GB2465377A

GB2465377A - A wall formed with recessed bricks which when assembled form a continuous channel in the surface of the wall to accommodate a flue or flue liner

Info

Publication number: GB2465377A
Application number: GB0820879A
Authority: GB
Inventors: Lee David Mchugh
Original assignee: Individual
Current assignee: Individual
Priority date: 2008-11-14
Filing date: 2008-11-14
Publication date: 2010-05-19
Also published as: GB0820879D0

Abstract

The invention relates to a cavity wall comprising inner 12 and outer leaves (14 figure 5) and a cavity (16 figure 5) between the leaves, wherein one of the inner 12 or outer leaves (14 figure 5) comprises an open channel 30 facing the cavity (16 figure 5). The channel 30 formed in the wall increases the width of the cavity such that a flue, a flue liner or a support for a flue or flue liner can be accommodated in the channel without the need for a chimney or a false chimney breast. The wall is formed from a plurality of interconnecting bricks 24, 26 comprising aligned recesses 28 which define a continuous channel 30 in the outer surface (32 figure 5) of the wall when the bricks are assembled. The bricks are preferably manufactured from concrete with pre-stressed reinforcing bars or stone or ceramic materials. Later embodiments relate to a kit of parts comprising one or more centrally recessed bricks.

Description

Title: Improvements in and relating to walls

Description:

This invention relates to improvements in and relating to walls, and in particular, but without limitation, to walls incorporating flues, Traditionally, houses have been built with chimneys to provide a conduit for the egress of combustion products from fires, but chimneys are expensive to build and maintain. Moreover, since the now almost universal uptake of central heating, fires are commonly employed for their decorative, rather than their heating properties, hence the call for heavy duty chimneys is in decline, As a result, there has been a tendency, in recent years, for new-build homes to be fitted with flues rather than chimneys to reduce building costs and to avoid unnecessary redundancy.

The basic function of a flue is to provide a conduit for exhaust gasses and combustion products from a fire to escape to atmosphere. Several different types of flue are currently available and can conveniently be categorised by their ability to convey different amounts and/or types of exhaust gasses and/or combustion products, In the United Kingdom, a so-called class 1" flue comprises a metal tube with a minimum internal diameter of 7 inches (17 8 cm) A class I flue is suitable for use with many types of fire, including solid fuel (e g coal, wood etc), gaseous fuel e.g. LPG, butane, etc.) and liquid fuel-burning fires (e.g. oil). Since a class 1 flue has a minimum internal diameter of 7 inches (17.8 cm), it can sustain sufficient draw to extract both gaseous (e.g. CO, C02, etc.) and particulate (e.g. soot, embers, etc.) combustion products from the fire. A class 1 flue system is, however, unnecessary in most domestic settings, where there is no need to be able to draw away particulate combustion products, viz, where only a gas fire is installed and in such cases, a so-called "class 2' flue suffices.

A class 2 flue is similar to a class 1 flue, except that its internal diameter is reduced, i.e. only 5 inches (12.7 cm), which means that it cannot sustain as much draw as a class 1 flue, but can, nevertheless, sustain sufficient draw to remove gaseous combustion products from the fire.

A problem with class 1 and class 2 flue systems, however, is that the width of the cavity of a typical cavity wall is only 4 inches (10.2 cm), which means that a false chimney breast is needed to accommodate the flue. A false chimney breast does not serve to contain the combustion products, but merely to encase I conceal the flue.

1 5 In recent years, home builders have installed pre-cast flue systems, which address the above problem and which obviate the need for a false chimney breast. A pre-cast flue comprises a stack of vertically aligned, gas-tight bricks that each has a central slot. When the blocks are sealed one on top of another using a proprietary gas-tight mortar, the slots define a rectangular cross-section tube that can be used as a conduit for combustion products. However, pre-cast flues are susceptible to leaking -if the gas-tight mortar is not properly applied, and obstruction -if the gas-tight mortar is squeezed/extruded into the slot during installation. Moreover, since the width of the slot of a pre-cast flue is typically between 1 to 2 inches (2.5 to 5 cm), over time, it can become blocked by foreign objects, e.g. falling friable mortar, dust and particulate combustion products.

