A masonry panel for a building structure

Abstract

A masonry panel 1 for a building structure comprises a plurality of elongate members 2 each defining a bed 3 accommodating a single course of masonry slips 4. The slips are retained by legs or flanges that engage in two slots in two sides of the slips. One or more shims 9 fill the gap between rear surfaces of the slips the bed to retain the slips in position relative to the bed. The shims may be tabs or projecting flaps comprising tines having a triangular profile. The elongate members may be fastened together or mounted on a supporting structure 11 in a side-by-side relationship so their beds are parallel. The elongate members may have a cross-sectional profile defining a channel with its legs or flanges projecting inwardly of the bed from the edges of opposing sides of the channel. The legs or flanges on opposing sides of the channel may be of equal or unequal width. One of the elongate members may, in use, form a soffit and have an L-shaped cross-sectional profile with its legs or flanges projecting at right-angles to one another to accommodate and retain slips having L-shaped cross-sectional profiles.

Description

A MASONRY PANEL FORA BUILDING STRUCTURE The present invention relates to a masonry panel for a building structure, in particular a masonry panel for use as part of the facade of a building. Modern building techniques make use of prefabricated components that are used to speed up and simplify the erection of building structures. Many buildings are constructed with an inner substructure that is provided with a decorative masonry facade that is secured to the substructure by various means. The masonry facade provides an attractive external appearance for the building but does not form part of the load-bearing substructure. It is therefore suitable for prefabrication and, as it is not load bearing, complex masonry patterns can be employed in its construction as specified by an architect that would otherwise be difficult to execute directly on site or not be possible if load-bearing considerations needed to be taken into account. Conventionally, such prefabricated facade panels are constructed using several known systems. Some are produced by an adhesive-based system wherein thin brick slips are bonded to a rigid, supporting back panel by adhesives, such as a polymer adhesive mortar. Others use mechanical ties or clips to secure brick slips to a back panel. Both of these systems have disadvantages. Some adhesive-based systems are prone to failure, particularly in climates with widely varying temperatures as this can weaken the bond between the slips and the back panel with the result that brick slips can become loose and fall off. This is a totally unacceptable and dangerous situation. For this reason, systems using mechanical ties or clips are preferred. However, these systems have the disadvantage that the prefabricated panels have to be tailored exactly to the position where they are to be employed as they cannot be adjusted once manufactured. This means that should unforeseen events happen during construction of a building, the prefabricated panels made for it may no longer fit or be appropriate to the position for which they were made. This can increase the cost of the building and delay its construction. In both cases, the prefabricated panels tend to be heavy and difficult to transport during which damage may occur to the slips, which can mar the appearance of the panel and mean that it cannot be used without replacement of the damaged slips, which may not be possible. It is an object of the present invention to overcome or substantially mitigate the aforementioned disadvantages. According to a first aspect of the present invention there is provided a masonry panel for a building structure comprising a plurality of elongate members each defining a bed accommodating a single course of masonry slips that are retained by means of legs or flanges that engage in two slots respectively formed in two sides of the slips whereby each slip is retained displaying an outer surface, one or more shims being provided that fill the gap between rear surfaces of the slips and a surface of the bed to retain the slips in position relative to the bed. The masonry panel of the present invention has been designed so that it can either be prefabricated or at least partially constructed on-site. In particular, it is possible to secure the slips to the elongate members after the panel has been secured to the substructure of a building. This makes fitment of the panel easier as it reduces the weight of the panel during transportation and securement to the substructure and ensures that damage to the slips does not occur during these processes. It will be appreciated that after securement of the masonry panel to a building substructure and location of the slips therein the panel is pointed so that the panel appears as an unbroken part of adjoining masonry and to hide all parts of the masonry panel other than the outer surface of the slips. According to a second aspect of the present invention there is provided an elongate member for use in a masonry panel for a building structure according to the first aspect of the present invention. Other preferred but non-essential features of the present invention are described in the dependent claims appended hereto. The present invention will now be described by way of example with reference to the accompanying drawings, in which:- Fig. 1 is a perspective front view of a first embodiment of masonry panel in accordance with the present invention; Fig. 2 is perspective view of the rear of the masonry panel shown in Fig. 1; Fig. 3 is an end view of part of the panel shown in Figs. 1 and 2 but to an increased scale; Fig. 4 is a perspective view of an elongate member forming part of the panel shown in Figs. 1 to 3; Fig. 51s an end view of the elongate member shown in Fig. 4 but to an increased scale; Fig. 6 is a perspective view of a second elongate member that forms a soffit; Fig. 7 is