GB2612883A

GB2612883A - Prefabricated masonry panel and method

Info

Publication number: GB2612883A
Application number: GB2213113.0A
Authority: GB
Inventors: Alfred Hoad Matthew
Original assignee: Matt Hoad Ltd
Current assignee: Matt Hoad Ltd
Priority date: 2020-03-03
Filing date: 2020-03-03
Publication date: 2023-05-17
Anticipated expiration: 2040-03-03
Also published as: GB202213113D0; GB2612883B

Abstract

A prefabricated masonry panel 1101 comprising a reinforcement grid 101 comprising a first plurality of rods 103 each extending along a first grid direction and spaced from one another along a second grid direction which is perpendicular to the first grid direction. The prefabricated masonry panel also comprises and a first rail 109 and a second rail each extending in the second grid direction and spaced from one another in the first grid direction, wherein each of the first and second rails connects at least some of the first plurality of rods to one another, and one or more attachment features 111 connected to the reinforcement grid for attaching the prefabricated masonry panel to a structure. The panel also includes a first column 1103 and a second column 1105 each comprising a respective plurality of masonry units, wherein the first column and the second column respectively define a first panel face and a second panel face, and wherein the reinforcement grid is positioned between the first and second columns.

Description

PREFABRICATED MASONRY PANEL AND METHOD

FIELD OF INVENTION

The present invention relates to masonry panel assembly systems, corresponding methods of building a masonry panel and masonry panels (which may or may not be built using the disclosed assembly systems or methods). Masonry panels of the sort to which the application relates include those for use in facades, such as curtain walling or other forms of suspended panelling, which are affixed to the exterior or interior of a structure, as well as walls supported by conventional foundations. In this context the term "masonry units" includes bricks (which may be cut or extruded), cast stone blocks, concrete masonry units and the like.

BACKGROUND

Masonry is the building of structures from a plurality of individual units.

Historically, these methods have employed both irregular units such as uncut stone, and more regular units, such as: cut stone blocks; clay or adobe bricks; concrete masonry units (including breeze blocks, cinder blocks, concrete blocks and clinker blocks); and blocks and bricks made of other materials. These individual units are typically laid in and joined by mortar, cementitious adhesive or another binding material. However, so-called 'dry set masonry' which is laid without mortar is also known.

Historically, the majority of masonry structures are constructed using regular, substantially cuboid masonry units which are easily transported, manipulated and laid. Examples of such masonry units include the British Standard brick has dimensions 215mm x 102.5 x 65 mm excluding mortar joints (and is defined in BS EN 771-1:2003 (Specification for Clay Masonry Units', National Annex (informative), 2011) and British concrete blocks which have a face with dimensions of 440 x 215 mm or 390 x 190 mm and are commonly supplied in a variety of widths. Structures built by laying courses of such bricks and/or blocks, which have a significant depth relative to their length and height, on top of one another are often termed 'hand laid masonry'. This traditional building technique results in a distinctive appearance and its aesthetics are considered desirable.

Conventionally, hand laid walls such as these would be built on-site, based on foundations put in place for the load bearing or self-weight of the structure. This is not only time-consuming and requires great expertise, but there are limits on the size and shape of structures built in this way. Building on site is also weather-dependent, heavily reliant on site labour with scaffolding systems and is inherently slow. Increasingly, therefore, structures such as buildings are being constructed by other techniques, such as utilising a steel or concrete frame with reinforced concrete floors joined thereto and light-weight wall panels which may be built from masonry (e.g. breeze blocks) or could also be formed of reinforced concrete. To the outside of the structure is affixed a suspended cladding panelling system which largely conceals the underlying structure from external view and allows for insulation (e.g. thermal insulation and/or fire protection) to be located between the structure walls and the suspended panels. The suspended panels can also be used to form a facade and therefore provide the building with a desired external aesthetic.

Panels for this purpose are typically not constructed in-situ, but rather are prefabricated either off-site or at the location of the build in a suitable facility. The prefabricated panels are then lifted (e.g. by crane) to the desired position on the outside of the structure and affixed to the structure by appropriate connectors. In order to withstand the movement involved in this process, the panels must be strong and stay intact under tension as well as compression. Conventional hand laid masonry walls are not suitable for this purpose, since they are not able to withstand tensional forces.

The currently available solutions for a facade with a brick-like appearance which can be used on buildings of any height fall into four general categories. The first is a solid brick wall, bonded with adhesive mortar, built onto a stainless steel or galvanised lintel which can be attached to the building structure. Ties are needed at regular intervals up and across the wall in order to transfer lateral loading from wind from the panel onto the underlying structure (ties are typically lengths of stainless steel or composite materials which are connected to the building structure and extend into the joints between bricks, where they are held in place by the mortar or other binding agent). This approach has the benefit of giving the appearance of hand laid masonry, but (unlike conventional mortars) the required high-strength epoxy-type adhesive mortars are relatively untried and untested, and cannot be recycled. Complex façade shapes are also difficult to form with this technique. The large number of wall ties necessarily also causes significant thermal bridging which can lead to a cold building interior and damp problems caused by condensation.

The second category is that of precast concrete-backed brick slips. This involves casting panels of concrete in moulds lined with brick slips (i.e. thin slices of brick) such that the concrete sets around the brick slips and engages with groves cut into the back of the brick slips. The brick slips are thereby affixed to the set concrete. The moulds are designed to result in the desired panel shape but since they have to be filled flat (and then the set concrete lifted out), complex facade shapes may need to be made of multiple panels. The lead-in time and expense of making the moulds and panels is often considerable. The concrete typically requires reinforcing with either steel or fibre and may often be up to 200mm thick. This results in an extremely heavy panel with cumbersome connections, difficulties in installation and problematic interface detailing. Very strong, heavy duty connectors for joining the panels to the structure framework are required, which also affects the design of the supporting structure (since it has to be stronger than would otherwise be the case). A variant of this approach is to form a "sandwich panel" having two concrete panels separated by an insulating core.

The same problems arise.

A third category of glass-reinforced concrete (GRC)-backed brick slips is based on the same principle as above, moulding GRC panels around brick slips face down in a mould in the same way. Due to the higher strength of GRC, the thickness of the panels, and hence the weight, is less than that of concrete panels but all of the other disadvantages outlined above are still encountered. In addition, CRC is a high cost material, has long lead-in times and is restricted to specialist manufacturers, thereby limiting availability.

The fourth category is metal-backed brick slips or files. Various commercial systems employing this principle are available and take many different forms. In essence, a metal backing tray or rack is provided which is fitted to the outside of the building structure at many points. The tray or rack includes fixtures such as rails or a framework into which brick slips or files with corresponding engagement features (e.g. grooves formed in their edges) can be fitted, before filling the gaps with specialist mortar In many cases, the brick slips need to be formed by extrusion (rather than cutting of conventional brick) in order to form the complex shapes needed, which results in an appearance different from that of hand laid brick (and therefore less desirable). For example, recessed raked mortar joints are often not possible to form due to the restricted depth against the metal backing tray. In addition, the systems typically suffer from significant thermal bridging due to the many point connections between the metal backing tray and the supporting structure, and are not well suited to forming complex façade profiles due to difficulty forming the necessary metal supports and also supporting the brick façade adequately at corners.

In summary, the existing solutions for prefabricated masonry panels are not optimum. A new system which overcomes some or all of the disadvantages mentioned above would be desirable

SUMMARY OF INVENTION

According to a first aspect of the invention, a masonry panel assembly system comprises: a reinforcement grid comprising a first plurality of rods each extending along a first grid direction and spaced from one another along a second grid direction which is perpendicular to the first grid direction; a plurality of masonry units, each masonry unit comprising a first presentation face and a first interior face opposed to the first presentation face, wherein the first interior face is shaped to define at least one keying feature; and a plurality of positioning elements each comprising: a receiving feature adapted to receive a portion of one of the first plurality of rods; and one or more keying members each adapted to key with a respective keying feature of one of the masonry units so as to hold, in use, the masonry unit at a respective predetermined distance from the received portion of the rod.

This masonry panel assembly system is a kit of parts which can be used to form masonry panels as discussed further below. Whilst the system is primarily designed for use in suspended façades, it can also be used advantageously to build walls on traditional foundations. Through the use of individual masonry units, a reinforcement grid and positioning elements as described, a number of benefits are provided. The masonry units can be of any available type, including extruded units formed at the outset with the keying feature(s) therein, as well as standard bricks from any manufacturer which have been cut to the desired form and to include the keying feature(s). The latter option is more preferred since this enables the complete range of bricks, formed in different ways, to be used. In particular, bricks formed using moulding are preferred since this gives a desirable hand-made and hand-laid aesthetic. The reinforcement grid provides strength to the assembled panel and enables it to withstand tension forces during installation and in use. Connections can be made between the reinforcement grid and the building structure on which the panel may be suspended. In a traditional, non-suspended arrangement on foundations, the reinforcement grid still provides additional strength to the wall than would otherwise be the case, and enables walls to be built which can be taller and thinner as compared with what is achievable with unreinforced brick. The positioning elements enable highly accurate relative positioning of the reinforcement grid and masonry units and in preferred embodiments will further act (either alone or in combination with mortar or another binding agent) to fix the masonry units to the reinforcement grid at the desired positions.

As described in more detail below, in the assembled panel, the masonry units are most advantageously arranged in first and second columns with the reinforcement grid between the two columns. Together with the positioning elements, this centrally-reinforced arrangement results in a high-strength assembly which can be lifted as a complete panel from the top or bottom of the panel, using lifting shackles for example. The assembled masonry panel is of rigid construction, and able to provide all the performance of a solid brick wall, in addition to withstanding tensional forces as would be expected of reinforced concrete. Per square meter, the weight of the assembled panel is substantially less than a precast concrete panel, and significantly lower in cost. For example, a typical panel formed using the presently disclosed system is estimated to weigh in the region of 150 to 200 kg/m2 as compared with 400 to 600 kg/m2 for a precast concrete panel, and costs are expected to be about half to two-thirds those of a precast concrete panel. Due to the internal reinforcement mesh, fewer or no lateral ties are needed between the panel and the building structure -rather, localised point connections need be made only at the top and bottom of each panel -significantly reducing thermal bridging as compared with solid brick and metal backed brick slip types of known system. Since the reinforcement grid can be made to any profile (flat or otherwise) and the masonry units are then fitted to one or preferably both side(s) of it, the system is well suited for forming complex or irregular façade shapes, including corners. Similarly, the system can be used to produce a wide range of bond patterns (e.g. lapped bonds and/or stacked bonds) and different bond patterns can be used in the first and second columns of masonry units simultaneously, forming a single cohesive unit of staggered brick bonds.

The disclosed system also enables a fast, precise design and build process. The reinforcement grid layout can be generated by CAD, based on the desired brick pattern projection and configured to deal with windows, doors and other façade complexities. The system allows for vertical building of the panel by conventional bricklayers prior to installation, who can employ known techniques similar to those used for building traditional walls to put together courses of the masonry units on top of one another, to form columns of such units on one or both sides of the reinforcement grid. Each panel can be assembled on the factory floor (on-site or off-site) and is engineered to withstand the stresses and strains encountered during movement (both transport to the site, installation itself and in use). The high degree of accuracy ensured by the reinforcement grid and positioning members ensures that each panel is made to the exact dimensions needed and will interface correctly with other components on-site in the build, such as window frames. At the same time, the use of a reinforcement grid and separate positioning elements enables the system to deal with tolerances which may be encountered from one masonry unity to the next. Once on-site, installation of the panels is fast due to their relatively low weight, dimensional accuracy and engineered fixing system. For instance, if desired the panels can be attached to the building structure from the inside of the building so that no scaffolding is required.

The positioning elements can take various different forms. In general, each positioning element is preferably configured such that, in use, the held masonry unit is oriented such that the first presentation face faces away from the reinforcement grid along a third grid direction which is perpendicular to the first grid direction and the second grid direction. The third grid direction will be substantially parallel to the direction which spaces the first presentation face from the first interior face of each masonry unit once the panel is assembled. In practice, this means that the keying member(s) of each positioning element should typically project away from the receiving feature which accommodates one of the reinforcement rods in use.

As mentioned above, the positioning elements' primary function is to accurately space and locate the masonry units relative to the reinforcement grid. Thus the keying members may be designed to key with the keying features on the masonry units only to the extent necessary in order to achieve the positioning (and without actively coupling the keying members and keying features together). However in other, more preferred implementations, the keying members and keying features may be configured to interlock with one another (either requiring or not requiring the presence of binding agent to complete the interlock) in which case they further act to join the masonry units to the reinforcement grid. Whatever function(s) the positioning elements provide, it should be noted that it is not necessary for every masonry unit to interact with a positioning element. Typically, a positioning element may be provided at least on every alternate masonry unit -e.g. for a stretcher bond pattern this may correspond to spacing of about 225mm vertically and about 900mm horizontally between positioning elements.. In practice, the number and position of positioning elements used will depend on what is required for different panels, bond patterns, shapes, configurations and openings in the panels.

On the positioning elements, each keying member could for instance comprise an elongate tab of material (such as stainless steel), which may be flat or corrugated, configured to extend into or around a corresponding keying feature (such as a slot) provided on the masonry units. The elongate tabs of material could each have one or more apertures therethrough to assist in interlocking with mortar. Alternatively, each keying element could comprise a shaped portion of material (such as plastic or stainless steel) sized and configured to fit exactly against or around corresponding shaped portions (such as protrusions) of the masonry units.

In preferred embodiments, each positioning element comprises two keying members. Thus, each positioning element can interact with either a single masonry unit (if the keying feature(s) are designed accordingly on the masonry unit) or with two masonry units. Advantageously, the two keying members extend along different respective directions that are preferably substantially perpendicular to one another. This has been found to be particularly beneficial since each positioning element can be deployed either with both keying members being located on one side of the reinforcement grid (such that they can interact with one or two masonry units in the same column), or rotated through 90 degrees such that the two keying members are located on opposite sides of the reinforcement grid (such that they can interact with a masonry unit on each side).

The system may comprise positioning elements of various different types (and could include a mixture of more than one type). In a preferred implementation, in each positioning element, the receiving feature and the one or more keying members form parts of an integral unit. For instance, the positioning element could comprise a single item providing both the receiving feature and the keying member(s) such that the receiving feature and the keying member(s) are substantially in fixed relation (save for some resilience in the item allowing the keying members to key with the masonry units). Positioning elements of this sort may be referred to hereinafter as "clips" for brevity. In particularly preferred cases, each clip may be formed of a single piece of material (such as stainless steel) which is cut and pressed to form the desired shape.

