WO2023217968A1 - A cavity tray and masonry support element - Google Patents
A cavity tray and masonry support element Download PDFInfo
- Publication number
- WO2023217968A1 WO2023217968A1 PCT/EP2023/062612 EP2023062612W WO2023217968A1 WO 2023217968 A1 WO2023217968 A1 WO 2023217968A1 EP 2023062612 W EP2023062612 W EP 2023062612W WO 2023217968 A1 WO2023217968 A1 WO 2023217968A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- masonry support
- optionally
- cavity
- tray
- cavity tray
- Prior art date
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Classifications
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F13/00—Coverings or linings, e.g. for walls or ceilings
- E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
- E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
- E04F13/0801—Separate fastening elements
- E04F13/0832—Separate fastening elements without load-supporting elongated furring elements between wall and covering elements
- E04F13/0857—Supporting consoles, e.g. adjustable only in a direction parallel to the wall
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/38—Connections for building structures in general
- E04B1/41—Connecting devices specially adapted for embedding in concrete or masonry
- E04B1/4178—Masonry wall ties
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/70—Drying or keeping dry, e.g. by air vents
- E04B1/7038—Evacuating water from cavity walls, e.g. by using weep holes
- E04B1/7046—Evacuating water from cavity walls, e.g. by using weep holes using trays
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F13/00—Coverings or linings, e.g. for walls or ceilings
- E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
- E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
- E04F13/14—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements stone or stone-like materials, e.g. ceramics concrete; of glass or with an outer layer of stone or stone-like materials or glass
- E04F13/142—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements stone or stone-like materials, e.g. ceramics concrete; of glass or with an outer layer of stone or stone-like materials or glass with an outer layer of ceramics or clays
Definitions
- the present invention is in the field of cavity trays and masonry support elements.
- Masonry support elements serve to transfer loads from external building facades to internal building structures.
- Cavity trays may be used to passively remove moisture within the cavity.
- Fire prevention structures and barriers may be used alongside both these to help reduce the risk of fire.
- the present invention in particular relates to the attachment of a fire prevention structure and a fire barrier onto a cavity tray, masonry support element, or masonry support bracket and of a cavity tray to a masonry support element.
- Modern building techniques utilise an internal building structure to which a masonry fagade is attached. There is often a gap between the internal building structure and the masonry fagade.
- Masonry support elements may be used to transfer the load of the masonry fagade to the internal building structure. The masonry support elements may also sit within the gap (known as a cavity) between the masonry fagade and the internal building structure.
- Such a cavity may be prone to moisture accumulation which can lead to issues relating to damp and mould.
- the cavity area may also be utilised effectively from a fire safety perspective. Therefore, there is a need in some implementations for the masonry support elements to provide secondary functionality in line with these issues, such as collecting any moisture running down the internal building structure, and aiding in the prevention of fire.
- masonry support elements are bulky and heavy items that can be difficult to install. Therefore, a problem to be addressed includes reducing the mass of the masonry support element, and making installation simpler. Installation issues are also seen with cavity trays and fire barriers.
- cavity trays and fire barriers are independent instruments to one another and therefore can be complicated to implement together.
- the cavity tray and fire barrier arrangement as disclosed in this application is an integrated solution to the issues mentioned and one that compliments the cavity- found infrastructure used in industry today. This makes their implementation much more convenient in practice.
- attachment mechanism between two objects.
- adhesives for example, adhesives, mechanical attachment, and other such techniques may be used.
- mechanical attachment There is a need to provide a simple to use, mechanical attachment. In particular, this may be useful in the installation of a masonry support element.