This invention aims to provide a solution to one or more of the above problems.

A first aspect of the invention provides a wall comprising a plurality of interconnecting building elements comprising aligned recesses that together define a continuous channel in the surface of the wall.

A second aspect of the invention provides a cavity wall comprising an outer leaf and an inner leaf comprising a plurality of interconnecting building elements the inner leaf comprising channel in its outer surface.

A third aspect of the invention provides a building comprising a cavity wall, the cavity wall comprising an outer leaf and an inner leaf, wherein the inner leaf comprises a continuous channel in its outer surface and/or the outer leaf comprises a continuous channel in its inner surface.

A fourth aspect of the invention provides a set of interconnecting building elements stackable so as to form a wall comprising a generally planar first surface and a generally planar second surface opposite the first surface, which second surface comprises a continuous channel.

By providing a channel in a wall, the width of a cavity may be increased sufficiently to accommodate a flue, a flue liner or a support for a flue or flue liner, without the need for a chimney or a false chimney breast, The channel may be suitable for receiving a flue, a flue liner or a support means for a flue or flue liner.

The interconnecting building elements may comprise bricks. The bricks may comprise centrally recessed bricks. i.e. comprising: substantially parallel planar front and rear faces; substantially parallel planar end faces; substantially parallel planar upper and lower faces; and a recess that intersects the upper, lower and rear faces of the brick.

The bricks may comprise end recessed bricks, i.e. in which the recess additionally intersects an end face of the brick.

The building elements may be manufactured of stone, ceramic or cast material, e.g. concrete. Reinforcing means may be provided to strengthen the building elements, in particular in the vicinity of the channel / recess.

The building elements may be manufactured of concrete and may additionally comprise reinforcing metal bars. The metal bars may optimally be pre-stressed.

A fifth aspect of the invention provides a kit of parts comprising one or more of a centrally recessed brick and an edge recessed brick. The kit may further comprise a metal flue box, and/or a support tube, and/or an access box. The flue box and/or the access box may comprise a spigot adapted to engage an end of the support tube. The kit may further comprise a lintel comprising a central recess, which lintel may be manufactured of concrete and which may comprise pre-stressed longitudinal reinforcing bars.

Preferred embodiments of the invention shall now be described, by way of example only, with reference the accompanying drawings in which: Figure 1 is a schematic perspective view of a first embodiment of a cavity wall in accordance with the invention: Figure 2 is a schematic perspective view of second embodiment of a cavity wall in accordance with the invention; Figures 3 and 4 are schematic perspective views of sets of building elements according to the invention; Figure 5 is a schematic partial cross-section through a first building structure according to the invention; and Figure 6 Is a schematic partial cross-section through a second building structure according to the invention.

In Figure 1, a cavity wall 10 comprises an inner leaf 12 and an outer leaf 14 separated by a continuous 4 inch (10 cm) gap or cavity 16. The outer leaf 14 and the majority of the Inner leaf 12 are of conventional construction, that is being comprised of a plurality of interlocking, generally cubold bricks 20 stuck together using mortar 22 in an overlapping arrangement.

A portion of the Inner leaf 12 is made up of a plurality of interlocking bricks 24,26 according to the invention, each having pre-formed recesses 28, therein. The recesses 28, 30 are vertically aligned so as to form a continuous vertical channel 30 in the outer surface 32 of the inner leaf 12.

The depth of the channel 20 is approximately 2 inches (5 cm), making the cavity 16 approximately 6 inches (15 cm) wide in the vicinity of the channel 30.

The invention therefore provides a cavity wall comprising inner and outer leaves and a cavity therebetween, wherein one of the inner or outer leaves comprises an open channel facing the cavity.

A circular cross-section metal tube 32 of 534 inch (14.6 cm) outer diameter is located within the channel 30, which supports, and guides during insertion, a flexible, reinforced metal foil flue liner 34 of conventional design.

Figure 2 shows a variation of the cavity wall 10 of Figure 1, In which both the inner leaf 12 and the outer leaf 14 comprise a channel 30. Such an arrangement can be used where the cavity 16 is of reduced width, and/or where a support tube 32 of a larger diameter is be used.