In another preferred implementation, at least one of the positioning elements comprises: two or more ties each comprising a receiving portion which is adapted to receive, in use, a portion of a respective one of the first plurality of rods and a spacing portion comprising a plate having a plurality of perforations therethrough, configured such that the plate lies in a plane substantially perpendicular to the first grid direction and is rotatable about the received rod; an elongate connecting member adapted to extend, in use, along the first grid direction through a respective perforation of each tie so as to prevent rotation of the ties when the ties are attached to different ones of the first plurality of rods; and a clip which comprises the one or more keying members, wherein the clip further comprises a connecting feature adapted to connect the clip to the 5 connecting member.

In this embodiment, each positioning element comprises four components which are movable relative to one another and once assembled form a triangle with the two receiving portions at two corners and the elongate connecting member at the third corner, from which the keying members also extend. The triangular nature of the arrangement braces the element so that the distance between the corners cannot be changed once the element is in place. Nonetheless, the positioning element can be assembled in various different ways, so as to change the predetermined distance between the receiving portions and the keying features.

This is achieved by selecting different ones of the perforations in the tie plates for the elongate connecting member to pass through. Desirably, the perforations are located at predetermined reference locations on each tie plate which result in a certain predetermined set of distances between the receiving portions and the keying features, from which the user can select depending on which perforations are used to join the components together The clip component is preferably the same as the preferred implementation of the single-piece positioning element mentioned above. In this way, the system need only comprise a number of clips, ties and elongate connection members which the person assembling the panel can choose from and deploy as necessary for the panel design in question. As indicated above, in practice the system may use a mixture of the different positioning element types mentioned above. To enable the same clip component to be used in the two different ways indicated, preferably the elongate connecting member is a shaft having a diameter substantially the same as that of one of the first plurality of rods. In this way, the same feature on the clip can act as a receiving feature either for one of the reinforcement rods or for the elongate connecting member.

The receiving feature can take any form which accommodates one of the rods of the reinforcement grid, such as an aperture through which the rod can pass (preferably a friction fit) or a clamp which can open and close around the rod.

Arrangements which allow the positioning element to be fitted onto the grid laterally and do not require sliding the positioning element along the full rod length are far preferred. In a particularly advantageous embodiment, the receiving feature comprises a first curved lip which is shaped to define a first section of a channel extending along a channel axis so as to be capable of receiving, in use, a portion of one of the plurality of rods aligned with the first axis. Thus the receiving section can be placed around part of the circumference of the rod.

Still preferably, the positioning element further comprises a second curved lip which is shaped to define a second section of the channel so as to be capable of receiving, in use, a portion of one of the plurality of rods aligned with the first axis, wherein the first and second lips are spaced from one another along the channel axis and are opposite one another in a direction perpendicular to the first axis. In this way, the positioning element can be slid laterally onto the rod with the channel perpendicular to the rod axis, the rod being located in the space between the first and second lips. Upon rotation of the positioning element through 90 degrees, the rod axis becomes aligned with the channel axis and the first and second lips substantially encircle the rod but at different positions along the channel. This holds the positioning element in substantially fixed relation to the reinforcement grid, at least in the second and third grid directions. Preferably the sizing of the positioning element is such that once on the rod, friction also prevents or impedes movement of the element along the rod in the first grid direction.

In an especially preferred implementation, the first and second lips each comprise a respective projecting feature that extends along the direction of the first axis towards the other of the first and second lips, wherein the projecting features are offset with respect to one another in an azimuthal direction orthogonal to the first axis. This enables the positioning element to remain affixed to the rod even before it has been rotated through 90 degrees, and in some implementations the clips may remain in this position in the finished panel. In other cases, in use, one of the first plurality of rods may pass between the projecting features at an angle that is non-parallel to the first axis and then the receiving feature may be rotated about a second axis perpendicular to the first axis such that the rod is received by the first curved lip and the second curved lip. Preferably, the projecting features are spaced from one another along the channel axis by a distance less than a diameter of one of the first plurality of rods such that one of the first plurality of rods cannot pass between the projecting features at an angle perpendicular to the first axis.

Throughout this disclosure, the term "presentation face" means a face of the masonry unit which will be exposed on one of the outer surfaces of the finished panel (whether this ultimately faces the building structure or is visible from the building exterior is irrelevant). The term "interior face" refers to a face of the masonry unit opposite the presentation face which will face the reinforcement grid in use. Each masonry unit will also have one or more side faces, which are those which will abut other masonry unit(s) in the same course, via a joint containing mortar or other binding agent, and two bedding faces, which are those which will lie in the plane of each course and face the bedding joints between courses. A presentation face will be a finished face (i.e. having the desired appearance to form a visible part of the panel) and may be flat or could have another shape (e.g. curved or stepped), depending on the desired configuration of the outer face of the panel. An interior face, in contrast, will typically either be flat (planar) aside from the keying features formed therein, or may be designed to interlock with other masonry units. Examples of such interlocking masonry units suitable for this purpose include the "F-shaped" or "E-shaped" masonry units disclosed in our British patent application no. 1912532.7. Side faces are typically flat, and may be unfinished (e.g. with roughened surfaces for keying with mortar). Bedding faces may be flat or provided with one or more depressions (e.g. a "frog" or perforations) for receiving mortar in use.

In preferred examples, the first presentation face of each masonry unit is a stretcher face or a header face. This will typically be the case for standard, generally cuboidal masonry units. However, the system may additionally or alternatively include other types of masonry units, such as corner masonry units which may comprise both a stretcher presentation face and a header presentation face, and/or "U-shaped" masonry units which could comprise either two stretcher presentation faces and one header presentation face, or one stretcher presentation face and two header presentation faces. More generally, at least some of the masonry units may further comprise a second presentation face and a second interior face opposite the second presentation face. In such cases, the second interior face may or may not define a further keying feature.

As mentioned above, the keying feature(s) on the masonry units could take various forms including shaped edges or faces of the units, protrusions and/or recesses. Each masonry unit could be provided with a single keying feature, two keying features or more than two keying features. Where two or more keying features are provided on any one interior face of a single masonry unit, the repeat distance between the keying features is preferably substantially equal to the repeat distance between the first plurality of rods in the reinforcement grid, or an integer multiple or fraction thereof. In particularly preferred implementations, each keying feature comprises one or more slots each shaped to receive a respective one of the keying members, the one or more slots preferably being cut into the first interior face of the masonry unit. The corresponding keying members on the positioning elements may then comprise elongate tabs of material configured to extend into the slots as mentioned above. Desirably, each slot extends continuously from an upper bedding face to a lower bedding face of the respective masonry unit, wherein each of the upper and lower bedding faces is substantially perpendicular to the first interior face. This allows the keying members on the positioning elements to be slid into the slots along the direction spacing the upper and lower bedding faces of the masonry unity. Most preferably, each slot extends into the masonry unit from the first interior face along a direction that is not normal to the first interior face. Desirably, this direction lies at about 45 degrees to the normal.

In a particularly preferred embodiment, each keying feature comprises two slots, each of the two slots extending into the masonry unit from a common point on the first interior face, wherein preferably the common point is located at a distance of about 1/3, 1/2 or 2/3 of an elongate dimension of the first interior face from the end of the interior face. Thus each keying feature describes a "V-shaped" arrangement of two slots, which mirrors the above-described preferred configuration of the keying members on each positioning element. Most preferably, the respective acute angles between each of the two slots and the first interior face are substantially equal, and desirably the respective acute angles are in the range of 30 to 60 degrees, more preferably 40 to 50 degrees, most preferably about 45 degrees. Where an angular spacing of about 45 degrees is used for both the slots and the keying members (preferably elongate tabs) on the positioning elements, this is particularly advantageous since any one positioning element can either be arranged to mesh with the two slots of one keying feature on a single masonry unit, or can be arranged to mesh with one slot of each of two keying features on two respective masonry units. Preferably, each of the plurality of masonry units comprises exactly one or two keying features. For instance, on stretcher masonry units, either a single keying feature (e.g. one "V-shaped" set of slots) may be provided half way along the internal face, or two such keying features could be provided, e.g. at 1/3 and 2/3 positions along the long dimension of the unit. On header masonry units, one keying feature (e.g. one "V-shaped" set of slots) may be provided, e.g. at the half way point.

The masonry panel assembly system can advantageously be used to form panels with a thickness (in the direction normal to the reinforcement grid) which is either constant or non-constant. The latter option may be used to provide the exterior of the panel with a varying profile or pattern, examples of which are again described in our British patent application no. 1912532.7. A varying thickness can be provided in different ways. In one implementation, the plurality of masonry units comprises at least a first plurality of masonry units in which the first interior face and first presentation face are separated by a first unit depth and a second plurality of masonry units in which the first interior face and the first presentation face are separated by a second unit depth, which is different to the first unit depth. That is, masonry units of different depths are employed meaning that even if their interior faces all lie on the same plane, their presentation faces opposite will not, thereby forming a pattern. (It should be noted that such a plurality of different sized units could also be used to form first and second columns of different respective thicknesses, one either side of the reinforcement grid, without resulting in any patterning). In another implementation, the aforementioned positioning elements can be used to hold certain masonry units at different distances from the reinforcement grid to form a pattern. Of course, both approaches could be employed in combination if desired.

Preferably, the keying features of the masonry units are configured such that in use the masonry units can be held by the positioning elements in regular courses which extend parallel to the reinforcement grid along the second grid direction, wherein the repeat distance of the masonry units within each course is an integer multiple of the repeat distance of the first plurality of rods along the second direction, preferably one, three or six times. In practice, this means that the spacing of the reinforcement rods is one of: approximately equal to the length of a header masonry unit; approximately equal to a third the length of a stretcher masonry unit or approximately equal to a sixth the length of a stretcher masonry unit. In each case the approximation is needed to take account of the thickness of the joints (designed to hold mortar or other binder) between each masonry unit in the finished panel, which are typically of the order of lOmm.

The reinforcement grid could be comprised solely of the aforementioned first plurality of rods. This is especially appropriate where the masonry units used are of an interlocking variety (such as the "F-shaped" and "E-shaped" units disclosed in our British patent application no. 1912532.7), since such units can pass through the grid in order to interlock with one another. However, in more preferred embodiments, the reinforcement grid further comprises a second plurality of rods each of which is oriented non-parallel, preferably also non-perpendicular, to the first grid direction. This greatly increases the strength and rigidity of the grid and hence of the finished panel as a whole. Most preferably, the second plurality of rods are arranged as a one-dimensional or two-dimensional regular lattice, preferably a two-dimensional orthogonal lattice. A one-dimensional lattice in this context means a set of spaced, parallel rods (much like the first plurality of rods but orientated along a different direction). A two-dimensional lattice introduces a third plurality of rods which are again parallel but orientated in a third direction.

Desirably, the lattice is oriented at a non-parallel and non-perpendicular angle with respect to the first grid direction, wherein the angle is preferably about 45 degrees. The combination of the first plurality of rods with a two-dimensional lattice which is not orthogonal or parallel to the first plurality of rods is referred to for brevity hereinafter as a "diagrid" and is strongly preferred due to its excellent mechanical properties. The use of a reinforcement grid with rods in two or more non-orthogonal directions requires, however, that the masonry units are arranged in columns which do not intersect (cross) the reinforcement mesh. This helps to optimise connections between the mesh and all courses of the masonry units.

Each of the first plurality of rods may preferably be substantially circular in cross-section, to facilitate fitting of the positioning elements thereto. Preferably, each of the second plurality of rods is substantially circular or quadrate (e.g. square or rectangular) in cross-section and/or is a flat bar. Each of the second plurality of rods may for example be welded to one or more of the first plurality of rods, preferably at each intersection between one of the first plurality of rods and one of the second plurality of rods. The reinforcement grid rods are preferably formed of steel or another suitable metal or alloy.

As noted above, the system can be used to make masonry panels which are flat or follow a more complex profile. In the latter case, the reinforcement grid preferably comprises a plurality of planar sections, most preferably including planar sections which do not lie in the same plane as one another (In such cases the first, second and third grid directions are considered local to each planar section, and are defined relative to the rods in that planar section). In some implementations, the reinforcement grid extends continuously between the planar sections. This may be achieved for instance by starting with a flat reinforcement grid and bending/stamping it into the desired 3D form. However, in practice this can be extremely difficult to perform successfully due to the intrinsic rigidity of the rods forming the grid, and can give rise to distortions in the grid. Hence in a more preferred implementation, the planar sections of the grid are detached (separate) from one another and the masonry panel assembly further comprises a plurality of clamps each adapted to connect two adjacent planar sections in use. The clamps and the diagrid are preferably sized so that the clamps will fit between adjacent rods of the diagrid at least in regions along each of the first rods.

As noted above, the masonry panel assembly system is most advantageously used to form panels for suspending on a structure, for instance, to form a façade, e.g. as part of a curtain walling system. To further enable this the reinforcement grid preferably further comprises a first rail which extends along the second grid direction and which connects at least some of the first plurality of rods to one another, preferably all. The first rail may define an upper edge of the reinforcement grid. Similarly, the reinforcement grid may further comprise a second rail which extends along the second grid direction and which connects at least some of the first plurality of rods to one another, preferably all, wherein the first and second rails are spaced from one another along the first grid direction. The second rail may preferably define a lower edge of the reinforcement grid. The first and/or second rails preferably have some or all of the reinforcement rods joined thereto, e.g. by welding, and therefore play an important role in stiffening strengthening the panel and enabling its attachment to a building structure. The first and second rails typically pick up the ends of the primary rebar (the first plurality of rods) and the second plurality of rods Of provided) may also be joined to the rails. Stresses and strains experience by the reinforcement rods during movement or in use are transferred to the rail(s) thereby further ensuring that lateral ties to the building structure are not required. Preferably, the first and/or second rails each comprise one or more attachment features for attachment to a structure. Alternatively or in addition, such attachment features could be fixed to other part(s) of the reinforcement grid, e.g. welded to one or more of the rods. Suitable attachment features are described further below with reference to the second aspect of the invention.

It should be noted that, especially where the reinforcement grid comprises multiple planar sections in different planes from one another, the first and second rails may not be continuous along the second grid direction. Rather, the rails may also be provided in separate sections, one for each planar section of the grid.

