GB2449336A

GB2449336A - Masonry Wall Panel

Info

Publication number: GB2449336A
Application number: GB0807563A
Authority: GB
Inventors: Adrian Galvin
Original assignee: Individual
Current assignee: Individual
Priority date: 2007-05-01
Filing date: 2008-04-25
Publication date: 2008-11-19
Also published as: GB0708486D0; GB0807563D0

Abstract

A masonry wall panel 1 having horizontal support fins 2. The masonry wall panel has means by which it can be attached to other wall panels. Also disclosed is a support system constructed from steel, stainless steel, or other suitable materials, including aluminium, or GRP, which is designed to tie together masonry, including bricks, and concrete blocks. When the masonry is correctly fitted and bonded into the support, it enables a masonry wall to be pre-fabricated, and later, moved into position as a ready assembled wall panel. The support consists of a vertical backing sheet, (perforated where required) 3, to which, one side is fitted with number of fins 2, with one edge folded, in cases where increased fixing area is required. These fins can be bonded, or fixed mechanically, as can the additional support posts on the other side of the backing sheet. The fins alternate with rows of masonry, and can be perforated, to provide increased bonding strength as the bonding agent can flow through the perforations to lock the masonry in place.

Description

1 2449336 Masonry Wall Structural Panel

Technical field

The present invention relates to a system for supporting structural masonry walls to allow them to be built in one position, and later, erected as required.

Background of the invention

It is wide spread practice, in the building industry, to tie the outer skin of brick work to an inner skin of brick, or block work, with a cavity left between the two skins of masonry, forming what is commonly known as a cavity wall. The two skins are usually tied together with one of the many forms of wire brick or wall ties which are available on the market at present. It is also quite common practice to tie the outer veneer of brick work to timber studs with similar ties. These ties may be placed in rows vertically and horizontally, with the ties being set at a specified distance apart.

Many of the brick ties mentioned are embedded in the mortar between horizontal rows of bricks, bridging the cavity, however, these ties can provide localized pockets of strength, while areas not tied, are left unsupported.

The use of wind posts in conjunction with ties is wide spread and addresses some of the strength issues with masonry walled construction, however, some areas may still be left unsupported.

It is well known that building domestic and commercial premises is a long and involved task susceptible to many variables, including weather, storage of materials on site, and variation in availability of labour. There have been many inroads made into the supply of pre-formed buildings, however, Many of these are of full timber, or hybrid steel/timber construction. Masonry and mortar is a very old, and still, a very popular way of constructing buildings. A building constructed of masonry is quite robust, and is also thermally and acoustically efficient. A pre fabricated building of brick veneer, or cavity wall construction, erected in panels, would allow a solid carcass of masonry wall to be constructed, in a relatively short time. This would combine the popular characteristics of a masonry building with the short build times, and convenience of pre fabricated buildings.

Summary of the invention

The inherent strength of the invention, allows it to be lifted into position, and, also increases the structural integrity of a wall to enable it to withstand greater static structural, and randomly imposed, live loads, whilst blending in with almost any Street's appearance.

The present invention, in one form, although it may not be the only, and not encompass all variations, comprises a backing sheet, to which vertical, inner supports, and outer, horizontal flat fin plate supports, are fixed. The present invention can be constructed from Stainless Steel, Mild steel, Aluminium or non metallic materials such as GRP. The inner posts can be fixed to posts of an inner leaf of the present invention, where the two panels are positioned back to back, for cavity wall construction. The inner posts can alternatively be fixed to timber studs and noggins, and dry lining, to form a wall of brick veneer. The outer support plates can have an up turned flange, and fit between successive runs of brickJblock work. These horizontal flats can be perforated to allow wet mortar, mortar with latex, (or other additives), or other, more flexible, bonding agents, used instead of mortar, to penetrate, and lock the bricks/blocks in position.

Proprietary brick ties can be fixed to the present invention where required, mainly in cases involving extending existing walls. A wall constructed from the present invention can also be fixed to the foundation to increase stability.

The method of construction involved in the present invention, allows the walls of a building, including the dry lining, to be constructed off site and installed complete. Electrical and Plumbing, can be routed through cut out holes, in the vertical, inner supports prior to delivery to site. All that is then required, is to make the final connections to the mains, and the systems are ready to use. Alternatively, the non-masonry portion of the walls can be erected on site separately. The brick/block in fill can be laid on site, at a later date, with great speed.

This is possible because the bricks/blocks are laid in specifically positioned rows as designated by the horizontal fun plates.

The present invention can be formed to suit almost any shape required, and can support structural steel and woodwork.

