrangement such that the support members are fixed to the backing member by fixing means that are positioned between covering elements when the covering elements are applied to the backing member.
Advantageously, due to the size and/or predetermined spacings of the support members, fixing means for fixing the backing member to the support members 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.
Preferably, the support members are directly or indirectly connected to one another thereby providing a supporting frame to which a backing member/board can be fixed.
Advantageously, the support member framework can be designed and manufactured in a factory, thereby minimising onsite construction times.
Ideally, the supporting frame, most preferably the support members, define a virtual plane to which a backing member/board can be mounted.
Ideally, one or more support members are elongate support members.
Preferably, the supporting structure is adapted to receive mechanical fixings such as screws or bolts.
Advantageously, this enables the backing member/board to be mechanically fixed to the supporting structure.
Ideally, the supporting structure comprises apertures sized to receive fixings such as screws or bolts.
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.
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.
Preferably, the support arrangement has a fascia-forming face.
Advantageously, the support arrangement may be used to form at least part of the fascia of a building.
Ideally, the support arrangement has a soffit-forming face.
Advantageously, the support arrangement may be used to form at least part of the soffit of a building.
Ideally, the fascia-forming face and/or the soffit-forming face are defined by the backing member.
Ideally, the fascia-forming face and the soffit-forming face are planar.
Preferably, the fascia-forming face and the soffit-forming face are arranged orthogonally to one another.
Preferably, one or more support members are fixed to the attachment means.
Ideally, one or more elongate support members are arranged extending away from the attachment means, most preferably, such that the longitudinal axis of the support member is perpendicular to the longitudinal axis of the attachment means.
Ideally and advantageously, the attachment means is further functional as a support member and can form a part of the supporting structure.
Preferably, the support members and the attachment means can be arranged defining a virtual plane to which a backing member/board can be mounted.
Advantageously, bespoke supporting structures can be produced by the manufacturer to accommodate a variety of shapes and sizes of backing members/boards.
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 (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 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 support members and/or the attachment means are formed at least partially from metal, most preferably at least partially from steel.
Ideally, one or more of the support members are formed from metal angles, most preferably, from folded metal angles.
Preferably, the support members extend along the rear of the fascia-forming face and/or the soffit forming face.
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.
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 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.
According to a second aspect of the invention there is provided a building assembly comprising a support arrangement for supporting covering elements on a soffit of a building, the support arrangement comprising a backing member that is operable to receive covering elements and is formed at least partially from non-metallic material, the support arrangement further comprising an attachment means for attaching the support arrangement to a building or building component such that it forms a part of the building, 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.
Ideally, the mount is adapted to receive and retain the support arrangement thereto.
Ideally, the mount is adapted to engage with the support arrangement attachment means to mechanically fix, interlock or hang the support arrangement therefrom.
Preferably, the mount is adapted to form at least a part of a lintel or soffit supporting structure.
Ideally, the mount comprises a support surface for masonry.
Preferably, the support surface is an elongate support surface.
Ideally, at least a portion, most preferably each longitudinal end portion, of the support surface is shaped to fit between rows of masonry blocks/bricks.
Advantageously, the end portions can be embedded in a leaf of a wall, with the support surface extending over an aperture in the wall that is formed for a window or door. Masonry can then be placed on the support surface to continue the construction of the leaf over the aperture.
Preferably, the mount comprises fixings, and/or is adapted to receive fixings, the fixings being operably engageable with the attachment means to retain the support arrangement on the mount.
Preferably, the engagement between the mount and the attachment means is adjustable.
Advantageously, this provides further adjustability of the location of the cover element support arrangement on the building facing even after the mount has been mounted on a surface such as an inner leaf of a cavity wall.
Ideally, the mount comprises one or more male fixing elements operable to engage with a female fixing element on the support arrangement.
Alternatively, the mount comprises one or more female fixing elements operable to engage with a male fixing element on the support arrangement.
Alternatively again, the mount comprises an interlock arrangement to interlock with the attachment means.
Preferably, the mount comprises one or more apertures sized to receive a male fixing element such as a bolt.
Ideally, the one or more apertures are located at or about the masonry support surface.
Preferably, the one or more apertures are elongate.