The first aspect of the invention also provides a method of constructing a masonry panel, the method comprising: providing a reinforcement grid comprising a first plurality of rods each extending along a first grid direction and spaced from one another along a second grid direction which is perpendicular to the first grid direction; providing a plurality of masonry units, each masonry unit comprising a first presentation face and a first interior face opposed to the first presentation face, wherein the first interior face is shaped to define at least one keying feature; providing a plurality of positioning elements each comprising: a receiving feature adapted to receive a portion of one of the first plurality of rods; and one or more keying members each adapted to key with a respective keying feature of one of the masonry units so as to hold, in use, the masonry unit at a respective predetermined distance from the received portion of the rod; arranging the masonry units in at least a first column adjacent to the reinforcement grid, the masonry units in the first column each being oriented such that the first interior face of each masonry unit is on an interior side of the column which faces the reinforcement grid; arranging the positioning elements such that the receiving feature of each positioning element receives a portion of one of the first plurality of rods and at least one of the keying members of each positioning element keys with a keying feature of one of the masonry units.

The method can advantageously be performed using a masonry panel assembly system as already described, with any of the preferred features thereof.

Preferably, arranging the masonry comprises arranging the masonry units into the first column and a second column, wherein the reinforcement grid is positioned between the first and second columns, the masonry units in the second column each being oriented such that the first interior face of each masonry unit is on an interior side of the column which faces the reinforcement grid. As already mentioned, this results in a centrally-reinforced panel which is particularly well suited for use in a suspended façade but can also be implemented on traditional foundations. It should be noted that in some versions of the method only a single column of masonry units may be provided, e.g. if the panel is configured to surround an item such as a structural column or I-beam.

In particularly preferred implementations, the masonry units in the first and second columns do not intersect the reinforcement grid. As mentioned previously, this allows for the use of a more rigid reinforcement grid, such as one with rods in at least two non-orthogonal directions -preferably a diagrid.

The various masonry units could be positioned at different distances from the reinforcement grid if desired, e.g. to facilitate a 3-dimensional pattern in the brickwork as described further below. However generally it is preferred that in each column the first interior faces of the masonry units are arranged to be substantially coplanar, wherein preferably the plane of the first interior faces of the first column is spaced from the plane of the first interior face of the second column by a distance corresponding to at least the thickness of the reinforcement grid. Uniform spacing of the masonry units in this way is faster to build, with less possibility for human error, and allows for a constant amount of mortar or other binding agent to be provided between the two columns.

If an external brickwork pattern is desired, preferably in the first column the first presentation faces of the masonry units are spaced at varying distances from the reinforcement grid, such that the panel is formed with a non-uniform depth in a third direction which is orthogonal to the first and second grid directions. This could be achieved if the spacing of the masonry units from the reinforcement grid varies. For instance, in an advantageous embodiment, the plurality of positioning elements include positioning elements each configured to hold a masonry unit at different respective predetermined distances from the reinforcement grid, and are arranged such that one or more of the masonry units in the first column are held at different distance(s) from the reinforcement grid to others of the masonry units in the first column. Alternatively or in addition, the first column may comprise masonry units of different depth in the direction between the first interior and first presentation faces thereof. This latter approach may be preferred since it enables the interior faces to maintain constant spacing from the reinforcement mesh which is desirable for the reasons given above.

The positioning elements can comprise single units ("clips") or assemblies made up of multiple components in the manner already described above. Hence preferably, at least some of the positioning elements each comprise one or more ties, each tie comprising a receiving portion adapted to receive a portion of a respective one of the first plurality of rods and a spacing portion comprising a plate having a plurality of perforations therethrough, configured such that the plate lies in a plane substantially perpendicular to the first grid direction. The method may further comprise arranging each of the ties such that the receiving portion of the tie receives a portion of one of the first plurality of rods and the plate of the tie lies between two adjacent masonry units in one of the columns, preferably in a bedding plane. Advantageously, the method further comprises: arranging the ties of each pair such that the receiving portions of the pair of ties each receive a respective portion of different ones of the first plurality of rods, and such that one of the perforations of one tie is aligned with one of the perforations of the other tie along the first grid direction; arranging an elongate connecting member so as to extend through the aligned perforations, whereby the two ties are prevented from rotating about the received rods; connecting a clip to the connecting member by a connecting feature of the clip, the clip comprising the keying members of the positioning element; and keying at least one of the keying members of the connected clip with a respective keying feature in one of the plurality of masonry units such that the masonry unit is held at a predetermined distance from the reinforcement grid.

The positioning elements may have any of the other preferred features already mentioned above. Likewise, the masonry units and the reinforcement grid can have any of the features already described with respect to the disclosed masonry panel assembly system.

Desirably, the method further comprise arranging each positioning element such that either each keying member of the positioning element keys with keying features of a different masonry units, or both keying members key with keying feature(s) of one masonry unit. It should be appreciated that during performance of the method, one or more of the positioning elements may be arranged in the first manner indicated here and one or more of the positioning elements may be arranged in the second manner indicated here. Of importance is that each positioning element can be deployed in either manner, at the choice of the user building the panel.

As previously described, the reinforcement grid may comprise a plurality of planar sections, preferably including planar sections which do not lie in the same plane as one another. In this case preferably the method further comprises connecting the planar sections using a plurality of clamps. In some implementations, the planar sections could be arranged to enclose an interior volume on an interior side of the reinforcement grid and wherein the one or more columns are arranged on an exterior side of the reinforcement grid. For instance, this could be utilised to encase a supporting component such as a column or I-beam as mentioned above. Whilst in some cases the various components could be engineered to fit together without the need for mortar or the like, most preferably the method further comprises applying a binding agent to bind the masonry units, positioning elements and reinforcement grid together, wherein preferably the binding agent is a mortar, grout, cement or adhesive. Once solid, the binding agent mechanically interlocks the various components to one another The reinforcement grid and/or rails can also be used to attach or support other facade items such as stone or pre-cast features or windows. Items such as these can be connected to the reinforcement grid and configured to interface with the masonry units alongside them. This advantageously allows other components regularly forming part of a facade to be attached as part of a prefabricated system.

The first aspect of the invention further provides a masonry panel comprising: a reinforcement grid comprising a first plurality of rods each extending along a first grid direction and spaced from one another along a second grid direction which is perpendicular to the first grid direction; a plurality of masonry units, each masonry unit comprising a first presentation face and a first interior face opposed to the first presentation face, wherein the first interior face is shaped to define at least one keying feature, wherein the masonry units are arranged in at least a first column adjacent to the reinforcement grid, the masonry units in the first column each being oriented such that the first interior face of each masonry unit is on an interior side of the column which faces the reinforcement grid; and a plurality of positioning elements each comprising: a receiving feature adapted to receive a portion of one of the first plurality of rods; and one or more keying members each adapted to key with a respective keying feature of one of the masonry units so as to hold, in use, the masonry unit at a respective predetermined distance from the received portion of the rod; wherein the positioning elements are arranged such that the receiving feature of each positioning element receives a portion of one of the first plurality of rods and at least one of the keying members of each positioning element keys with a keying feature of one of the masonry units.

Again, the masonry panel can be made from the above-described masonry panel assembly and/or by performance of the above method. Any of the preferred features mentioned above can be incorporated.

Whilst as already mentioned the panel could comprise a single column of masonry units, more preferably the masonry units are arranged into the first column and a second column, wherein the reinforcement grid is positioned between the first and second columns, the masonry units in the second column each being oriented such that the first interior face of each masonry unit is on an interior side of the column which faces the reinforcement grid. Advantageously, the masonry units in each column do not intersect the reinforcement grid. This enables the use of a more rigid reinforcement grid with rods in at least two non-orthogonal directions.

As previously explained it is most preferable that in each column the first interior faces of the masonry units are arranged to be substantially coplanar, wherein preferably the plane of the first interior faces of the first column is spaced from the plane of the first interior face of the second column by a distance corresponding to at least the thickness of the reinforcement grid.

If a 3-dimensional brickwork pattern is desired (i.e. a relief pattern which projects out from the reinforcement grid), in the first column the first presentation faces of the masonry units may be spaced at varying distances from the reinforcement grid, such that the panel has a non-uniform depth in a third direction which is orthogonal to the first and second grid directions. As described in relation to the method, this can be achieved via two approaches. In some implementations, in the first column the spacing of the masonry units from the reinforcement grid varies. This can be facilitated by the plurality of positioning elements including positioning elements configured to hold a masonry unit at different respective predetermined distances from the reinforcement grid, and are arranged such that one or more of the masonry units in the first column are held at different distance(s) from the reinforcement grid to others of the masonry units in the first column. Alternatively or in addition the first column may comprise masonry units of different depth in the direction between the first interior and first presentation faces thereof.

The plurality of positioning elements can include single unit elements (e.g. "clips") and/or at least some of the positioning elements may each comprise assemblies as described above. In this case those positioning elements each comprise one or more ties, each tie comprising a receiving portion adapted to receive a portion of a respective one of the first plurality of rods and a spacing portion comprising a plate having a plurality of perforations therethrough, configured such that the plate lies in a plane substantially perpendicular to the first grid direction. Each of the ties may be arranged such that the receiving portion of the tie receives a portion of one of the first plurality of rods and the plate of the tie is either in contact with an upper bedding face or a lower bedding face of a respective one of the masonry units in the one or more columns, or is located in a bedding joint therebetween.

Preferably, the ties of each pair are arranged such that the receiving portions of the pair of ties each receive a respective portion of different ones of the first plurality of rods, and such that one of the perforations of one tie is aligned with one of the perforations of the other tie along the first grid direction; the elongate connecting member is arranged so as to extend through the aligned perforations, whereby the two ties are prevented from rotating about the received rods; a clip is connected to the connecting member by a connecting feature of the clip, the clip comprising the keying members of the positioning element; and at least one of the keying members of the connected clip is keyed with a respective keying feature in one of the plurality of masonry units such that the masonry unit is held at a predetermined distance from the reinforcement grid.

The positioning elements advantageously have any of the preferred features already described above. Likewise, the masonry units and the reinforcement grid can have any of the features already described with respect to the disclosed masonry panel assembly system.

Preferably the reinforcement grid further comprises a first rail and a second rail each extending in the second grid direction and spaced from one another in the first grid direction, wherein each of the first and second rails connects at least some of the first plurality of rods to one another Desirably, each of the first and second rails comprises one or more attachment features for attaching the prefabricated masonry panel to a structure. However, the attachment features could be affixed to alternative locations on the reinforcement grid (not to the rails) if desired.

The panel preferably further comprises a binding agent which binds the masonry units, reinforcement grid and positioning elements together, wherein preferably the binding agent is a mortar, grout, cement or adhesive. As is known in the art, mortar, grout and cement are workable aggregate pastes used to bind masonry units together and fill or seal gaps and cavities between them. Once cured mortar, grout or an alternative binding agent form a solid join or bond between masonry units. A wide variety of compositions of both mortar and grout are known and substantially any suitable composition may be used to bind masonry unit of the present invention together. Additionally or alternatively, any further suitable binding agents such as adhesives may also be used. Mortar is particularly preferred to structurally bind adjacent masonry units together and is typically laid with a thickness of approximately 10 mm, and designed for the normal tolerances expected of a masonry unit. In addition, mortar is visually preferred and provides a good aesthetic appearance. However, if cavities or gaps between masonry units are greater than 20 to 30 mm (or outside the relevant British standard for laying bricks), grout is preferred. The mortar in which the masonry units are laid may be finished (e.g. smoothed) where the joints are exposed. Alternatively, or additionally pointing may be applied to external or exposed joints. This pointing is typically weather resistant and/or sacrificial. The pointing may also provide further visual effects.

In accordance with a second aspect of the invention, a prefabricated masonry panel is provided, comprising: a reinforcement grid comprising a first plurality of rods each extending along a first grid direction and spaced from one another along a second grid direction which is perpendicular to the first grid direction, and a first rail and a second rail each extending in the second grid direction and spaced from one another in the first grid direction, wherein each of the first and second rails connects at least some of the first plurality of rods to one another; one or more attachment features connected to the reinforcement grid for attaching the prefabricated masonry panel to a structure; and a first column and a second column each comprising a respective plurality of masonry units, wherein the first column and the second column respectively define a first panel face and a second panel face, and wherein the reinforcement grid is positioned between the first and second columns.

This prefabricated masonry panel may or may not be constructed using the masonry panel assembly system or method of the first aspect of the invention. In particular, the use of positioning element (as described earlier) is not essential, although is still preferred.

In this aspect, the prefabricated masonry panel is centrally reinforced, with the first and second columns of masonry units being located on either side of the reinforcement grid and thereby enclosing it on both sides. As discussed previously, this results in a strong, rigid panel which can withstand the stresses and strains encountered during transportation and installation. The masonry units may or may not intersect the reinforcement grid. In the former case, this allows for the use of interlocking masonry units such as the "F-shaped" or "E-shaped" masonry units disclosed in our British patent application no. 1912532.7. In the latter case, a more complex reinforcement grid which includes rods in at least two non-orthogonal directions can be employed to achieve an even stronger panel.

The reinforcement grid can have any of the preferred features described above with reference to the first aspect of the invention and most preferably comprises a diagrid.

While the use of positioning elements is not essential in this aspect of the invention, they are still preferred and provide the additional benefits already discussed above. Any of the preferred features of the positioning elements discussed above in relation to the first aspect of the invention can be provided. Likewise, whilst the use of masonry units equipped with keying features is not essential, this is preferred and hence in advantageous embodiments the masonry units may have any of the features discussed with reference to the first aspect of the invention. This in preferred implementations, each masonry unit comprises a first presentation face and a first interior face opposed to the first presentation face, wherein the first interior face is shaped to define at least one keying feature; and wherein the prefabricated masonry panel further comprises: a plurality of a plurality of positioning elements each comprising a receiving feature which accommodates a portion of one of the first plurality of rods; and one or more keying members which keys with a respective keying feature of one of the masonry units whereby the masonry unit is held at a respective predetermined distance from the received portion of the rod.

If positioning elements and keying features are not utilised, it is preferable to use interlocking masonry units to ensure the masonry units and reinforcement grid are firmly connected (optionally, once mortar or other binding agent is added), in order that the panel's integrity is maintained. Indeed, in some cases the size and/or required engineering of a wall structure may make it necessary to use interlocking bricks (such as the "F-shaped" or "E-shaped" masonry units mentioned above), rather than the aforementioned system utilising positioning elements and keying features.