Doors, Windows and arches can be cut into shape prior to fabrication, which allows bricks to be laid to suit.

In some instances, a double brick wall may be required, in which case, horizontal masonry support flanges can be fixed to both sides of a backing sheet. This may be particularly suitable for exterior walls, such as those required for boundary or retaining walls.

Please refer to the attached drawings, which provide reference to the numbered points as follows.

Figure 1 shows an isometric, external view of the outer leaf of a corner between walls constructed using a version of the present invention Figure 2 shows an isometric, internal view of the outer leaf of a corner between walls constructed using a version of the present invention Figure 3 shows a plan view of the present invention as used in a brick veneer configuration Figure 4 shows a plan view of the present invention as used in a cavity wall configuration Figure 5 shows alternative horizontal plate configuration and an alternative, vertical backing sheet configuration as used in brick veneer configuration Figure 6 shows alternative horizontal plate configuration and an alternative, vertical backing sheet configuration as used in cavity wall configuration Figure 7 shows section A-A through figure 1 Figure 8 shows section B-B through figure 2 Figure 9 shows an internal elevation of a wall constructed of the proposed invention with brickwork and dry lining removed for clarity.

Figure 10 shows a portion of wall constructed using an alternative version of the present invention.

Detailed Description of the drawings

These notes refer to the numbered items as indicated by pointers.

Common items in the current invention's construction has resulted in the same numbered item appearing in more than one drawing

description, as required.

Referring to Fig.. 1, In the present invention, the outer leaf of the wall, 1, can be constructed from standard Bricks or Blocks. Stone or other masonry cladding materials can also be used. The chosen masonry for the outer leaf is laid between 2, the horizontal brick supports. The horizontal supports are fixed to the main backing sheet by mechanical means, and are spaced to alternate with courses of masonry. These can be perforated if required, and in some cases, also, fabricated to allow vertical pins, 16a, to be fitted through the masonry, acting as a secondary, reinforced fixing to the steelwork.

The Steelwork is designed, fabricated and positioned so that the masonry and mortar gain the best possible support. The mortar is laid between courses of bricks. The Mortar can flow between the horizontal supports and the bricks! blocks to hold them in position.

The whole wall must be supported until the mortar dries. The backing sheet, 3, keeps the brick faces level as they are pushed back tightly against it.

The horizontal support flanges are fixed to the vertical, backing sheet 3, which can be perforated if required. The backing sheet ties the horizontal, outer support, 2, with the vertical backing support posts, 4.

The vertical posts, 4, are fixed to the backing sheet via mechanical means. They can be fabricated from Stainless or Galvanized steel, Aluminium or plastics such as GRP or any other suitable material. The aperture of the vertical posts and the horizontal flanges, 2, can be altered to suit different sized bricks or blocks. The corner joints can be reinforced by bolting in supports, 21, fabricated from Stainless Steel, Mild Steel or other suitable materials. A 90 degree corner is shown, however, any angle is possible The Horizontal support flanges, 2, combined with the backing sheet, 3, and the vertical inner posts, 4, are sized to provide enough stiffness to the wall panel to allow it to be lifted and installed.

In Figure 2, is illustrated an internal view of a wall similar to Figure 1. A wall constructed using the present invention can be used in conjunction with Timber or metal studs, 28, to form a building of Brick veneer type construction. In the case of brick veneer construction, the present invention gives an excellent base for fixing interior dry lining (plaster board), 7a.

Each panel can be joined to another, either horizontally or vertically, by means of brackets, 6, continuous strips, or welding. In a corner, where an extra reinforcement may be required, an angle, 21, can be fixed to add extra strength, for a joint secured by means of welding, mechanical fixings, or adhesives. A 90 degree angle is shown, however, any angle is possible.

Once installed, the walls can be fixed to the foundations, 16, to give added strength to the structure. An extra set of vertical pins, 16a, can be used where extra secondary masonry reinforcement is required. These pins fit through the masonry and horizontal fin plates locking the masonry in position.

Figure 3, shows a plan detail of a wall of brick veneer, constructed using the present invention. The outer skin of masonry is shown hatched, and laid beneath the horizontal brick support, 2, with vertical pins, 16a, fitted through the masonry, and steel horizontal fins, acting as a secondary, reinforced fixing to the steelwork. The studs can be made of timber or metal, and are shown fixed to the current invention in various ways. Brackets, 4a, may be used in some cases, while other instances may call for the timber being fixed with screws direct to the backing sheet, 3. Additional vertical wind post style stiffeners, 4b, may be required and can be fixed to the backing sheet, 3. Centres of the vertical posts, 9, could be case specific, and could be determined by a structural engineer when required. In the case of Brick veneer construction, floor and ceiling joists, 5, can be supported by proprietary joist hangers, (also shown in Figures. 7, 8, and 9), or fabricated brackets. These may be fixed to the backing sheet or bear on a leaf of masonry.