an end view of the second elongate member shown in Fig, 6 accommodating a masonry slip; and Fig. 8 is perspective view from the rear of a second embodiment of masonry panel in accordance with the present invention that defines a soffit. A first embodiment of masonry panel 1 for a building structure is shown in Figs 1 to 3 of the drawings and comprises a plurality of elongate members 2 that each defines a bed 3 accommodating a single course of masonry slips 4. The elongate members 2 are preferably fabricated from metal sheets, in particular from sheet stainless steel whereas the masonry slips 4 are preferably brick but may be any other form of masonry, such as stone, or be synthetic. The elongate members 2 in the first embodiment of the invention as shown in Figs. 1 to 3 have a cross-sectional profile that defines a channel with the bed 3 forming its base. The slips 4 are accommodated and retained therein by means of legs or flanges 5 that project inwardly of the channel from edges of opposing sides 6 of the channel. In the illustrated embodiment the legs 5 are in the form of a single flange that runs along the full length of the elongate member but it will be appreciated that a plurality of side by side legs 5 could be replace the single flange. The two legs or flanges 5 respectively engage in two slots 6 that have been formed in opposing sides of the slips 4 so that each slip 4 is retained displaying an outer surface 7 and with a rear surface 8 facing the surface of the bed 3. In order to enable the slips 4 to be front loaded into the channel-shaped elongate members 2, as described below, the legs or flanges 5 on opposite sides of each elongate member 2 are of unequal width. In the illustrated embodiment the width of the upper leg or flange is wider than the width of the lower leg or flange 5b, as shown in Figs. 4 and 5. In order to hold the slips 4 in position and to prevent them from sliding along the length of the elongate member 2, one or more shims are provided that fill the gap between the rear surfaces 8 of the slips 4 and the surface of the bed 3. The shim or shims therefore create an interference fit between the bed 3 and the rear surfaces 8 of the slips 4. They can therefore take different forms dependent on the requirements of the panel. In some embodiments the shims take the form of one or more tabs 9 that project from the surface of the bed 3 and bear against the rear surfaces 8 of the slips 4. Preferably, the tabs 9 are projecting flaps cut from the base 3 of the bed and comprise tines 10 that engage the rear surfaces 8 of the slips 4. These tabs 9 therefore form resiliently deformable springs that exert force on the rear surfaces 8 of the slips 4 to retain the in-turned legs or flanges 5 in contact with sides of the slots 6 so that the slips 4 are retained by friction between the rear surfaces 8 and the tines 10 and between the surfaces of the slits 6 and the legs or flanges 5. Preferably, the tabs 9 have a triangular profile, the apex of which comprises the tine 10. However, it will be appreciated that the tabs could be given many other different profiles but a triangular profile is one of the easiest to produce. Preferably also, the apexes of the tabs 9 in each bed 3 are aligned and point in the same direction. This direction is determined by the manner in which the slips 4 are inserted into the elongate members, as will now be described. However, in some embodiments, it may be appropriate for the direction of the tines to vary. If the elongate members 2 have a substantially channel-shaped cross- sectional profile as described above, then the slips 4 may be located therein after a panel formed from a plurality of elongate members 3, as described below, has been secured to a substructure of a building. This is because the slips 4 are each front loaded into the member 3 by a “lift and drop” motion wherein the upper legs or flange 5a is first fully inserted into the uppermost slot 6 in the slip 4, which is then by rotated so that the lower legs or flange 5b engage within the lowermost slot 6 against the pressure exerted by the tabs 9. The apexes 10 of the tabs 9 are arranged to point downwardly so that they do not impede a slight downward movement of the slip 4 under the force of gravity as it comes to rest after the lower legs or flange 5b has been engaged within the lowermost slot 6 but thereafter engage the rear surface 8 of the slip to prevent any upwards or side to side movement. However, the relative sizes of the slips 4 and the depth of the channel defined by the elongate member is such that a builder can still insert his fingers or a tool between the rear surface 8 of the slip and the bed 3 to permit the position of the slip 4 to be adjusted or even removed from the elongate member 2 if required. As shown in Figs, 1 to 3, preferably prior to insertion of the slips 4 into the elongate members 2, a plurality of the latter are assembled into a panel 1 of a desired size that is then secured to a building substructure. The elongate members 2 are preferably arranged side-by-side so that their beds 3 are parallel. The elongate members 2 may then be either fastened together or mounted on a supporting structure to form the panel. In the former case the members may be riveted together but this does not provide a very rigid structure. Preferably, therefore, the elongate members are mounted on a supporting structure that comprises either a backboard (not shown) or at least one and preferably more gussets or stiffeners such as bars 11, as shown in Figs. 1 to 3, The bars 11 are preferably of channel section or similar with one leg or side secured to the elongate members 2, for example by means of rivets (not shown) leaving an opposite leg or side 12 that can be secured to a building substructure either directly or by means of a bracket or similar. If a backboard is used, the elongate members 2 may be fixed to a board, such as a magnesium oxide or cementitious board. In all cases, the panel 1 so formed is preferably of a manageable size such that one