The attachment features can be of any sort which enable connection of the panel to a building or other structure. For instance, each attachment feature could comprise a stub bracket or similar which is welded or bolted to the reinforcement grid and has connection means for joining to a corresponding component on the building, such as steel pins or a bracket set into concrete, or a bolted socket on a steel joist for instance. The one or more attachment features could be joined to the reinforcement mesh at any convenient location(s), including joining to one or more of the rods. However, in preferred cases, one or more of the attachment features are each connected to one of the first and second rails. This is advantageous since the stresses experienced by the panel during use will be transferred by the rods to the first and second rails, and if the attachment features are located there, on to the structure thereby preserving the panel. It should be noted that the first rail may not be connected to all of the rods of the reinforcement grid, and likewise the second rail, for instance if the reinforcement grid is not planar it may be necessary to provide multiple first rails, one for each planar section of the grid, and similarly multiple second rails. The multiple first rails may or may not be joined (e.g. welded) to one another, and likewise the multiple second rails may or may not be joined (e.g. welded) to one another, for increased stiffness and strength. Each rail will be connected to the rods in that planar section of the grid but may not be directly connected to the rods in the other planar sections.

Typically in such cases attachment features may be provided on each of the first rails and/or on each of the second rails.

One or more of the attachment features could be an areal or linear attachment feature configured to make a connection between the grid and the structure along the whole of a (two-dimensional) area of the grid (i.e. a portion with significant size in two directions) or along the whole of a linear portion of the grid, e.g. one of the first or second rails. However, preferably, each attachment feature is a nodal connector. That is, the connections are point connections made between specific positions on the grid (with minimal size in any direction, relative to the size of the panel as a whole) and the building structure. This further reduces thermal bridging and simplifies construction. Most preferably, each attachment feature comprises a thermally broken connection assembly configured to impede heat flow through the attachment feature. Suitable connectors comprising thermal breaks are available commercially.

The second aspect of the invention further provides a method of constructing a structure, the method comprising providing one or more prefabricated masonry panels as just described and attaching the prefabricated masonry panel(s) to the structure by attaching the attachment feature(s) of the one or more prefabricated masonry panels to corresponding attachment points on the structure.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Examples of a masonry panel assembly system, methods of constructing a masonry panel, and masonry panels in accordance with aspects of the invention will now be described with reference to the accompanying drawings, in which: Figure 1 shows examples of reinforcement grids suitable for use in embodiments of the invention; Figure 2 shows examples of clamps suitable for use in embodiments of the invention; Figure 3 shows first and second examples of a masonry units suitable for use in embodiments of the invention; Figure 4 shows a third example of a masonry unit suitable for use in embodiments of the invention; Figures 5 and 6 show variants of the masonry units shown in Figures 3 and 4; Figure 7 shows a clip suitable for use as, or as part of, a positioning element in embodiments of the invention; Figure 8 shows an example of a tie suitable for use as part of a positioning element in embodiments of the invention; Figure 9 shows an exemplary positioning element formed of the clip of Figure 7 and two ties as shown in Figure 8; Figure 10 illustrates the use of exemplary positioning elements suitable for use in embodiments of the invention; Figure 11 shows a masonry panel in accordance with an embodiment of the first and second aspects of the invention; Figure 12 shows a prefabricated masonry panel in accordance with an embodiment of the second aspect of the invention; Figure 13 shows further examples of masonry panels in accordance with the first aspect of the invention; Figure 14 shows exemplary masonry units suitable for use in implementations of the invention; Figure 15 shows a first positioning element suitable for use in embodiments of the invention with the masonry unit of Figure 14; Figure 16 shows a second positioning element suitable for use in embodiments of the invention with the masonry unit of Figure 14; Figure 17 shows the masonry unit and positioning elements of Figures 14 to 16 in use Figure 18 shows a masonry panel in accordance with an embodiment of the second aspect of the invention incorporating the masonry units of Figure 14; Figure 19 shows an exemplary masonry panel in accordance with embodiments of the invention attached to a structure; and Figure 20 shows an exemplary attachment feature suitable for use in embodiments of the invention.

As was explained above, a first aspect of the invention relates to a masonry panel assembly system, a method of constructing a masonry panel and a corresponding masonry panel. Figures 1 to 9 show examples of reinforcement grids, masonry units and positioning elements that can be included in such a system. An exemplary system in accordance with the first aspect of the invention can therefore comprise, for example, (i) the reinforcement grid of Figure 1(a) or 1(b) (or a reinforcement grid comprising a plurality of planar sections each as shown therein), (ii) a plurality of masonry units as shown in any of Figures 3 to 6; and (iii) a plurality of positioning elements as shown in Figure 7 or Figure 9. The same components can also be incorporated in masonry panels in accordance with the second aspect of the invention. Figures 10 to 13 show various examples of masonry panels in accordance with first and/or second aspects of the invention. Figures 14 to 17 show additional exemplary masonry units and positioning elements which are also suitable for use in systems, masonry panels and methods in accordance with the invention. Figures 18 and 19 show some further examples of masonry panels in accordance with either aspect. Figure 20 provides more detail of exemplary attachment features for use in either aspect.

Figure 1(a) shows a first example of a reinforcement grid 101 suitable for use in embodiments of the present invention. The reinforcement grid 101 includes a first plurality of rods 103, which extend along a first grid direction A and are spaced from one another along a second grid direction B. In this example, the first plurality of rods 103 are parallel to one another and are uniformly spaced along the second grid direction B. A third grid direction C lies perpendicular to both the first grid direction A and the second grid direction B. In this example, the reinforcement grid 101 also includes a second plurality of rods 105, which are arranged in an orthogonal lattice that is oriented at 45 degrees to the first grid direction A and the second grid direction B (and hence at 45 degrees to the first plurality of rods 103). Each of the second plurality of rods 105 thus lies diagonally with respect to the first plurality of rods in this example. For brevity, a reinforcement grid having a first plurality of rods 103 as described above and a second plurality of rods 105 that are both non-perpendicular and non-parallel to the first plurality of rods 103 will be referred to in some instances below as a "diagrid".

Where one of the second plurality of rods 105 intersects another of the second plurality of rods 105 and/or one of the first plurality of rods 103, the two intersecting rods are connected to one another, for example by welding. In this first example, the second plurality of rods 105 may be identical to the first plurality of rods 103.

The rods 103, 105 may be made of a metal or alloy, preferably steel (for example stainless steel), and are circular in cross-section. The second plurality of rods 105 strengthen the reinforcement grid 101 by bracing the first plurality of rods 103.

Figure 1(b) shows a second example of a reinforcement grid 101. This example includes a first plurality of rods 103, which, like in the first example, extend along the first grid direction A and are spaced from one another along the second grid direction B. This example also includes a second plurality of rods 107, which are arranged in an orthogonal lattice. In this example, however, the second plurality of rods 107 are each formed as flat bars, rather than with a circular cross-section.

The first plurality of rods could be connected to the flat bars 107 at their intersections, for example by welding.

As was explained earlier, only the first plurality of rods 103 is an essential feature of the reinforcement grid 101. However, the presence of a second plurality of rods 105, 107 is preferred as this improves the rigidity and strength of the reinforcement grid 101 (and hence that of the finished masonry panel). The second plurality of rods 105, 107 being arranged as a diagrid, i.e. both non-parallel and non-perpendicular to the first plurality of rods 103, is particularly preferred since the diagonal rods 105, 107, when connected to the first plurality of rods 103, form triangles that brace the reinforcement grid 101 very effectively.

In Figures 1(a) and 1(b), the reinforcement grids 101 are shown as being planar, i.e. flat in the plane of the first grid direction A and second grid direction B. However, implementations of the invention may also use reinforcement grids that have more complex, non-planar shapes. The reinforcement grids 101 shown in Figures 1(a) and 1(b) could, for example, be bent at one or more positions about the first grid direction so that the grid comprises a plurality of planar sections (each still parallel to the first grid direction but not all lying in the same plane as one another). The reinforcement grid could also be provided as several detached sections each as shown in Figure 1(a) or 1(b), which could be connected using, for example, clamps.

Although not shown here, reinforcement grids suitable for carrying out embodiments of the invention could be configured to includes features such as windows or doorways defined by openings in the reinforcement grid 101 (e.g. by cutting away parts of the rods 103, 105). Such features could be supported by lintels or other additional structural elements in the reinforcement grid 101.

Figure 2 shows examples of clamps 201 suitable for connecting detached planar sections of a reinforcement grid in embodiments of the invention. Each clamp 201 includes two pairs of opposed plates 203a, 213a, 203b, 213b, which in each pair are parallel to one another. The plates 203a, 213a, 203b, 213b are formed with ridges 205, which are shaped and positioned to define channels each capable of receiving one of the first plurality of rods 103. One pair of plates 203a, 213a receives two of the first plurality of rods 103 of one planar section (one rod for each pair of ridges), and the other pair of plates 203b, 213b receives two of the first plurality of rods in another planar section. Each of the plates 203a, 203b, 213a, 213b can have a flared end 209, which can make it easier for a user to fit the clamp 201 to the reinforcement grid 101. The clamp 201 can be produced by, for example, joining two separate pieces of material 203, 213, of which one has the plates 203a, 203b and the other has the plates 213a, 213b. The two pieces of material 203, 213 can be joined by welding together the sections between the plates, for example, or by mechanical fixtures such as screws or bolts.

Holes are formed through each pair of plates 203a, 213a, 203b, 213b such that a screw 207 can extend through both plates 203a, 213a, 203b, 213b. The screws 207 can be inserted and tightened to as to secure the clamp 201 to the received rods 103. The holes could be pre-tapped, i.e. formed with a thread before receiving screws 207, in which case the screws 207 could be machine screws.

Alternatively, the holes may not be pre-tapped and the screws 207 could be self-tapping (i.e. configured to form a thread in the hole as the screw is screwed into the hole). An advantage of using self-tapping screws is that the holes in opposite plates 203a, 213a, 203b, 213b and their respective threads do not need to be carefully aligned prior to insertion of the screw 207. Bolts could also be used in place of the screws 207 described above.

The clamps 201 can be configured to connect detached planar sections of the reinforcement grid 101 at various angles. In the clamp shown in Figure 2(a), the two pairs of plates 203a, 213a, 203b, 213b are at right angles to one another, so this clamp can be used to connect two perpendicular sections of the reinforcement grid 101. In the clamp 201 shown in Figure 2(b), the two pairs of plates 203a, 213a, 203b, 213b are at an obtuse angle with respect to one another.

In the example of Figure 2(c), the two pairs of plates 203a, 213a, 203b, 213b are parallel to one another but the clamp 201 is shaped such that the pairs of plates 203a, 213a, 203b, 213b are spaced from one another along the direction perpendicular to the plane of the plates 203a, 213a, 203b, 213b. This clamp 201 is thus suitable for connecting two planar sections that are parallel but not coplanar.

Co-planar detached sections of the reinforcement grid 101 could also be attached using a clamp shaped such that the two pairs of plates are co-planar (not shown).

Figure 3 shows an example of a masonry unit 301 suitable for use in embodiments of the present invention. The masonry unit 301 is generally cuboidal in shape. It has a presentation face 303, which is opposite an interior face 305. In this example, the presentation face 303 and the interior face 305 are generally parallel to one another. The presentation face in this example is generally planar, but could be provided with a texture or shaped in accordance with a pattern, for example. The presentation face 303 in this example is a stretcher face.

The masonry unit 301 has an upper bedding face 309 and a lower bedding face 311. It also has a first side face 313 and a second side face 315, which are at opposed ends of the masonry unit 301.

The interior face 305 is shaped to define two keying features 307. Each keying feature 307 comprises two slots 307a, 307b, which originate at the same position on the interior face 305 and extend into the masonry unit 301 away from the interior face 305. In this example, the slots 307a, 307b both extend into the masonry unit 301 at 45 degrees to the direction normal to the plane of the interior face 305, which in Figure 3 is labelled at the Y direction. The slots 307a, 307b extend continuously along the Z direction between the upper bedding face 309 and the lower bedding face 311. The keying features 307 are preferably cut into the masonry unit 301.

The keying features 307 are each positioned at a distance along the X direction from the nearest end of the masonry unit 307 that is approximately equal to 1/3 the length of the masonry unit 301 along the X direction, and the keying features 307 are spaced from one another along the X direction by the same distance. As was explained previously, this allows the masonry units 301, when incorporated in a masonry panel, to be arranged in courses in which the repeat distance of the masonry unit corresponds to an integer multiple of the spacing between a first plurality of rods in a reinforcement grid. The positioning of the keying features 307 can thus be selected to take account of the presence of a binding agent, e.g. mortar, between adjacent masonry units 301 in the finished masonry panel.

Figures 3(e) to (g) show another exemplary masonry unit 331. The masonry unit 331 is identical to the masonry unit 301 described above, except that it has only one keying feature 337, which is positioned on the interior face 335 about half way between the side faces 343, 345 along the X direction. The keying feature 337 has two slots 337a, 337b as described above with references to the keying feature 307. The presentation face 333 is a stretcher face, like in the masonry unit 301. The upper bedding face 339 and lower bedding face 341 are opposite one another along the Z direction.

The masonry units 301, 331 can be manufactured by cutting a standard masonry unit, for example the British standard brick having dimensions British Standard brick has dimensions 215mm x 102.5 x 65 mm, to the required shape. A standard masonry unit 321 suitable for manufacturing the masonry units 301, 331 is shown in Figure 3(h). The standard masonry unit 321 is generally cuboidal in shape and is thus suitable for bonding to other masonry units in a modular manner, for example in columns formed of regular courses of masonry units. Masonry units 301, 331 cut from the standard masonry unit 321 can also be generally cuboidal in form and thus similarly suitable for bonding to one another in a modular fashion.

As will be familiar to those of ordinary skill in the art, a standard masonry unit is described as having three different types of face, each of which has different dimensions. The two "bedding" faces are those which have the two greatest dimensions of the masonry unit (and hence the greatest area). In the standard masonry unit 321, the bedding faces 329 lie in the X-Y plane. The "stretcher" faces are those which have the second greatest area. In the standard masonry unit 323, the stretcher faces 323 lies in the X-Z plane. The "header" faces are the two faces with the smallest area (defined by the two smallest perpendicular dimensions of the masonry unit). In the standard masonry unit 321, the header faces 325 lie in the Y-Z plane.