Advantageously, the fixing elements can be moved within the aperture to adjust the position of the support arrangement before fixing the support arrangement to the mount.
Ideally, the mount is mountable on a surface such as an inner leaf of a cavity wall.
Preferably, the mount has mounting means, most preferably adjustable mounting means, for mounting the mount to a surface.
Advantageously, the adjustable mounting means allow the position of the mount relative to the surface to which it is fixed to be adjusted after installation. This allows fine adjustment of the position of the building component and this correspondingly allows fine adjustment of the location of the cover element support arrangement on the face/soffit of the building.
Preferably, the mounting means comprises one or more brackets operable to be mounted to a surface such as an inner leaf of a cavity wall.
Ideally, the masonry support surface is engaged with and is supported by the one or more brackets.
Ideally, the one or more brackets comprise a slot to receive a bracket fixing means.
Preferably, the mount comprises a lock washer that can be locked relative to the slot in more than one configuration.
Advantageously, changing the configuration of the lock washer relative to the slot can adjust the location of the bracket relative to the surface to which the bracket is fixed via a bracket fixing means that extends through the slot and into the surface.
Ideally the lock washer comprises a body; a protrusion disposed on one face of the body, the protrusion being configured to be disposable in a corresponding slot of a bracket; an engagement means disposed on the protrusion, the engagement means being configured to be engageable with the slot of the bracket and to hold the body stationary with respect to the bracket; and a slotted hole disposed in the body, the slotted hole being configured to admit a shaft of a bracket fixing means therethrough so as to allow lateral movement of the body relative to the shaft while the shaft is admitted through the slotted hole.
Ideally, the mount comprises a spacer insertable between the bracket and a mounting surface in use.
Preferably, the spacer is a shim.
Advantageously, this provides yet further adjustability by altering the position of the bracket, and therefore the masonry support surface, relative to the surface to which the mount is fixed.
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 providing a cementitious/composite backing member and an attachment means and fixing the attachment means to the cementitious/composite backing member.
Ideally, the method comprising the step of forming a supporting structure and fixing the supporting structure to the cementitious/composite backing member.
Advantageously, the supporting structure and the attachment means can be formed as a single structure which can be fixed to the cementitious/composite backing member in a single step.
Ideally, the method comprising the step of connecting a plurality of supporting members to form a supporting frame to which a backing member can be fixed.
Preferably, the method comprising the step of mounting the backing member to supporting structure and/or 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.
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.
In
The support arrangement 1 further has an attachment arrangement 10 to enable the support arrangement 1 to be attached to a building or building component, the support arrangement 10 in this embodiment being an attachment channel 10. 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. The top of the attachment channel 10 is flush with the top of the fascia-forming face when the support arrangement 1 is orientated upright as it would be when fitted to a building component. The support members 6 are interconnected via an elongate attachment channel 10 that extends between the support members 6. The longitudinal axis of the attachment channel 10 is perpendicular the longitudinal axis of the support members 6. Specifically, the longitudinal axis of the attachment channel 10 is perpendicular to the longitudinal axis of part of the flat portion 7 that is fixed to the attachment channel 10. The flange 8 of each support member 6 is shaped to extend along a portion of the attachment channel 10. The attachment channel 10 is bifunctional in that it forms a part of the support framework to which the backing board 3 is 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 base 15 with two mutually opposing sidewalls 16a, 16b 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 (see
The support arrangement 101 has a backing board 103 formed from fibre cement boards. The backing board 103 is shaped to form a soffit surface having three rows 125a, 125b, 125c of brick slips wherein the middle row 125b is offset relative to the top 125a and bottom 125c row to replicate the appearance of a traditional brick wall. One row of the brick slips 125a forms a part of the face of the building when the support arrangement 101 is mounted, and each brick slip in this row has a right angle turn which extends out from the soffit surface and upwards along a portion of the face of the building. In this embodiment, the flat portion 107 of the support members 120, 121 extends perpendicular to the plane of the sidewall 116a of the attachment channel 110 and is coplanar with the plane of the base 115 of the attachment channel 110. The attachment channel 110 sits at the right angle of the brick slips 125a that form a part of the face of a building, and the support members 120, 121 extend back across the rows of brick slips 125a, 125b, 125c. The support arrangement 101 is shaped such that it can interlock with an adjacent support arrangement 101 of the same shape and interlock such that a continuous surface is formed. The rows 125a, 125b and 125c are all of equal length but the middle row 125b is offset relative to the upper and lower rows 125a, 125c, thereby creating a projection at one end that is engageable with an opening in a similar support arrangement, and an opening at the opposing end of the row 125b to receive a similar projection of an adjacent similar support arrangement. The shorter support members 121 extend across two rows 125a, 125b, terminating at the location of the third row 125c. The longer support members 120 extend between brick slips of the third row 125c.