In Figures 3 and 4, two sets of bricks according to the invention are shown.

In Figure 3, the set of bricks comprises conventional brick 20, a centrally recessed brick 26 and an endrecessed brick 24. The bricks can be used in different numbers to construct a wall as previously described.

The conventional brick 20 is generally cuboid and has generally planar front 40 and rear 42 faces and generally planar end faces 44, 46. The upper and lower faces 48, 50 comprise a generally planar peripheral edge 52 which surrounds an inclined wall portion 54 that leads to planar surface 56 that lies in a plane parallel to the peripheral edge 52 of the brick. The inclined wall portion 54 and the central, rectangular planar surface 56 together define a recess 58 (also known as a "frog") that assists, in use, keying/bedding the 1 5 brick 20 into mortar (not shown).

The centrally recessed brick 26 is of a similar construction to the conventional brick in as much as it comprises a generally planar rear 42 face, generally planar end faces 44, 46 and upper and lower faces 48, 50 comprising a recess 58 as previously described. The front face 40 of the brick 26, however, comprises two coplanar face portions 60, 62 and a third face portion 68 set back from the copIanar face portions 80, 62. Rebate face portions 68 extend at right angles from the inner edges 70 of the coplanar face portions 60, 62 and intersect the outer edges 72 of the setback face portion 68. The coplanar face 60, 62, the rebate face 68 and the setback 66 face portions thereby define a central recess 74 that forms, in use, part of the channel 30 of the wall.

The edge recessed brick 24 is of a similar to the centrally recessed brick 26 and also comprises a generally planar rear 42 face, generally planar end faces 44, 46 and upper and lower faces 48, 50 comprising a recess 58 as previously described. The front face 40 of the brick 26, however, comprises a major face portion 78 and a minor face portion 80 set back from the major face portion 78. A rebate face portion 82 extends at right angles from the inner edge 84 of the major face portion 78 and intersects the outer edge 86 of the minor face portion 80. The major face 78, the rebate face 82 and the minor 80 face portions together define an edge recess 88 that forms, in use, part of the channel 30 of the wall.

In Figure 4, the set of bricks is similar to that described in relation to Figure 3, except the bricks comprise vertical through apertures 90 (to facilitate keying I bonding with mortar, and which also provide intra-wall ventilation), rather than the recesses 58 previously described.

Figure 5 shows how the invention can be incorporated into a building structure 92 comprising a cavity wall 10 having inner 12 and outer 14 leaves, as previously described.

The cavity wall 10 is built leaving an aperture 94 for receiving a metal flue box 96 of conventional design. The flue box 96 comprises an open-fronted housing manufactured 98 from pressed sheet metal into which a fire (not shown) wifl eventually be positioned.

The flue box 96 comprises generally planar metal side walls 120, a base 122 and a rear wall 124 that abuts the internal face of the external leaf 14 of the wall. The flue box 96 also comprises an upper wall 126 from which a vertical spigot 100 extends upwardly that, in use, fits inside the flared lower end 102 of a metal support tube 32.

The flue box 96 also comprises a partial front wall 128 that extends downwardly from the front edge of the upper wall, but leaving an open aperture in the front of the flue box for receipt, in use, of a fire (not shown).

Located behind the partial front wall 128 is a truncated pyramidal collector hood 130 which, in use, collects and funnels combustion products from the fire (not shown) towards a vertical spigot 132 that connects to the lower end of the flue liner 34.

The walls of the flue box 96 can be double-skinned, although this is optional.

The collector hood 130 is removably connected to the flue box 96 using screws, which enables the flue system to be installed without a flue liner being present. Thus, a flue liner can be inserted or replaced post-installation by a procedure involving removing the collector hood 130, inserting a flue liner 134, connecting the lower end of the flue liner 134 to the collector hood's spigot 132, and reinserting and reattaching the collector 130 to the flue box 96. This feature is particularly beneficial as it enables the flue liner to be relatively easily installed, serviced, replaced and/or upgraded after the building has been constructed.