As was mentioned above, the masonry unit 301 of Figures 3(a) to (d) can be cut from a standard masonry unit 321. This can be achieved by cutting the standard masonry unit 321 along the X-Z plane, the cut being made for example approximately half way along the Y direction. The keying features 307 can then be cut into the cut face (which becomes the interior face in the finished masonry unit 301). When the masonry unit 301 is made in this way, its presentation face 303 is one of the original stretcher faces 323 of the standard masonry unit. The end faces 313, 315 each constitute the retained parts of the header faces 325 of the standard masonry unit 321, and similarly the bedding faces 309, 311 are the retained parts of the original bedding faces 329. The depth of the masonry unit 301 (i.e. its dimension along the Y direction) can be chosen by varying where the cut is made in the standard masonry unit 321 along the Y direction with respect to the stretcher face 323 that is to be retained. The masonry unit 331 of Figures 3(e) to (g) can be manufactured in the same way.

In embodiments of the invention, masonry panel assembly systems and masonry panels can include masonry units with different depths, i.e. different separations between the interior face(s) and respective presentation face(s). In these embodiments, the masonry units can be held by the positioning elements such that their interior faces are each at substantially the same distance from the reinforcement grid but, as a result of the varying depth, with their presentation faces at different will be at different distances. This allows patterns to be formed on the visible faces of the masonry panel based on the varying distance of the presentation faces from the reinforcement grid. Alternatively, the same effect can be achieved by the use of positioning elements configured to hold the masonry units at variable distances. An example of this will be described later with reference to Figure 9.

As an alternative to cutting the masonry units 301, 331 from a standard masonry unit 321, the masonry unit 301 could be an extruded unit. However, it is preferred that the masonry units 301, 331 are cut from standard masonry units 321 since the presentation faces 303, 333 will then have the authentic appearance of a standard masonry unit 321 (which can be produced by moulding techniques that give rise to different visual characteristics to those that can be obtained by extrusion).

Figure 4 shows a second example of a masonry unit 401 suitable for use in embodiments of the invention. Like the masonry unit 301 of Figure 3, the masonry unit 401 is generally cuboidal in shape and has a presentation face 403 and an interior face 405, an upper bedding face 409 and a lower bedding face 411, and two side faces 413, 415. However, the masonry unit 401 includes only one keying feature 407, which includes two slots 407a, 407b and is preferably the same as the keying feature 307 described above in the masonry unit 301 described above.

The masonry unit 401 has a length along the X direction that is about half that of the masonry unit 301 shown in Figure 3. Its height along the Z direction is the same as that of the masonry unit 301. The keying feature 407 is equally spaced from the two side faces 413, 415 along the X direction.

The masonry unit 401 can also be manufactured from a standard masonry unit 321 as shown in Figure 3(h). In this case, however, the cut would be made in the Y-Z plane, and the presentation face 403 would correspond to an original header face 325 of the standard masonry unit 321. The side faces 413, 415 would thus be the retained portions of the stretcher faces 323.

Figures 5(a) to (c) show a variant of the masonry unit 301 of Figure 3. In this example, the upper bedding face 309 has a depressed area 309a (sometimes known as a "frog"). The masonry unit 301 shown in Figure 5 is otherwise the same as that shown in Figures 3(a) to (d). The depressed feature 309a can improve the ability of the masonry unit 301 to key with a binding agent. Figures 5(d) to (f) show an equivalent variant of the masonry unit 331 of Figures 3(e) to (g), which has a frog 339a.

Figure 6 shows a variant of the masonry unit 401 of Figure 4 which includes a depressed area 409a (or "frog") in the upper bedding face 409 similar to that described above with reference to Figure 5. The masonry unit 401 shown in Figure 6 is otherwise identical to that shown in Figure 4.

The masonry units 301, 401 shown in Figures 5 and 6 can be cut from standard masonry units formed with frogs in the same way described above with reference to Figures 3 and 4.

Figure 7 shows an example of a clip 701 that is suitable for use as either the whole or part of a positioning element in embodiments of the invention. The use of the clip 701 will be described in detail later.

The clip 701 has a receiving feature 703. The receiving feature 703 is defined by two curved lips 707a, 707b, each of which curves at a substantially constant radius around a channel axis L. The two curved lips 707a, 707b thus each define a respective section of a channel that extends along the channel axis L. The diameter dc of the channel may correspond to the diameter of one of the first plurality of rods 103 of the reinforcement grid with which the clip is intended to be used.

The curved lips 707a, 707b are spaced from one another along the channel axis L. Each curved lip 707a, 707b includes a respective projecting feature 709a, 709b that extends along the direction of the channel axis L towards the other curved lip 707a, 707b. The projecting features are offset with respect to one another in an azimuthal direction P. which is an angular direction about the channel axis L. The clip 701 includes two keying members 705a, 705b. Each keying member 705a, 705b is an elongate tab, which, in this example, is generally planar and lies parallel to the channel axis L. The keying members 705a, 705b extend radially away from the receiving feature 703. In this example the keying members have equal lengths IK along the direction perpendicular to the channel axis L, and are preferably angled at 45 degrees to one another about the channel axis L. The keying members 705a, 705b can optionally include a plurality of perforations 711. The perforations 711 can be formed by piercing the keying members 705a, 705b, preferably in such a way that results in the edge of each perforation 711 extending out of the plane of the keying member 705a, 705b. The perforations 711 help the keying members 705a, 705b to key with a binding agent and/or keying feature of a masonry unit with which the keying members 705a, 705b are in contact. Alternatively or in addition to perforations 711, the keying members 705a, 705b could be provided with corrugations that extend out of the plane of the tab.

The keying members 705a, 705b and the curved lips 707 are each joined to a spine 713, which extends continuously along the channel in the direction of the channel axis L and is curved about the channel axis L at the same diameter dc as the curved lips 707.

The clip 701 has a length lc along the direction of the channel axis L. The length lc preferably corresponds approximately to the a dimension of a masonry unit with which the clip is to be used, for example the height in the Y direction of the masonry units shown in Figures 3 to 6.

The clip 701 can be formed from a single, planar piece of material, for example a metal or alloy (preferably stainless steel). For example, the piece of material could be stamped with a suitable template and then worked into the shape shown.

Figure 8 shows an example of a tie 801 that can be used in some implementations of the invention. As will be explained later, the tie 801 can form part of a positioning element that also incorporates a clip 701 as described above.

The tie 801 includes a receiving feature 803, which is configured similarly to the receiving feature 703 of the clip 701 described above. The receiving feature 803 includes two curved lips 807a, 807b, which are curved about a channel axis L'. Each curved lip 807a, 807b defines a section of a channel extending along the channel axis L. Like in the clip 701, each curved lip 807a, 807b includes a projecting feature 809a, 809b that extends towards the other curved lip 807a, 807b along the direction of the channel axis L. The projecting features are offset from one another in an azimuthal direction P', which is an angular direction orthogonal to the channel axis L'. The curved lips 807a, 807b are both connected to a spine 813 that extends continuously along the channel. The internal diameter dr of the channel defined by the curved lips 807a, 807b is such that that receiving feature 803 can accommodate one of the first plurality of rods 103, and is preferably about equal to the diameter of one of the first plurality of rods 103.

The tie 801 includes a plate 805 that is connected to one end of the receiving feature 803 and lies in the plane perpendicular to the channel axis L. The plate 805 extends radially away from the receiving feature 803. The plate 805 has a length lp as measured from the channel axis L (at the centre of the channel). In this example, the plate 805 has an elongate, curved form.

The plate 805 includes a plurality of perforations 811. The function of the perforations 811 will be explained below with reference to Figures 9 and 10.

Figure 9 shows a positioning element 901 that includes a clip 701 as shown in Figure 7, two ties 801 each as shown in Figure 8, and an elongate connecting member 903, for example a straight shaft with the same diameter as one of the first plurality of rods 103 in a reinforcement grid. The connecting member 903 is disposed inside the channel defined by the curved lips 707 of the clip 701. Each end 905 of the connecting member 903 extends through one of the perforations 811 in the plates 805 of the ties 801. The perforations 811 are preferably each shaped to form an interference fit with the received end 905 of the connecting member 903 in this configuration (and thus mechanically lock the connecting member 903 in place).

The receiving features 803 of the ties 801 are parallel to one another in this configuration. As will be explained later, each receiving feature 803 can receive a respective portion of a different one of the first plurality of rods 103. In this arrangement, the receiving features 803 of the ties 801 and the receiving feature 703 of the clip are fixed in place with respect to one another. This forms a triangle with vertices at the positions of the two rods 103 and the connecting member 903. As a result, the keying members 705a, 705b of the clip 701 are rigidly held at a distance from the reinforcement grid 101 that is determined by the distance of the perforations 811 by which the ends 905 elongate connecting member 903 are receiving from the receiving features 803 of the respective ties 801.

As was explained above, Figures 1 to 9 show exemplary components of a masonry panel assembly system in accordance with the first aspect of the invention The use of these components to assemble masonry panels in accordance with embodiments of the invention will now be described.

Figure 10(a) illustrates how the clip 701 shown in Figure 7 can be used as a positioning element in embodiments of the invention. Two clips 701 are shown, each one having a respective one of the first plurality of rods 103 in a reinforcement grid 101 extending through its receiving feature along the first grid direction A. The clips are thus oriented such that their keying members 705 are each parallel to the first grid direction A. Two masonry units 301 of the kind shown in Figure 5 are positioned one each side of the reinforcement grid 101. The masonry units 301 are oriented such that their interior faces 305 face towards the reinforcement grid 101, and their presentation faces 303 face away from it.

The clip 701 on the left-hand side is arranged such that each keying member 705 keys with one of the keying features 307 of each masonry unit 301 (with each keying member 705 occupying one slot 307a, 307b of each respective keying feature 307). Each masonry unit 301 is held by this clip 701 at the same predetermined distance from the reinforcement grid 101. When, in use, mortar or another binding agent is added between adjacent masonry units 301 and into the slots 307a, 307b, a strong interlocking that fixes the masonry units 301 in place with respect to one another and the reinforcement grid 101 is achieved.

The clip 701 on the right-hand side is oriented such that both of its keying members 705a, 705b key with the same keying feature 307 of one masonry unit 301. One keying member 705a, 705b extends into each slot 307a, 307b of the keying feature 307. The clip 701 thus holds the masonry unit at a predetermined distance from the reinforcement grid 101.

Figure 10(b) shows the positioning element 901 of Figure 9 in use. A different one of the first plurality of rods 103 extends through the receiving feature 803 of each tie 801. As described above with reference to Figure 9, the elongate connecting member 903 extends through the receiving feature of the clip 701 and through one perforation 811 of each tie 801. The dimensions of the clip 701 and the connecting member 903 are such that one tie lies above the masonry unit 301 and the other lies below it. Both plates are parallel to the upper bedding face 309 and lower bedding face 311 of the masonry unit 301 in this example.

In this example, the distance of the clip 701 from the reinforcement grid dependents on which perforations 811 the connecting member 903 extends through. The plurality of perforations 811 are thus preferably arranged such that connecting member 903 can be arranged to hold the clip 701 at various predetermined distances from the reinforcement grid 101. Once the keying members 705a, 705b of the clip 701 are keyed with a keying feature 307 of the masonry unit 301, the masonry unit will thus also be held with its presentation face at a predetermined distance from the reinforcement grid 101. As was explained above, a binding agent can be added in use to the spaces between adjacent masonry units 301 and can encase the plates 805 and clip 701 in order to resiliently join the masonry units 301 to the reinforcement grid 101.

It should be noted that positioning elements of the sort shown in Figures 10(a) and 10(b) can also be used together. For example, in the Figure 10(b) arrangement, an additional positioning clip 701 of the sort shown in Figure 7 could be provided connecting another of the first plurality of rods 103 to the masonry unit 309 on the opposite side of the reinforcement grid from that to which positioning element 901 connects (not shown in Figure 10(b)).

In the examples of Figures 10(a) and 10(b), the masonry units 301 that are shown can be arranged in regular courses that extend along the second grid direction B on either side of the reinforcement grid. Several such courses can be stacked in the first grid direction A so as to form columns on either side of the reinforcement grid 101. The masonry units 301, the clips 701, reinforcement grid 101 and, if present, ties 801 can be bound together by a binding agent, for example mortar, grout, cement or adhesive. In that case, the fies 801 shown in Figure 10(b) would each lie between two masonry units and be encased in the binding agent. In both examples the keying members 705 can also be at least partly encased in the binding agent. The masonry units 331 of Figures 3(e) to (g) can be used with clips 701 in the same way, i.e. by inserting one or each keying member 705a, 705b into a respective slots 337a, 337b.

Figures 10(c) and (d) illustrate how the exemplary clips 701 and positioning elements 901 can be used to hold masonry units 301 at different distances from a reinforcement grid 101. By placing the connecting member into different perforations 811 in the plates 805, the distance between the reinforcement grid 101 and the clip 701 held by the connecting member 903 along the third grid direction C can be varied. In this example, the spacing between the masonry units 301 and reinforcement grid 101 is minimised when the clip 701 alone is used as the positioning element. Figure 10(e) shows an example of a masonry panel 1051 which has a first column 1053 and a second column 1055 of masonry units 301.

In the first column 1053 the spacing between the masonry units 301 and the reinforcement grid 101 along the third grid direction C varies along the second grid direction B. This can be achieved using the adjustable positioning element 901 in the manner described above.

Figure 11(a) shows an example of an unfinished masonry panel 1101 (or a portion thereof) in accordance with the invention, and Figure 11(b) shows an exploded view of the same masonry panel 1101. The masonry panel 1101 includes a reinforcement grid 101 of the kind shown in Figure 1(a). The reinforcement grid 101 includes a first plurality of rods which extend along the first grid direction A and are spaced from one another in the second grid direction B. The masonry panel also includes a plurality of masonry units 301, 401, which in this example are masonry units of the kind described above with reference to Figures 3 and 4. The masonry units 301, 401 are arranged on either side of the reinforcement grid 101 in a first column 1103 and a second column 1105 (such that the reinforcement grid 101 is positioned between the first and second columns 1103, 1105). The masonry units 301, 401 in this example do not intersect the plane of the grid 101.