The third embodiment of a support arrangement is shown in
Further provided by the invention and as shown in
The mount 50 further has two spaced apart brackets 54a, 54b that each support the masonry support surface 51. The brackets 54a, 54b have a slot (not shown) and a lock washer 55a, 55b arranged to attach the brackets 54a, 54b to a wall with bolts 56. The bolts 56 extend through the slot and are fixed relative to the slot by the lock washers 55a, 55b. Each lock washer 55a, 55b has a body (not shown) and a protrusion (not shown) disposed on one face of the body. The protrusion is configured to be disposable in a corresponding slot of a bracket 54a, 54b. The lock washer further has an engagement arrangement (not shown) disposed on the protrusion that is configured to be engageable with the slot of the bracket 54a, 54b and hold the body stationary with respect to the bracket 54a, 54b. Further, there is a slotted hole (not shown) disposed in the body configured to admit a shaft of a bolt 56 therethrough to allow lateral movement of the body relative to the shaft while the shaft is admitted through the slotted hole. The mount 50 further has a shim 57a, 57b located and the wall, providing adjustability of the building arrangement.
In use, the support arrangement 1, 101, 201 can be prefabricated to a desired shape and size before fitting on a building. Initially, the supporting structure 2, 102, 202 is manufactured by assembling and welding together or otherwise connecting support members 6, 120, 121, 231, 232a, 232b, 232c to produce a desired framework. Ideally, although not essentially, an awareness of the final brick slip location should be considered when designing the support member framework. For example, in the first and second embodiments 1, 101, the fixings of the support members 6, 120, 121 are located between the brick slips. Either before or after assembling the supporting structure 2, 102, 202, holes should be drilled through the support members 6, 120, 121, 231, 232a, 232b, 232c. The attachment channel 10, 110, 210 should also be attached to the supporting structure 2, 102, 202 at this stage. The backing board 3, 103 is cut to size and then a mechanical fix (see
The support arrangement 1, 101, 201 is mounted to a wall by first attaching a mount 50 to the surface of the wall. The brackets 54a, 54b of the mount 50 are first attached to the surface of the wall using a bolt 56 for each bracket 54a, 54b. A lock washer 55a, 55b is also used. The bolt 56 passes through the lock washer 55a, 55b and a slot of the bracket 54a, 54b and into the wall. The lock washer 55a, 55b can fixedly adjust the location of the bracket 54a, 54b relative to the placement of the bolt 56 after the bolt has been inserted into the wall. This enables the final location of the support arrangement 1, 101, 201 on the building to be adjusted even after the bolt has been inserted into the wall. Once the brackets 54a, 54b are fixed to the wall, the support arrangement 1, 101, 201 can then be fixed to the masonry support surface 50. The location of the attachment channel 10, 110, 210 relative to the fascia forming face 61 is such that when the support arrangement 1, 101, 201 is fitted to the masonry support surface 50, covering elements on the support arrangement 1, 101, 201 form a continuous, preferably patterned surface, with the brickwork that is disposed on and supported by the masonry support surface 50. Initially, spring nuts 240 are inserted into the attachment channel 10, 110, 210 and moved along the attachment channel 10, 110, 210 to the location of the slots 52a, 52b in the masonry support surface 50. Then bolts 53a, 53b are inserted through the slots 52a, 52b and the support arrangement 1, 101, 201 is raised, with the attachment channel 10, 110, 210 being located at the bolts 53a, 53b. The bolts 53a, 53b are tightened through the spring nuts 240 to fix the support arrangement 1, 101, 201 to the mount 50.
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.
| Number | Date | Country | Kind |
|---|---|---|---|
| 1904977.4 | Apr 2019 | GB | national |