Panels can be joined by site welding, or, with flanges, angles, brackets, 6, lap plates, or folded laps, to provide increased wall length or height where required. Dry lining / plaster board, 7a, can be fixed to wall studs and noggins. Damp proof membrane, 8, can be applied where required.

The wall thickness, 10, can be varied to take into account such Factors, as extra insulation, and is also dependant on building and Architectural requirements In Figure 4, is illustrated a plan view of a wall constructed using the present invention and constructed in a cavity wall type configuration.

A wall constructed using the present invention can be used in conjunction with another similar wall to create a completed wall containing an outer and inner leaf of masonry.

The outer and/or inner leaves, 1 and la, of the wall can be constructed from standard Bricks and Blocks. Stone, or other masonry based materials can also be used. The inner and outer skins of masonry is shown hatched and laid beneath the horizontal brick support, 2 and 18. Extra reinforcement pins, 16a, can be fitted where required. The backing sheets, 3, form the cavity, and the vertical members, 4, 4a, and 4b can be fixed to each other, within the cavity, to tie the outer and inner leaves of the wall together. The need for insulated spacers may be required, and can be constructed from rubber or other similar materials, to add extra insulation between steel surfaces if cold bridging is a problem. Centres of the vertical posts, 9, can be case specific, and could be determined by a structural engineer when required. Once installed, the walls can be fixed to the foundations, 16, to give added strength to the structure.

Floor and ceiling joists, 5, can be hung in brackets fixed to the backing plate or designed to bear on the inner leaf of masonry. Panels can be joined by site welding, or, with flanges, angles, brackets, 6, lap plates, or folded laps, to provide increased wall length, or height, where required. Dry lining / plaster board, 7a, can be fixed to wall.

Damp proof membrane, 8, can be applied where required.

The wall thickness, 10, can be varied to take into account such factors, as extra insulation, and is also dependant on building and architectural requirements Figure 5 shows a plan view of a wall constructed using the current invention in the case of a brick veneer type construction. This figure shows the use of an alternative horizontal plate configuration, as the perforated plates can be replaced by proprietary expanded metal, 15, mesh or similar products. These produsts are available in Stainless Steel or Mild Steel, Aluminium, or GRP, at present, but any suitable plastics or other materials may also be used.

An alternative, vertical backing sheet, 14, can also be used. This could be fabricated from a suitable profile to lessen the need for vertical wind posts, 4a, however, they may still be required, and brackets may still be required for fixing timber stud work.

Figure 6 shows a plan view of a wall constructed using the current invention in a cavity wall situation. This figure shows the wall constructed using an alternative, horizontal plate configuration, and an alternative, vertical backing sheet configuration. In the present invention, the outer and/or inner leaves of the wall, 1 and la, can be constructed from standard Clay Bricks, and Concrete, or similar, Blocks. Stone or other masonry cladding materials can also be used.

The horizontal brick supports, 2 and 18, can be constructed of proprietary expanded metal, 15, mesh or similar products. These produsts are available in Stainless Steel or Mild Steel, or aluminium at present, but any suitable plastics or other materials may also be used.

An alternative, vertical backing sheet, 14, can also be used. This could be fabricated from a suitable profile to lessen the need for vertical wind posts, 4a, however, they may still be required, and brackets may still be required for fixing timber stud work. Floor and ceiling joists can be hung on fabricated brackets, or, in proprietary joist hangers, 5, fixed to the backing plate. They can also be designed to bear on a leaf of masonry.

Insulated spacers can be added as required, and, can be constructed from rubber or other similar materials, to add extra insulation between steel surfaces if cold bridging is a problem.

In Figure 7 is shown a section through a brick veneer wall constructed using one version of the present invention. The outer wall, 1, in this case uses bricks with frogs, however, the aperture can be adjusted to suit common house bricks/blocks or other specified materials. The mortar, 28, is shown locking the bricks in place. The horizontal support flanges, 2, can be seen to alternate with courses of masonry. The backing sheet, 3, can also lined with mortar, or other, adhesive substances, to help hold the masonry in position. The vertical member shown, 4a, can be fixed to the timber studs, 29, using mechanical fixings or adhesives.

Vertical wind post stiffeners, 4b, can be fixed to the backing sheet at appropriate centres, if required.