or two persons can hold and carry it. A second embodiment of panel 13 is shown in Fig. 9. This differs from the first embodiment by the provision in the panel 13 of differently constructed second and third elongate members 14 and 15 that in use of the panel 13 form a soffit. Hence, the panel 13 comprises a part 16 that is similar to the panel 1 and the elongate members 14 and 15 that form the soffit. The elongate members 14 and 15 are fastened to the part 16 by means of brackets 17 that are secured to the bars 11 of the part 16. However, it will be appreciated that dependent on the size of soffit required, part 15 could be omitted from the panel 13 but in other circumstances additional third elongate members 15 could be added to the panel 13 adjacent the first third elongate member 15. Alternatively, elongate members 2 could be used in place of the third elongate member 15. The construction of the elongate members 14 and 15 forming the soffit will now be described with reference to Figs. 6 to 8. The second elongate member 14 is preferably fabricated from sheet metal, which is preferably stainless steel, and has a substantially L-shaped cross-sectional profile with legs or flanges 18 that project substantially at right-angles to one another at the free edges of the L shape so that they lie parallel to the adjacent sides of the L-shape at one side of a box-like channels 19. However, unlike the elongate member 2, in the elongate member 14 the legs or flanges 18 are preferably of substantially equal width. The member 14 therefore defines a right-angled bed 20 supporting L- shaped slips 21. To provide additional support, a series of fingers 22 project outwards from the bed 20 along the angle of the L-shaped profile in a forwards direction as determined by the front edge of the soffit when in use. The bed 20 is also provided with tabs 9 that are similar to those described above for the elongate members 2. The tabs 9 therefore have a triangular profile, the apex of which comprises the tine 10. In addition, the apexes of the tabs 9 are preferably aligned and point in the same direction but in this case instead of pointing downwardly, they all point in a direction towards one end of the bed 20 defined by the member 14. This is because the slips 21 are not front loaded but are slid into the member 14 from an end opposite to the direction in which the tines 10 point. It is not possible to front load the slips 21 by a “lift and drop” manipulation owing to the directions in which the legs 18 extend. Hence, panels such as the panel 13 comprising a soffit have the elongate member 14 defining the soffit pre-loaded with slips 21, as will now be described. The slips 4 to be loaded in the elongate member 2 can, however, be loaded before or after securement of the panel 13 to a building substructure as described above. The slips 21, as depicted in Figs.7, have an L-shaped cross-sectional profile that mirrors the profile of the bed 20 and define a right-angled front surface 23 and a rear surface 24 that in use faces the bed 20. First and second slots 25 are respectively formed in the end surfaces of the L-shape and a third slot 26 is formed adjacent the angle in a rear surface 24 of the slip 21. The slips 21 are inserted into the elongate member 14 from one end so that the legs or flanges 18 slid respectively into the first and second slots 25 and the fingers 22 slide into the third slot 26. The slips 21 are pushed along the bed 20 over the tabs 9 until they each reach their desired location. At this point the tines 10 of the tabs 9 prevent the slips 21 from being moved back along the bed 20 and exert force on the slip so that it is frictionally retained with the legs or flanges 18 in contact with the rear surfaces of the slots 25. As the slips 21 are suspended from the bed 20 when the panel is in use, the engagement of the third fingers 22 into the additional, third slot 26 prevents the slips 21 from sagging under their own weight and ensures that they are retained in contact with the tines 10 at the end of the tabs 9. In other respects the panel 13 is used and operates in the same way as the panel 1. The third elongate member 15 combines features of the first and second elongate members 2 and 14. In a similar fashion to the first elongate members 2, it has a cross-sectional profile that defines a channel with a bed 3 forming its base. The slips 4, which can be identical to those in the elongate members 2 are accommodated and retained therein by means of legs or flanges 27 that project inwardly of the channel from edges of opposing sides of the channel. However, these slips may be slid into the member 15 from one end in a similar manner to the slips 21 described above. To this end, the legs of the elongate member 15 may therefore be of substantially equal width. Similarly, the tabs 9 provided in a bed 29 of the member 15 are arranged with tines 30 that are preferably aligned and point in the same direction towards one end of the bed 29 defined by the member 15. Other configurations of panel are possible and elongate members similar to the members 14 and 15 can be used to form the jambs or side walls of windows as well as provided soffits at the top of windows and doors. Indeed, the elongate members 2, 14, 15 can be arranged to form panels of any shape, size and configuration as required for any particular building and their beds 3, 20, 30 can be made to run horizontally or be angled, as required. Similarly, the slips 4, 21 or some of them can be made so that they project from the front surface of the panels and they can be arranged in any bond pattern, as desired, so that the panel provides an appropriate decorative surface. It will be appreciated that after a panel 1, 13 has been located in position on a building substructure and completed by the loading of slips into the elongate members 2, the panel is pointed so that only the front surfaces 7, 23 are visible from the exterior of the building and the slips appear as a unified part of the rest of the masonry of the building.