The outer leaf 14, and the inner leaf 12 of the cavity wall 10 either side of the aperture 94, are built-up using conventional bricks 20. When the inner leaf 12 has been built up to a level above the top of the flue box 98, a lintel 104 is placed over the aperture 94. The lintel is generally cuboid, but has a central recess 74 similar to that of the centrally recessed brick 26 described above in Figure 3. The lintel 104 is manufactured of reinforced concrete and comprises pre-stressed longitudinal reinforcing bars 106 that provide additional strength to compensate for the reduction in strength that would otherwise result from the recess 74 being present.

Vertically above the lintel 104, centrally-recessed 26 and edge-recessed 24 bricks are placed in an overlapping and/or interlocking manner to construct the inner leaf 12 with a continuous vertical channel 32 for accommodating the support tube 32.

When the inner leaf 12 and the outer leaf 14 of the cavity wall have been built up to the level of the upper end of the support tube 32, a further support tube is added by inserting the upper end of the lower support tube 32 into the flared lower end 102 of the upper support tube, Building continues until an uppermost storey ceiling level 108 is reached.

At this point, the support tube 32 can be cut to length and an access box 110 connected to the upper end thereof. The access box 110 is essentially a scaled-down and inverted version of the flue box in as much as it comprises an open-fronted housing manufactured 98 from pressed sheet.

The access box 110 comprises a vertical spigot 112 extending downwardly from its lower wall whose flared lower end 114 fits around the upper end of the metal support tube 32. The inclined upper wall 116 of the access box 110 acts: as a guide for the flexible flue liner 34, which will eventually be inserted into, and fed down inside the support tube 32; and also enables it to be easily accommodated at the junction of a wail and a sloping roof 118 of a building.

Construction of the wall can continue to a level above the access box, if desired.

Figure 5 also shows a further type of brick 120 similar to the centrally recessed brick 26 of Figure 3 except that the recess is inclined to enable the channel 30 to follow a non-straight and/or a non-vertical path up a wall. Since the diameter of the support tube 32 is approximately % inch (1.9 cm) greater than that of the flue liner 34, the flexible flue liner is able to slide within the support tube 32 around corners, junctions etc. formed by the use of such bricks 120.

The support tube 32 can optionally be held in situ by brackets or wires (not shown) laid into the mortar 22 between brick courses as the wall is built.

Finally, Figure 6 shows an alternative embodiment of the invention.

One problem with flue systems is that the depth of a fire that can be installed is limited to the sum of the thickness of the bricks used to construct the inner leaf 12 of the building and the width of the cavity 16. However, certain fires require a greater depth that can only be accommodated in a conventional chimney breast.

In Figure 6, a trunking box 136 is installed above the lintel 104 that steps the support tube 32 and the flue liner 34 out of the cavity, through the inner leaf 14 and into the room. The trunking box 136 comprises hollow body 138, vertical spigot 138 that communicates with the interior of the body 139 and whose upper end connects to the lower end of the support tube 32, and an elbow spigot 142 that extends horizontally outwardly from the front face of the body 138 and whose downwardly open lower end is located above the fire (not shown), or can be connected to a flue box 96.

The flue liner 34 can pass through the trunking box 136, thereby removing the need for it to be gas tight.

As can be seen in Figure 6, a false chimney breast 144 (or indeed a deep fireplace) can be provided to conceal the elbow spigot, although this is purely for aesthetic, rather than functional, reasons because the flue support tube 32 and the flue liner 34 are routed upwardly within the cavity 16.The invention is not limited to the details of the foregoing embodiments. In particular, the materials, dimensions, building methods etc. quoted are intended to be illustrate, rather than restrictive.