The interior faces 305, 405 of the masonry units face towards the reinforcement grid 101 along the third grid direction C. A plurality of clips 701 are arranged so as to hold some of the masonry units 301, 401 at a predetermined distance from the reinforcement grid 101 in the manner described above with reference to Figure 10(a). It should be understood than not all of the masonry units 301, 401 must be engaged with a respective clip 701. The masonry panel 1101 could be constructed with a predetermined ratio between the number of clips 701 and number of masonry units 301, 401, for example. Preferably one clip 701 is provided every 450 mm in each diagonal direction (i.e. the two directions at 45 degrees to the first grid direction A and second grid direction B). The number and arrangement of the clips 701 can, however, be varied, for example to account for the presence of features such as windows or attachment features in the reinforcement grid 101.

The reinforcement grid 101 includes a first rail 109, which extends along the second grid direction B and connects the first plurality of rods 103 to one another.

The first rail 109 in this example carries an attachment feature 111, which is configured to be connected to a part of a structure (for example a building) so as to attach the masonry panel 1101 to the structure A detailed example of an attachment feature will be described later To complete the masonry panel 1101, any further courses of masonry units 301, 401 desired will be added on top of those shown, and mortar or another binding agent will be applied to fill all the joints. Once solid, the components will be firmly interlocked resulting in a strong and rigid masonry panel.

Figure 12 shows an example of a masonry panel 1201 in accordance with an embodiment of the invention. This masonry panel 1201 demonstrates an example of a complex panel geometry that can be achieved in embodiments of the present invention. Again, in order to allow some of the internal parts of the masonry panel 1201 to be clearly visible, the masonry panel 1201 is shown in an unfinished state.

The masonry panel 1201 can be completed by providing further courses of masonry units and applying mortar or another binding agent in the same manner as mentioned above.

The masonry panel 1201 includes a reinforcement grid 101 of the sort described above, which here is made up of a plurality of planar sections 113, 113'. Each planar section 113, 113' includes a first plurality of rods 103, which extend along the first grid direction A. The reinforcement grid 101 in this example is a diagrid and hence also includes a second plurality of rods 105, which, within each planar section 113, 113', are connected to the first plurality of rods 103 as described above with reference to Figure 1(a).

It should be understood that in any planar section of a reinforcement grid, the term "second grid direction" refers to the direction along which the first plurality of rods 103 are spaced. For each planar section, the second grid direction thus lies in the plane of that section. In the example of Figure 12, planar sections are present in two orientations. A first plurality of planar sections 113 are oriented such that the second grid direction of each one is the direction labelled B. A second plurality of planar sections 113' are oriented perpendicular to the first plurality of planar sections 113, and the second grid direction in each of these sections is along the direction labelled B'. Another planar section 113" is at about 45 degrees to both the first plurality 113 and second plurality 113' of planar sections. Each plurality of planar sections also has a corresponding different third grid direction, which are labelled C and C' respectively. In general, planar sections of a reinforcement grid in embodiments of all aspects of the invention could be present in any number of orientations, each of which will have respective first, second and third grid directions.

Adjacent planar sections 113, 113' are connected to one another using clamps 201 such as those described above with reference to Figure 2. Preferably at least two clamps are used to connect each pair of adjacent planar sections 113, 113' as shown, since this strengthens the reinforcement grid 1201. Again, this applies to reinforcement grids for use in implementations of all aspects of the invention. The second plurality of rods 105 are sufficiently spaced from one another to allow the clamps 201 to attach to the first plurality of rods 103 at the edges of the planar sections 113, 113'. As Figure 12 shows, connecting a plurality of planar sections 113, 113' in this way allows masonry panels with complex, non-planar shapes to be constructed.

In one of the planar sections 113, the reinforcement grid 101 has a first rail 109, which extends along the second grid direction B and connects the first plurality of rods 103 to one another. Similarly, a second rail 115 extends along the second grid direction B in the same planar section 113, parallel to the first rail 109, and connects the first plurality of rods 103 in the planar section 113 to one another.

The first rail 109 and the second rail 115 could be welded to the first plurality of rods in this planar section 113, for example. The first rail 109 and the second rail 115 are spaced from one another along the first grid direction A. An attachment feature 111 is carried by the first rail 109. The attachment feature 111 is configured to be connected to a structure (for example a building under construction) such that the masonry panel 1201 is attached to the structure. Another such attachment feature 111 is carried directly by the first plurality of rods 103 and second plurality of rods 105 in a different planar section 113.

The reinforcement grid 101 could be provided with additional first and/or second rails 109, 115, which could be present in some or all of the planar sections 113, 113' The reinforcement grid could also be provided with additional attachment features 111 connected to the bars 103, 105 and/or rails 109, 115.

The masonry panel 1201 includes a first column 1203 and a second column 1205, each of which comprises a plurality of masonry units 1207. The reinforcement grid 101 is positioned between the two columns 1203, 1207. In this example, within the columns 1203, 1205 the masonry units 1207 are arranged in parallel courses that extend along the second grid direction B, B' at each part of the grid. Additional courses of masonry units 1207 could be added to each of the columns 1203, 1205 such that each column 1203, 1205 covers more of, or the whole of, the reinforcement grid 101 on its respective side. Preferably the clamps 201 are shaped such that they can fit between the two columns 1203, 1205 without disrupting the regular ordering of the masonry units 1207 within the columns 1203, 1205. In preferred embodiments, the masonry panel 1201 can also be provided with positioning elements such as clips 701 as shown in Figure 7 and/or the positioning elements 901 as shown in Figure 9 in order to space the masonry units from the reinforcement grid 101 and attach the masonry units thereto However, in this case the use of positioning elements is optional.

Figure 13 shows two further examples of masonry panels 1323, 1333 in accordance with the the invention. In each example the masonry panel 1323, 1333 encloses a feature of a structure, such as a support column or I-beam.

In the example of Figures 13(a) and (b), the masonry panel 1323 encloses a pillar 1321, which has a substantially square cross-section as shown in Figure 13(b).

The pillar 1321 could be a concrete pillar, for example.

In the example of Figures 13(c) and (d), the masonry panel 1333 encloses a vertical support member 1331, which has a cross-section in the shape of a Latin "H" as shown in Figure 13(d). The vertical support member 1331 could be a steel column in a building, for example.

In each example, the reinforcement grid 101 has a plurality of planar sections 113, 113' connected by clamps 201. The reinforcement grid in both examples encloses an interior volume occupied by the respective vertical feature (i.e. the pillar 1321 and the vertical support member 1331). The respective masonry panel 1323, 1333 has a column of masonry units 1301 on only one side of the reinforcement grid 101 (the exterior side in relation to the enclosed volume).

The masonry units 1301 each have two presentation faces. The first presentation face 1303 is a stretcher face of the masonry unit 1301. The second presentation face 1303' is a header face. Each presentation face 1303, 1303' lies opposite a respective interior face 1305, 1305' of the masonry unit 1301. The first interior face 1305, which is opposite the first presentation face 1303, has two keying features 1307, while the second interior face 1305', which is opposite the first presentation face 1303', does not have any keying features. The second presentation face 1303' and corresponding second interior face 1305' are configured to be able to extend around the corners of the reinforcement grid 101. The spacing between the second presentation face 1303' and the second interior face 1305' is the same as the spacing between the first presentation face 1303 and first interior face 1305. As a result, each second presentation face 1303' in the masonry panel 1323, 1333 is coplanar with the adjacent first presentation faces 1303 in the column.

The masonry panel 1333 in shown in Figures 13(c) and (d) includes masonry units 1301 as described above, but also includes masonry units 1301' of another shape.

The masonry units 1301' have a first presentation face 1303, which is opposite a first interior face 1305. It also includes a second presentation face 1303', which is a header face, and a second interior face 1305' opposite the second presentation face 1303'. Furthermore, the masonry unit 1301' includes a third presentation face 1303", which is perpendicular to the first presentation face 1303 and at an opposite end of the masonry unit 1301' to the second presentation face 1303'. There is a third interior face 1305" opposite the third presentation face 1303". The spacing between the presentation faces and their respective interior faces in the masonry unit 1301' is the same as in the other masonry units 1301. The second and third presentation faces 1305', 1305" do not have keying features

in this example.

Both masonry panels 1323, 1333 include a plurality of clips 701, which are attached to the first plurality of rods 103 in the manner described previously and hold the masonry units 1301, 1301' in position with respect to the respective reinforcement grid 101. The clips 701 thus serve as positioning elements in this example. It will be understood that positioning elements 901 as shown in Figure 9 could also be used in these examples to hold the masonry units as different distances from the reinforcement grid 101. The positioning elements 901 could be configured such that the distance between the presentation faces and the reinforcement grid along the third grid direction C, C' varies, for example to create a pattern in the columns In the preceding examples, masonry units with keying feature(s) formed as angled slots in an interior face of the masonry unit have been described. An alternative form of masonry unit and corresponding positioning elements will now be described, which will be referred to as "F-shaped" masonry units. The masonry panel assembly systems and masonry panels described above incorporate masonry units of the kind described below could be modified to incorporate F-shaped masonry units, as will be explained below. F-shaped masonry units including those discussed below, and various ways of producing masonry panels with patterned surfaces, are described in detail in United Kingdom patent application number 1912532.7.

Figures 14(a) and (b) show an example of an F-shaped masonry unit 1401 suitable for use in implementations of the invention. The F-shaped masonry unit 1401 has a presentation face 1403 and a header face 1413, which is adjacent and perpendicular to the presentation face 1403. A first bedding face 1409 and a second bedding face 1411 of the masonry unit 1401 are opposite one another and perpendicular to the presentation face 1403 and the header face 1413.

The masonry unit 1401 is a right prism, such that its cross section is constant in all planes parallel to the bedding faces 1409, 1411. The masonry unit 1401 further comprises a cuboidal main body 1410 extending in the X direction from the header face 1413 a trailing end 1402 of the masonry unit 1401. The extent of the main body 1410 is indicated by dashed lines in Figures 14(a) and (b).

The masonry unit 1401 has an interior face 1405 opposite the presentation face 1403. The interior face 1405 is shaped to define a header leg 1420 and a main leg 1430. The header leg 1420 and the main leg 1430 extend in the Y direction perpendicular to the main body 1410.

The header leg 1420 extends from the main body 1410 at the end of the masonry unit 1401 at which the header face 1413 is located. The header leg 1420 and the main leg 1430 are spaced from one another in the X direction such that the masonry unit 1401 comprises a main recess 1440 between the header leg 420 and main leg 430. In addition, the main leg 1430 is spaced from the trailing end 1402 of the masonry unit along the X direction. This spacing defines a trailing recess 1450 between the main leg 1430 and the trailing end 1402 of the masonry unit 1401.

The main leg 1430 is approximately twice the width of the header leg 1420 in the X direction. The main recess 1440 is approximately twice the width of the trailing recess 1450 in the X direction.

The main recess 1440 is substantially the same width as the main leg 1430 in the X direction, and substantially twice the width of the header leg 1420 in the X direction. The trailing recess 1450 is substantially the same width as the header leg 1420 in the X direction and substantially half the width of the main leg 1430 in the X direction. The main leg 1430 is thus substantially twice the width of the header leg 1420 in the X direction.

As will be shown later, each of the main leg 1430 and the header leg 1420 constitutes a keying feature of the interior face 1405 that is configured to key with one or more keying members of a suitable positioning element.

The configuration of the header leg 1420 and main leg 1430 in the presentation face 1405 described above allows the main recess 1440 to accommodate either one main leg 1430 of another such masonry unit 1410 or two or two header legs 1420 (each of a respective other masonry unit 1410). This is illustrated in Figure 14(c) and (d). In Figure 14(c), the masonry units 1401 are oriented such that the main leg 1430 and header leg 1420 of each masonry unit 1410 are respectively received by the main recess 1440 and trailing recess 1450 of one other masonry unit 1410.

Figure 14(d) shows one way in which the masonry units 1401 can be arranged into two opposed courses which are spaced from one another along the direction labelled J. Within each course, the main bodies 1410 lie in the same plane and extend along the I direction. The interior faces 1405 of the masonry units 1410 in each course face one another Each main leg 1430 extends into either a main recess 1440 or trailing recess 1450 of another masonry unit 1410 in the other course. Each masonry unit 1401 is arranged such that its header leg 1420 is received by a main recess 1440 or trailing recess 1450 of different adjacent masonry unit 1401 in the other course.

As will be shown later, a reinforcement grid can be positioned between two columns of F-shaped masonry units 1401 in embodiments of the invention. The spacing along the J direction between the opposed masonry units 1401 shown in Figures 14(c) and (d) could be varied such that each leg 1430, 1420 extends only part-way into the recess. In preferred embodiments of invention, this can be achieved by the use of suitable positioning elements. Several such courses of masonry units 1401 could be stacked above one another (along the K direction) in a column of masonry units 1401.

Examples of positioning elements suitable for use with F-shaped masonry units of the kind described above are shown in Figures 15 and 16.

Figure 15 shows a first positioning element 1501 suitable for use with the F-shaped masonry units 1401 shown in Figure 14. The first positioning element 1501 has two main arms 1503 which are parallel to one another and extend along the Y direction. The main arms 1503 are spaced from one another along the X direction and define a primary recess 1507, which has dimensions matching those of the main leg 1430 of the masonry unit 1401. The primary recess 1507 is therefore able to accommodate a main leg 1430 of one of the masonry units 1401, or two adjacent header legs 1420. Each of the primary arms 1503 is thus a keying member that is capable of keying with a keying feature (i.e. a main leg 1430 or header leg 1420) of a masonry unit.

The height of the first positioning element 1501 along the Z direction is substantially the same as that of the masonry unit 1401.

The first positioning element 1507 also has two secondary arms 1505, which extend along the Y direction and are parallel to one another. The secondary arms 1505 are spaced from one another along the X direction by the same distance as are the primary arms 1503. The secondary arms 1505 define a secondary recess 1509, which in this example is less deep along the Y direction than the primary recess 1509.

The pair of primary arms 1503 is spaced from the pair of secondary arms 1505 along the Y direction by a spacing portion 1511. The spacing portion 1511 has a depth along the Y direction that can be chosen based on the desired spacing between courses of masonry units 1401 between which the positioning element is to be arranged.