Claims

CLAIMS 1. A masonry panel for a building structure comprising a plurality of elongate members each defining a bed accommodating a single course of masonry slips that are retained by means of legs or flanges that engage in two slots respectively formed in two sides of the slips whereby each slip is retained displaying an outer surface, one or more shims being provided that fill the gap between rear surfaces of the slips and a surface of the bed to retain the slips in position relative to the bed. 2, A masonry panel as claimed in Claim 1, wherein the elongate members are either fastened together or mounted on a supporting structure in a side-by-side relationship so that their beds are parallel.

3. A masonry panel as claimed in Claim 1 or Claim 2, wherein the supporting structure comprises either a backboard or one or more gussets or stiffeners.

4. A masonry panel as claimed in any of Claims 1 to 3, wherein the shim or shims comprise a plurality of tabs that project from the surface of the bed and that bear against the rear surfaces of the slips.

5. A masonry panel as claimed in Claim 4, wherein the tabs are resiliently deformable in order to exert force on the rear surfaces of the slips to retain the legs or flanges of the elongate member in contact with sides of the slots.

6. A masonry panel as claimed in Claim 4 or Claim 5, wherein the tabs are projecting flaps that have been cut from the bed of the elongate member.

7. A masonry panel as claimed in any of Claims 4 to 6, wherein the tabs comprise tines that engage the rear surfaces of the slips.

8. A masonry panel as claimed in Claim 7, wherein the tabs each have a triangular profile, the apex of which comprises the tine.

9. A masonry panel as claimed in Claim 7 or Claim 8, wherein the tines are aligned and point in the same direction.

10. A masonry panel as claimed in any of Claims 1 to 9, wherein at least one of the elongate members is an elongate member with a cross- sectional profile defining a channel and with its legs or flanges arranged projecting inwardly of the bed from the edges of opposing sides of the channel.

11. A masonry panel as claimed in Claim 10, wherein the legs or flanges that engage in the slots formed in the slips on opposing sides of the channel are of unequal width.

12. A masonry panel as claimed in Claim 11 when dependent on Claim 9, wherein the tines in the elongate member have a cross-sectional profile defining a channel all point in a direction towards one side of the channel.

13. A masonry panel as claimed in Claim 10, wherein the legs or flanges of that engage in the slots formed in the slips on opposing sides of the channel are substantially of equal width.

14. A masonry panel as claimed in Claim 13 when dependent on Claim 9, wherein the tines in the elongate member having a cross-sectional profile defining a channel all point in a direction towards one end of the channel.

15. A masonry panel as claimed in any of Claims 1 to 14, wherein one of elongate members, in use, forms a soffit and has a substantially L- shaped cross-sectional profile with its legs or flanges projecting substantially at right-angles to one another.

16. A masonry panel as claimed in Claim 15, wherein the said elongate member that in use forms a soffit comprises a series of projecting fingers that engage within a third slot cut into a rear surface of the brick slips accommodated in its bed.

17. A masonry panel as claimed in Claim 16, wherein the slips accommodated in the bed defined by said elongate member that in use forms a soffit have an L-shaped cross-sectional profile and the first and second slots are respectively formed in the end surfaces of the L-shape with a third slot formed adjacent the angle in the rear surface of the slip into which the projecting fingers extend.

18. A masonry panel as claimed in any of Claims 15 to 17, wherein the legs or flanges of said second elongate member that in use forms a soffit are of substantially equal width.

19. A masonry panel as claimed in any of Claims 15 to 18 when dependent on Claim 8, wherein the tines of the tabs in said elongate member that in use forms a soffit point in a direction towards one end of the bed defined by said elongate member.

20. An elongate member for use in a masonry panel for a building structure as claimed in any of Claims 1 to 19.

21. An elongate member as claimed in Claim 20 that is comprised of stainless steel.