Claims

Claims: 1. A wall comprising a plurality of interconnecting building elements comprising aligned recesses, which recesses define a continuous channel in the surface of the wall.
2. A cavity wall comprising an outer leaf and an inner leaf comprising a plurality of interconnecting building elements the inner leaf comprising channel in its outer surface.
3. A set of interconnecting building elements stackable so as to form a wall comprising a generally planar first surface and a generally planar second surface opposite the first surface, which second surface comprises a continuous channel,
4. A wall, a cavity wall, or a set of interconnecting building elements according to any of claims 1 to 3, in which the channel is suitable for receiving a flue, a flue liner or a support means for a flue or flue liner.
5. A wail, a cavity wail, or a set of interconnecting building elements according to any preceding daim, wherein the interconnecting building elements comprise bricks.
6. A wall, a cavity wall, or a set of interconnecting building elements according to claim 5, wherein the or each brick comprises: substantially planar front and rear faces; substantially planar end faces; substantially planar upper and lower faces; and a recess that intersects the upper, lower and one of the front or rear faces of the brick.
7. A wall, a cavity wall, or a set of interconnecting building elements according to claim 6, wherein the recess additionally intersects an end face of the brick.
8. A wall, a cavity wall, or a set of interconnecting building elements according to any preceding claim, wherein one or more of the interconnecting building elements comprises reinforcing means.
9. A wall, a cavity wall, or a set of interconnecting building elements according to claim 8, when dependent on claim 6 or claim 7, wherein the is reinforcing bars are located in the vicinity of the recess.
1O.A wall, a cavity wall, or a set of interconnecting building elements according to claim 8 or claim 9, wherein the reinforcing bars are pre stressed.
I I.A wall, a cavity wall, or a set of interconnecting building elements according any preceding claim, wherein the recesses are verticall)' aligned to define a substantially vertical channel in the wall,
12.A wall, a cavity wall, or a set of interconnecting building elements according the recess is inclined to define a non-vertical channel in the wal
13.A wall, a cavity wall, or a set of interconnecting building elements according to any preceding claim, wherein the depth of the channel is approximately 2 inches.
14.A wall, a cavity wall, or a set of interconnecting building elements according to any preceding claim, further comprising a support tube located within the channel.
15.A wall, a cavity wall, or a set of interconnecting building elements according to any preceding claim, wherein at least one of the I s interconnecting building elements comprises a centrally recessed brick comprising a generally planar rear face, generally planar end faces and upper and lower faces, and a front face comprising two co-planar face portions and a third face portion set back from the co-planar face portions.
16.A wail, a cavity wall, or a set of interconnecting building elements according to any of claims I to 14, wherein at least one of the interconnecting building elements comprises an edge recessed brick comprising a generally planar rear face, generally planar end and upper and lower faces, and a front face comprising a major face portion and a minor face portion set back from the major face portion.
17.A wall, a cavity wall, or a set of interconnecting building elements according to claim 15 or claim 16, wherein the upper and/or the lower face of each brick comprises a recess or a through aperture.
18.A kit of parts comprising one or more of centrally recessed brick according to claim 15 and an edge recessed brick according to claim 16.
19.A kit of parts according to claim 18, further comprising a metal flue box, a support tube, and an access box. I 020.A kit of parts as claimed in claim 19, wherein the flue box and/or the access box comprise a spigot adapted to engage an end of the support tube.21.A kit of parts as claimed in any of claims 18 to 20, further comprising a lintel comprising a central recess.22.A kit of parts as claimed in claim 21, wherein the lintel is manufactured of concrete and comprises prestressed longitudinal reinforcing bars. -( Li)23.A building comprising a cavity wall, the cavity wall comprising an outer leaf and an inner leaf, wheren the inner eaf comprises a continuous channel in its outer surface and/cr the cuter leaf comprises a continuous channel in its inner surface.24.A cavity wall comprising inner and outer leaves and a cavity therebetween, wherein one of the inner or outer leaves comprises an open channel facing the cavity.25.A wall, a cavity wall, or a set of interconnecting building elements substantially as hereinbefore described, with reference to. and as illustrated in, the accompanying drawings.26.A wall substantially as hereinbefore described, with reference to, and as illustrated in, the accompanying drawings.27.A cavity wall substantiaHy as hereinbefore described, with reference to, and as illustrated in, the accompanying drawings.Is 28.A set of interconnecting building elements substantially as hereinbefore described, with reference to, and as illustrated in, the accompanying drawings.29.A building substantially as hereinbefore described, with reference to, and as illustrated in, the accompanying drawings.