The primary arms 1503 and secondary arms 1505 each carry a plurality of receiving features 1513. Each receiving feature 1513 has the form of a partially-closed channel that extends along a respective channel axis parallel to the Z direction. Each receiving feature is configured to receive one of a first plurality of rods in a reinforcement grid, as will be shown later Figure 16 shows a second positioning element 1601. This positioning element 1601 has one primary arm 1603, which extends along the Y direction, and one secondary arm 1605, which also extends along the Y direction and is coplanar with the primary arm 1603. The primary arm 1603 and secondary arm 1605 are separated by a spacing portion 1611. In this example the spacing portion 1611 has the same depth along the Y direction as the spacing portion 1511 of the first positioning element 1501. The primary arms 1603 and secondary arms 1605 are also each provided with a plurality of receiving features 1613 as described above with reference to the first positioning element 1501. The primary arm 1605 and spacing portion 1611 partially enclose a primary recess 1609, and the secondary arm 1605 and spacing portion 1611 partially enclose a secondary recess 1609. The width of the spacing portion 1611 along the X direction is about half the width of the spacing portion 1511 of the first positioning element 1501.

Figure 17 shows an example of how the primary positioning element 1501 and secondary positioning element 1601 can be used in combination with an F-shaped masonry unit 1401. As was explained above, the primary arms 1503, 1603 key with the main leg 1430 and the header leg 1420. The main and header legs of another masonry unit arranged opposite the masonry unit 1401 shown could also be received by the secondary recesses 1509, 1609 such that the secondary arms 1505, 1605 key with those legs.

Figure 18 shows an unfinished masonry panel 1801 that includes F-shaped masonry units 1401 of the kind described above. The masonry panel 1801 is similar in structure to the masonry panels described previously (e.g. those shown in Figures 11 and 12), and includes a reinforcement grid 101 that has a first plurality of rods 103 and a first rail 109 and second rail 115, each of which carries an attachment feature 111 A column of F-shaped masonry units 1401 is arranged on either side of the reinforcement grid, and within each column the masonry units are arranged in courses extending along the second grid direction B. The legs 1430, 1420 of the masonry units 1401 intersect the plane of the reinforcement grid 101. Where masonry units 1401 from each column interlock with one another in this way, the resulting masonry panel has a high mechanical strength since the masonry units 1401 can be bound to one another in addition to the reinforcement grid 101. It can be seen that the spacing between the masonry units in the two columns increases along the second grid direction B. In some preferred embodiments, this is achieved by placing positioning elements such as those shown in Figures 15 and 16 between the masonry units 1401 in the manner described above.

(Positioning elements are however not essential in this embodiment of the invention.) The masonry units 1401, reinforcement grid 101 and, where present, positioning elements could be bound together by a binding agent, examples of which have been mentioned previously.

The main legs 1430 and header legs 1420 of some of the masonry units 1401 cross the plane of the reinforcement grid 101 and extend between adjacent ones of the first plurality of rods 103. If positioning elements as shown in Figures 15 and 16 are provided, these will also cross the plane of the reinforcement grid 101. This means that it is not possible for the reinforcement grid in this masonry panel to include rods extending across the reinforcement grid 101 at a non-parallel angle to the first plurality of rods 103 (such as the second plurality of rods 105, 107 shown in Figure 1). It will be appreciated in light of this example that the use of clips 701 such as those shown in Figure 7 as positioning elements, either alone or in combination with ties 801 as shown in Figure 8, together with masonry units such the examples shown in Figures 3 to 6 is advantageous in that this allows for a second plurality of rods to be present in order to strengthen the reinforcement grid 101 As in the previous examples, the masonry panel 1801 can be finished by providing any further courses of masonry units desired, and applying mortar or another binding agent.

Figure 19 shows an example of a masonry panel 1901 attached to a structure. The masonry panel 1901 includes a reinforcement grid 101, which has a first plurality of rods 103 and, preferably, a second plurality of rods 105 (arranged as a diagrid, for example, as discussed above with reference to Figure 1). The reinforcement grid 101 also includes a first rail 109 and a second rail 115, each of which carries an attachment feature 111. Each attachment feature 111 is connected to one of two horizontal slabs 1903, 1905, which are parts of the structure.

The masonry panel 1901 has a first column 1911 of masonry units 1907 and a second column 1913 of masonry units 1907. So that the reinforcement grid 101 can be seen clearly, some of the masonry units 1907 in the first column 1911 have been omitted from Figures 19(a) and (c) (on the left-hand side of each drawing).

In preferred embodiments, clips 701 and/or positioning elements 901 are incorporated in the masonry panel 1901 in the manner described previously so as to hold the masonry units 1907 in each column at a predetermined distance from the reinforcement grid 101.

Figure 20 shows an exemplary attachment feature 111 which may be incorporated in reinforcement grids in embodiments of the invention. The attachment feature has a first plate 2001, which is configured to be connected to a reinforcement grid (e.g. to a rail thereof) by screws, bolts or other such connecting means extending through holes 2003 formed in the plate 2001. A second plate 2007 is arranged opposite the first plate 2001. In this example the through holes 2003 have an elongate shape, which allows for the position of the attachment feature 111 in the reinforcement grid 101 to be adjusted, for example to account for tolerances in the manufacture of the reinforcement grid 101 and its constituent parts, e.g. rails 109.

This also allows for the position of the masonry panel that carries the attachment feature 111 with respect to the structure to be adjusted. The first plate 2001 and second plate 2007 are connected by a bridging section 2005.

The second plate 2007 carries a thermal break 2009, which is arranged to lie between the second plate 2007 and the structure to which the attachment feature is connected. The thermal break 2009 has low thermal conductivity and heavily impedes the flow of heat through the attachment feature 111 (and hence between the structure and the masonry panel). Holes 2011 extend through the thermal break 2009 and second plate 2007, and can receive bolts, screws or other such connecting means for connecting the attachment feature to a structure.

In Figure 20(b), the attachment feature 111 is attached to part of a structure 2021. Bolts 2013 extend through the holes 2011 in the second plate 2007 and thermal break 2009 and connected the attachment feature 111 to the structure 2021. The attachment feature 111 can be configured to place the thermal break 2009 within the thermal line of the façade of the structure to which it is attached, to provide the most advantageous structural connection with the minimum of thermal bridging.

Figure 20(b) also shows how the attachment feature 111 is connected to a first rail 109 of a reinforcement grid (such as the reinforcement grids described in the examples above). The first rail 109 is connected to a first plurality of rods 103, which extend along the first grid direction A. Masonry units 301 are arranged in columns either side of the reinforcement grid 101.

The attachment feature in this example is configured to form a nodal connection between a masonry panel and a structure. However, masonry panels in accordance with embodiments of the invention could also be provided with attachment features configured to form an extended point of contact with the structure, for example a tray of the kind suitable for supporting conventional hand-laid masonry.

Aspects of the invention are set out in the following clauses: Clause 1. A masonry panel assembly system comprising: a reinforcement grid comprising a first plurality of rods each extending along a first grid direction and spaced from one another along a second grid direction which is perpendicular to the first grid direction; a plurality of masonry units, each masonry unit comprising a first presentation face and a first interior face opposed to the first presentation face, wherein the first interior face is shaped to define at least one keying feature; and a plurality of positioning elements each comprising: a receiving feature adapted to receive a portion of one of the first plurality of rods; and one or more keying members each adapted to key with a respective keying feature of one of the masonry units so as to hold, in use, the masonry unit at a respective predetermined distance from the received portion of the rod.

Clause 2. The masonry panel assembly system of clause 1, wherein each positioning element is configured such that, in use, the held masonry unit is oriented such that the first presentation face faces away from the reinforcement grid along a third grid direction which is perpendicular to the first grid direction and the second grid direction.

Clause 3. The masonry panel assembly system of any preceding clause, wherein each positioning element comprises two keying members.

Clause 4. The masonry panel assembly system of clause 3, wherein the two keying members extend along different respective directions that are preferably substantially perpendicular to one another.

Clause 5. The masonry panel assembly system of any preceding clause, wherein in each positioning element, the receiving feature and the one or more keying members form parts of an integral unit.

Clause 6. The masonry panel assembly system of any of clauses 1 to 4, wherein each positioning element comprises: two or more ties each comprising a receiving portion which is adapted to receive, in use, a portion of a respective one of the first plurality of rods and a spacing portion comprising a plate having a plurality of perforations therethrough, configured such that the plate lies in a plane substantially perpendicular to the first grid direction and is rotatable about the received rod; an elongate connecting member adapted to extend, in use, along the first grid direction through a respective perforation of each tie so as to prevent rotation of the ties when the ties are attached to different ones of the first plurality of rods; and a clip which comprises the one or more keying members, wherein the clip further comprises a connecting feature adapted to connect the clip to the connecting member.

Clause 7. The masonry panel assembly system of clause 6, wherein the elongate connecting member is a shaft having a diameter substantially the same as that of one of the first plurality of rods.

Clause 8. The masonry panel assembly system of any preceding clause, wherein the receiving feature comprises a first curved lip which is shaped to define a first section of a channel extending along a channel axis so as to be capable of receiving, in use, a portion of one of the plurality of rods aligned with the first axis.

Clause 9. The masonry panel assembly system of clause 8, further comprising a second curved lip which is shaped to define a second section of the channel so as to be capable of receiving, in use, a portion of one of the plurality of rods aligned with the first axis, wherein the first and second lips are spaced from one another along the channel axis and are opposite one another in a direction perpendicular to the first axis.

Clause 10. The masonry panel assembly system of clause 9, wherein the first and second lips each comprise a respective projecting feature that extends along the direction of the first axis towards the other of the first and second lips, wherein the projecting features are offset with respect to one another in an azimuthal direction orthogonal to the first axis.

Clause 11. The masonry panel assembly system of clause 10, wherein the projecting features are spaced from one another along the channel axis by a distance less than a diameter of one of the first plurality of rods such that one of the first plurality of rods cannot pass between the projecting features at an angle perpendicular to the first axis.

Clause 12. The masonry panel assembly system of any preceding clause, wherein the first presentation face of each masonry unit is a stretcher face or a header face.

Clause 13. The masonry panel assembly system of any preceding clause, wherein at least some of the masonry units further comprise a second presentation face and a second interior face opposite the second presentation face wherein the second interior face may or may not define a further keying feature.

Clause 14. The masonry panel assembly system of any preceding clause, wherein each keying feature comprises one or more slots each shaped to receive a respective one of the keying members, the one or more slots preferably being cut into the first interior face of the masonry unit.

Clause 15. The masonry panel assembly system of clause 14, wherein each slot extends continuously from an upper bedding face to a lower bedding face of the respective masonry unit, wherein each of the upper and lower bedding faces is substantially perpendicular to the first interior face.

Clause 16. The masonry panel assembly system of clause 14 or clause 15, wherein each slot extends into the masonry unit from the first interior face along a direction that is not normal to the first interior face.

Clause 17. The masonry panel assembly system of clause 16, wherein each keying feature comprises two slots, each of the two slots extending into the masonry unit from a common point on the first interior face, wherein preferably the common point is located at a distance of about 1/3, 1/2 or 2/3 of an elongate dimension of the first interior face from the end of the interior face.

Clause 18. The masonry panel assembly system of clause 17, wherein the respective acute angles between each of the two slots and the first interior face are substantially equal, and wherein preferably the respective acute angles are in the range of 30 to 60 degrees, more preferably 40 to 50 degrees, most preferably about 45 degrees.

Clause 19. The masonry panel assembly system of any of clauses 14 to 18, wherein each of the plurality of masonry units comprises exactly one or two keying features.

Clause 20. The masonry panel assembly system of any preceding clause, wherein the plurality of masonry units comprises at least a first plurality of masonry units in which the first interior face and first presentation face are separated by a first unit depth and a second plurality of masonry units in which the first interior face and the first presentation face are separated by a second unit depth, which is different to the first unit depth.

Clause 21. The masonry panel assembly system of any preceding clause, wherein the keying features of the masonry units are configured such that in use the masonry units can be held by the positioning elements in regular courses which extend parallel to the reinforcement grid along the second grid direction, wherein the repeat distance of the masonry units within each course is an integer multiple of the repeat distance of the first plurality of rods along the second direction, preferably one, three or six times.

Clause 22. The masonry panel assembly system of any preceding clause, wherein the reinforcement grid further comprises a second plurality of rods each of which is oriented non-parallel, preferably also non-perpendicular, to the first grid direction Clause 23. The masonry panel assembly system of clause 22, wherein the second plurality of rods are arranged as a one-dimensional or two-dimensional regular lattice, preferably a two-dimensional orthogonal lattice.

Clause 24. The masonry panel assembly system of clause 23, wherein the lattice is oriented at a non-parallel and non-perpendicular angle with respect to the first grid direction, wherein the angle is preferably about 45 degrees.

Clause 25. The masonry panel assembly system of clause 24 or clause 25, wherein each of the second plurality of rods is substantially circular or quadrate in cross-section and/or is a flat bar.

Clause 26. The masonry panel assembly system of any of clauses 22 to 25, wherein each of the second plurality of rods is welded to one or more of the first plurality of rods, preferably at each intersection between one of the first plurality of rods and one of the second plurality of rods.

Clause 27. The masonry panel assembly system of any preceding clause, wherein each of the first plurality of rods is substantially circular in cross-section.

Clause 28. The masonry panel assembly system of any preceding clause, wherein the reinforcement grid comprises a plurality of planar sections, preferably including planar sections which do not lie in the same plane as one another.

Clause 29. The masonry panel assembly system of clause 28, wherein the reinforcement grid extends continuously between the planar sections.

Clause 30. The masonry panel assembly system of clause 28, wherein the planar sections are detached from one another and wherein the masonry panel assembly further comprises a plurality of clamps each adapted to connect two adjacent planar sections in use.

Clause 31. The masonry panel assembly system of any preceding clause, further comprising a first rail which extends along the second grid direction and which connects at least some of the first plurality of rods to one another, preferably all.

Clause 32. The masonry panel assembly system of clause 31, wherein the first rail defines an upper edge of the reinforcement grid.

Clause 33. The masonry panel assembly system of clause 31 or clause 32, further comprising a second rail which extends along the second grid direction and which connects at least some of the first plurality of rods to one another, preferably all, wherein the first and second rails are spaced from one another along the first grid direction.

Clause 34. The masonry panel assembly system of clause 33, wherein the second rail defines a lower edge of the reinforcement grid.

Clause 35. The masonry panel assembly system of clause 33 or clause 34, wherein the first and second rails each comprise one or more attachment features for attachment to a structure.