Floor and ceiling joists, 5, can be hung in fabricated, or off the shelf, proprietary, brackets fixed to the backing plate. One configuration of a vertical joint, 6, is shown. These joints can be fixed as required, to increase the height of a wall constructed from the present invention.

Damp proof membrane, 8, can be applied where required In Figure 8 is shown a section through a cavity wall constructed using one version of the present invention. The outer leaf of the wall, 1, in this case, is shown constructed from standard Bricks. Perforated, horizontal, brick supports, 2, are shown fixed to the main backing sheet, 3, and sit so that they alternate with courses of masonry, locking the bricks/ blocks in position. The vertical members fixed to backing sheet act as wind posts, and joining brackets to the inner leaf. These can also have cut out areas removed, 20, for routing of electrical, data and telephone cables as well as plumbing.

Floor and ceiling joists can be hung in brackets, 5, fixed to the backing plate or designed to bear on the inner leaf of masonry.

Panels can be joined by site welding, or, with flanges, angles, brackets, 6, as shown, lap plates, or folded laps, to provide increased wall length or height where required.

Figure 9 shows an internal elevation of a wall, constructed using the present invention, in a brick veneer configuration. The hidden bricks, which would be shown in dashed lines, on the outside, have been removed for clarity. The horizontal brick support flanges, 2, are shown dashed as they are also on the outside. The aperture, 19, can be adjusted to suit common house bricks/blocks, or other specified materials. The backing sheet, 3, with horizontal members fixed on one side, and vertical members fixed on the other, is shown perforated. Indicative vertical support members, 4b, are shown fixed to the backing sheet.

The brackets, 5, to support floor and ceiling joists, can be proprietary or fabricated, and fixed to the backing plate as shown if required. Structural steelwork, 5a, can also be fixed to the current invention, using fabricated brackets, or can be designed to sit on pad stones integrated into the masonry of the wall. The corner joints, 21, can be reinforced by bolting to supports.

The Lintels, 22, are integrated in the supporting structure of the wall, alleviating the need, in many cases, of fitting specialized Luntels, If a lintel is required, it can be fixed onto a thicker, integrated horizontal plate, or with brackets and bolts. Stud or masonry walls, 23, can be attached to the present invention with brackets and bolts, or welded as desired.

Typical window openings, 24, and door openings, 25, can easily be designed into a wall panel constructed from the current invention.

Windowsills, 27, can be fixed via brackets and/or mortar to the wall panel as required.

In Figure 10, another proposed type of backing sheet is shown. It is of a suitable profile to lessen the need for vertical wind posts. It may be constructed from proprietary panels or fabricated to suit. Brackets may still be required for fixing timber stud work or inner leaf of reinforced wall panel.

Horizontal brick supports, 2, are shown, and the outer leaf of masonry, 1, in this case, is shown as brickwork.

Claims

Claims 1/ A Masonry Wall panel capable of being moved into position, to

form a structural panel of a building, or to be used in retaining, or exterior walls, with the means to be attached to other such panels.

2/ A Masonry Wall panel according to claim 1, where the reinforcing material is fabricated to form fin like supports, which alternate with rows of masonry, where one edge may be upturned to add strength.

3/ A Masonry Wall panel according to claim 1, where the supports in claim 2, may be fixed to a backing panel, allowing the supports to be tied in position.

4/ A Masonry Wall panel according to claims 1, 2, and 3, where the Masonry, supports, and backing panel, may be fixed to additional supports, either perpendicular to, or angled, as in cross bracing.

5/ A Masonry Wall panel according to any of the preceding claims, where vertical timber studs can be fixed to one side to form a masonry veneer type construction.

6/ A Masonry Wall panel according to any of the preceding claims, which may be used in conjunction with, and fixed to, if required, another skin of masonry constructed using a similar panel.

7/ A Masonry Wall panel according to any of the preceding claims, where an additional support can be passed through the masonry and supports in claim 2, for additional strength.

8/ A Masonry Wall panel according to any of the preceding claims, which can be fixed to floor or ceiling joists, or, structural steelwork, where required.

9/ A Masonry Wall panel according to any of the preceding claims, which can be attached to a temporary lifting frame if so required.

10/ A Masonry Wall panel according to any of the preceding claims, where any of the components can be perforated, allowing the bonding agent to flow between masonry and supports.

11/ A Masonry Wall panel according to any of the preceding claims, which can be connected to, and support a roof, where required.

12/ A Masonry Wall panel according to any of the preceding claims, which can be fabricated with openings, often, not requiring lintels, prior to assembly.

13/ A Masonry Wall panel according to any of the preceding claims, which can be manufactured from Steel, Stainless Steel, Aluminium, or other products including GRP.