Clause 36. A method of constructing a masonry panel, the method comprising: providing a reinforcement grid comprising a first plurality of rods each extending along a first grid direction and spaced from one another along a second grid direction which is perpendicular to the first grid direction; providing a plurality of masonry units, each masonry unit comprising a first presentation face and a first interior face opposed to the first presentation face, wherein the first interior face is shaped to define at least one keying feature; providing a plurality of positioning elements each comprising: a receiving feature adapted to receive a portion of one of the first plurality of rods; and one or more keying members each adapted to key with a respective keying feature of one of the masonry units so as to hold, in use, the masonry unit at a respective predetermined distance from the received portion of the rod; arranging the masonry units in at least a first column adjacent to the reinforcement grid, the masonry units in the first column each being oriented such that the first interior face of each masonry unit is on an interior side of the column which faces the reinforcement grid; arranging the positioning elements such that the receiving feature of each positioning element receives a portion of one of the first plurality of rods and at least one of the keying members of each positioning element keys with a keying feature of one of the masonry units.

Clause 37. The method of clause 36, wherein arranging the masonry comprises arranging the masonry units into the first column and a second column, wherein the reinforcement grid is positioned between the first and second columns, the masonry units in the second column each being oriented such that the first interior face of each masonry unit is on an interior side of the column which faces the reinforcement grid.

Clause 38. The method of clause 36 or clause 37, wherein the masonry units in each column do not intersect the reinforcement grid.

Clause 39. The method of any of clauses 36 to 38 wherein in each column the first interior faces of the masonry units are arranged to be substantially coplanar, wherein preferably the plane of the first interior faces of the first column is spaced from the plane of the first interior face of the second column by a distance corresponding to at least the thickness of the reinforcement grid.

Clause 40. The method of any of clauses 36 to 39, wherein in the first column the first presentation faces of the masonry units are spaced at varying distances from the reinforcement grid, such that the panel is formed with a non-uniform depth in a third direction which is orthogonal to the first and second grid directions.

Clause 41. The method of clause 40, wherein in the first column the spacing of the masonry units from the reinforcement grid varies.

Clause 42. The method of clause 40 or clause 41, wherein the first column comprises masonry units of different depth in the direction between the first interior and first presentation faces thereof.

Clause 43. The method of any of clauses 40 to 42, wherein the plurality of positioning elements include positioning elements each configured to hold a masonry unit at different respective predetermined distances from the reinforcement grid, and are arranged such that one or more of the masonry units in the first column are held at different distance(s) from the reinforcement grid to others of the masonry units in the first column.

Clause 44. The method of any of clauses 36 to 43, wherein at least some of the positioning elements each comprise one or more ties, each tie comprising a receiving portion adapted to receive a portion of a respective one of the first plurality of rods and a spacing portion comprising a plate having a plurality of perforations therethrough, configured such that the plate lies in a plane substantially perpendicular to the first grid direction.

Clause 45. The method of clause 44, further comprising arranging each of the ties such that the receiving portion of the tie receives a portion of one of the first plurality of rods and the plate of the tie lies between two adjacent masonry units in one of the columns, preferably in a bedding plane..

Clause 46. The method of clause 44 or clause 45, wherein one or more of the positioning elements each comprise two ties; the method further comprising: arranging the ties of each pair such that the receiving portions of the pair of ties each receive a respective portion of different ones of the first plurality of rods, and such that one of the perforations of one tie is aligned with one of the perforations of the other tie along the first grid direction; arranging an elongate connecting member so as to extend through the aligned perforations, whereby the two ties are prevented from rotating about the received rods; connecting a clip to the connecting member by a connecting feature of the clip, the clip comprising the keying members of the positioning element; and keying at least one of the keying members of the connected clip with a respective keying feature in one of the plurality of masonry units such that the masonry unit is held at a predetermined distance from the reinforcement grid.

Clause 47. The method of any of clauses 36 to 46, wherein each positioning element comprises two keying members Clause 48. The method of clause 47, wherein the two keying members extend along respective directions that are preferably substantially perpendicular to one another.

Clause 49. The method of clause 47 or 48, comprising arranging each positioning element such that either each keying member of the positioning element keys with keying features of a different masonry units, or both keying members key with keying feature(s) of one masonry unit.

Clause 50. The method of any of clauses 36 to 49, wherein the reinforcement grid comprises a plurality of planar sections, preferably including planar sections which do not lie in the same plane as one another.

Clause 51. The method of clause 50, further comprising connecting the planar sections using a plurality of clamps.

Clause 52. The method of clause 50 or clause 51, wherein the planar sections are arranged to enclose an interior volume on an interior side of the reinforcement grid and wherein the one or more columns are arranged on an exterior side of the reinforcement grid.

Clause 53. The method of any of clauses 36 to 52, further comprising applying a binding agent to bind the masonry units, positioning elements and reinforcement grid together, wherein preferably the binding agent is a mortar, grout, cement or adhesive.

Clause 54. The method of any of clauses 36 to 53 performed using the system of any of clauses 1 to 35.

Clause 55. A masonry panel comprising: a reinforcement grid comprising a first plurality of rods each extending along a first grid direction and spaced from one another along a second grid direction which is perpendicular to the first grid direction; a plurality of masonry units, each masonry unit comprising a first presentation face and a first interior face opposed to the first presentation face, wherein the first interior face is shaped to define at least one keying feature, wherein the masonry units are arranged in at least a first column adjacent to the reinforcement grid, the masonry units in the first column each being oriented such that the first interior face of each masonry unit is on an interior side of the column which faces the reinforcement grid; and a plurality of positioning elements each comprising: a receiving feature adapted to receive a portion of one of the first plurality of rods; and one or more keying members each adapted to key with a respective keying feature of one of the masonry units so as to hold, in use, the masonry unit at a respective predetermined distance from the received portion of the rod; wherein the positioning elements are arranged such that the receiving feature of each positioning element receives a portion of one of the first plurality of rods and at least one of the keying members of each positioning element keys with a keying feature of one of the masonry units.

Clause 56. The masonry panel of clause 55, wherein the masonry units are arranged into the first column and a second column, wherein the reinforcement grid is positioned between the first and second columns, the masonry units in the second column each being oriented such that the first interior face of each masonry unit is on an interior side of the column which faces the reinforcement grid.

Clause 57. The masonry panel of clause 55 or clause 56, wherein the masonry units in each column do not intersect the reinforcement grid Clause 58. The masonry panel of any of clauses 55 to 57, wherein in each column the first interior faces of the masonry units are arranged to be substantially coplanar, wherein preferably the plane of the first interior faces of the first column is spaced from the plane of the first interior face of the second column by a distance corresponding to at least the thickness of the reinforcement grid.

Clause 59. The masonry panel of any of clauses 55 to 58, wherein in the first column the first presentation faces of the masonry units are spaced at varying distances from the reinforcement grid, such that the panel has a non-uniform depth in a third direction which is orthogonal to the first and second grid directions.

Clause 60. The masonry panel of clause 59, wherein in the first column the spacing of the masonry units from the reinforcement grid varies.

Clause 61. The masonry panel of clause 59 or clause 60, wherein the first column comprises masonry units of different depth in the direction between the first interior and first presentation faces thereof Clause 62. The masonry panel of any of clauses 59 to 61, wherein the plurality of positioning elements include positioning elements configured to hold a masonry unit at different respective predetermined distances from the reinforcement grid, and are arranged such that one or more of the masonry units in the first column are held at different distance(s) from the reinforcement grid to others of the masonry units in the first column.

Clause 63. The masonry panel of any of clauses 55 to 62 wherein at least some of the positioning elements each comprise one or more ties, each tie comprising a receiving portion adapted to receive a portion of a respective one of the first plurality of rods and a spacing portion comprising a plate having a plurality of perforations therethrough, configured such that the plate lies in a plane substantially perpendicular to the first grid direction.

Clause 64. The masonry panel of clause 63, wherein each of the ties is arranged such that the receiving portion of the tie receives a portion of one of the first plurality of rods and the plate of the tie is in contact with an upper bedding face or a lower bedding face of a respective one of the masonry units in the one or more columns.

Clause 65. The masonry panel of clause 63 or clause 64, wherein one or more of the positioning elements each comprise two ties; wherein: the ties of each pair are arranged such that the receiving portions of the pair of ties each receive a respective portion of different ones of the first plurality of rods, and such that one of the perforations of one tie is aligned with one of the perforations of the other tie along the first grid direction; the elongate connecting member is arranged so as to extend through the aligned perforations, whereby the two ties are prevented from rotating about the received rods; a clip is connected to the connecting member by a connecting feature of the clip, the clip comprising the keying members of the positioning element; and at least one of the keying members of the connected clip is keyed with a respective keying feature in one of the plurality of masonry units such that the masonry unit is held at a predetermined distance from the reinforcement grid.

Clause 66. The masonry panel of any of clauses 55 to 65, wherein each positioning element comprises two keying members.

Clause 67. The masonry panel of clause 66, wherein the two keying members extend along respective directions that are preferably substantially perpendicular to one another.

Clause 68. The masonry panel of clause 66 or 67, wherein each positioning element is arranged such that either each keying member of the positioning element keys with keying features of a different masonry units, or both keying members key with keying feature(s) of one masonry unit.

Clause 69. The masonry panel of any of clauses 55 to 68, further comprising a first rail and a second rail each extending in the second grid direction and spaced from one another in the first grid direction, wherein each of the first and second rails connects at least some of the first plurality of rods to one another.

Clause 70. The masonry panel of clause 69, wherein each of the first and second rails comprises one or more attachment features for attaching the prefabricated masonry panel to a structure.

Clause 71. The masonry panel of any of clauses 55 to 70, further comprising a binding agent which binds the masonry units, positioning elements and reinforcement grid together, wherein preferably the binding agent is a mortar, grout, cement or adhesive.

Clause 72. The masonry panel of any of clauses 55 to 71, being formed of a masonry panel assembly system in accordance with any of clauses 1 to 35.

Clause 73. A prefabricated masonry panel comprising: a reinforcement grid comprising a first plurality of rods each extending along a first grid direction and spaced from one another along a second grid direction which is perpendicular to the first grid direction, and a first rail and a second rail each extending in the second grid direction and spaced from one another in the first grid direction, wherein each of the first and second rails connects at least some of the first plurality of rods to one another; one or more attachment features connected to the reinforcement grid for attaching the prefabricated masonry panel to a structure; and a first column and a second column each comprising a respective plurality of masonry units, wherein the first column and the second column respectively define a first panel face and a second panel face, and wherein the reinforcement grid is positioned between the first and second columns.

Clause 74. The prefabricated masonry panel of clause 73, wherein each masonry unit comprises a first presentation face and a first interior face opposed to the first presentation face, wherein the first interior face is shaped to define at least one keying feature; and wherein the prefabricated masonry panel further comprises: a plurality of a plurality of positioning elements each comprising a receiving feature which accommodates a portion of one of the first plurality of rods; and one or more keying members which keys with a respective keying feature of one of the masonry units whereby the masonry unit is held at a respective predetermined distance from the received portion of the rod.

Clause 75. The prefabricated masonry panel of clause 73 or 74, wherein the presentation faces of the masonry units define the first and second panel faces.

Clause 76. The prefabricated masonry panel of any of clauses 73 to 75, wherein one or more of the attachment features are each connected to one of the first and second rails.

Clause 77. The prefabricated masonry panel of any of clauses 73 to 76, wherein each attachment feature is a nodal connector.

Clause 78. The prefabricated masonry panel of any of clauses 73 to 77, wherein each attachment feature comprises a thermally broken connection assembly configured to impede heat flow through the attachment feature.

Clause 79. The prefabricated masonry panel of any of clauses 73 to 78 made using the system of any of clauses 1 to 35.

Clause 80. A method of constructing a structure, the method comprising providing one or more prefabricated masonry panels in accordance with any of clauses 73 to 79 and attaching the prefabricated masonry panel(s) to the structure by attaching the attachment feature(s) of the one or more prefabricated masonry panels to corresponding attachment points on the structure.

Claims

CLAIMS1. A prefabricated masonry panel comprising: a reinforcement grid comprising a first plurality of rods each extending along a first grid direction and spaced from one another along a second grid direction which is perpendicular to the first grid direction, and a first rail and a second rail each extending in the second grid direction and spaced from one another in the first grid direction, wherein each of the first and second rails connects at least some of the first plurality of rods to one another; one or more attachment features connected to the reinforcement grid for attaching the prefabricated masonry panel to a structure; and a first column and a second column each comprising a respective plurality of masonry units, wherein the first column and the second column respectively define a first panel face and a second panel face, and wherein the reinforcement grid is positioned between the first and second columns.
2. The prefabricated masonry panel of claim 1, wherein one or more of the attachment features are each connected to one of the first and second rails.
3. The prefabricated masonry panel of any preceding claim, wherein each attachment feature is a nodal connector
4. The prefabricated masonry panel of any preceding claim, wherein each attachment feature comprises a thermally broken connection assembly configured to impede heat flow through the attachment feature.
5. The prefabricated masonry panel of any preceding claim made using a masonry panel assembly system comprising: a reinforcement grid comprising a first plurality of rods each extending along a first grid direction and spaced from one another along a second grid direction which is perpendicular to the first grid direction; a plurality of masonry units, each masonry unit comprising a first presentation face and a first interior face opposed to the first presentation face, wherein the first interior face is shaped to define at least one keying feature; and a plurality of positioning elements each comprising: a receiving feature adapted to receive a portion of one of the first plurality of rods; and one or more keying members each adapted to key with a respective keying feature of one of the masonry units so as to hold, in use, the masonry unit at a respective predetermined distance from the received portion of the rod.
6. The prefabricated masonry panel of any preceding claim, wherein each masonry unit comprises a first presentation face and a first interior face opposed to the first presentation face, wherein the first interior face is shaped to define at least one keying feature; and wherein the prefabricated masonry panel further comprises: a plurality of a plurality of positioning elements each comprising a receiving feature which accommodates a portion of one of the first plurality of rods; and one or more keying members which keys with a respective keying feature of one of the masonry units whereby the masonry unit is held at a respective predetermined distance from the received portion of the rod.
7. The prefabricated masonry panel of any preceding claims, wherein the presentation faces of the masonry units define the first and second panel faces.
8. A method of constructing a structure, the method comprising providing one or more prefabricated masonry panels in accordance with any preceding claim and attaching the prefabricated masonry panel(s) to the structure by attaching the attachment feature(s) of the one or more prefabricated masonry panels to corresponding attachment points on the structure.