- a masonry support element configured to sit in a cavity between an internal building structure and a fagade, and to transfer the load of the fagade to the internal building structure
- the masonry support element comprising: a masonry support bracket; a masonry support angle; a cavity tray; wherein the masonry support angle is configured to extend into the fagade, and to take the load of the fagade and transfer this load to the masonry support bracket; wherein the masonry support bracket is configured to be attached to the internal building structure, and is configured to transfer the load from the masonry support angle to the internal building structure;
- the masonry support bracket comprises a first column configured to lie parallel with the internal building structure, and at least one arm extending perpendicular to the column away from the internal building structure and towards the fagade, wherein the masonry support angle is attached to the masonry support bracket; wherein the cavity tray is configured to overlie the at least one arm of the masonry support bracket; wherein the cavity tray is configured to collect
- the cavity tray sitting above the masonry support angle may be advantageous. This may allow the masonry support angle to function as a second cavity tray to direct the water out of the cavity. This may reduce the overall mass of the masonry support element (as well as increasing the efficiency of removing moisture), and therefore make the element simpler to manufacture, fit and transport. This may also help reduce load on the internal building structure.
- the cavity tray of the first aspect may be optional in some embodiments in which the movement of water is not required.
- the masonry support element may comprise the masonry support bracket and the masonry support angle as described below without the cavity tray.
- the second column may offer structural support to the at least one arm.
- angled to comprises the arm extending from the first column towards the fagade, and the second column extending from the first arm downwards, approximately parallel to the fagade. This may provide particularly efficient structural support.
- the arm is a sheet, and is in a two dimensional plane, and wherein the second column is in the same two-dimensional plane.
- This may provide particularly efficient structural support. This may be because being in the same plane as the at least on arm means load can be transferred directly through the at least one arm and the second column.
- This dimensional plane may be perpendicular to the load that is being transferred from the masonry fagade, and so the strength in the two- dimensional plane of the second column and at least one arm is high, despite the mass of the second column and at least one arm being relatively low. It is strength in this plane, perpendicular to the load, that allows it to be transferred to the internal building structure.
- the masonry support angle being attached to the masonry support bracket comprises the masonry support angle being attached to the second column of the masonry support bracket.
- the at least one arm comprises two arms extending from the first column, such that the proximal end of the arms are attached to the first column. The use of two arms may increase the strength of the masonry support bracket, whilst minimising the mass of the masonry support bracket. This is especially the case where the arms are in the same two-dimensional plane.
- both the first arm and the second arm are attached to the second column. This may increase the strength of the masonry support bracket, especially in the two dimensional plane.
- first and second arms there is a void between the first and second arms. This may enable the mass of the masonry support bracket to be reduced.
- the first arm emanates from the top of the first column, and the second arm emanates from the bottom of the first column.
- This arrangement may increase the length of the column taking load, and therefore the strength of the bracket may be increased.
- the masonry support bracket comprises a second pair of arms, the third arm and fourth arm, that extend from the first column. This may further increase the strength of the masonry support bracket.
- the third arm and fourth arm are parallel to the first arm and second arm. Further optionally the third and fourth arms may be offset from the first and second arms. The parallel relationship enables the load to be born symmetrically and reduce risk of failure over time.
- the third arm and fourth arm are both joined to a third column.
- the third column may offer structural support to the at third and fourth arms.
- the third column is perpendicular the first column, and is parallel to the second column.
- the third column is angled relative to the third arm and the fourth arm, wherein the third and fourth arm extend from the first column towards the fagade, and wherein the third column extends downwardly approximately parallel the fagade. This may offer structural support to the masonry bracket.
- the arm is a sheet, and is in a two dimensional plane, and wherein the third column is in the same two-dimensional plane.
- This may allow the two dimensional plane to have a great deal of strength.
- the two two- dimensional planes are parallel and therefore together may be able to take a significant amount of load, despite the relative low mass of the masonry support bracket.
- the first column comprises a sheet of material, preferably metal, preferably stainless steel. This may reduce the mass of the masonry support bracket, whilst maintaining strength.
- the at least one arm comprises a sheet of material, preferably metal, preferably stainless steel. This may reduce the mass of the masonry support bracket, whilst maintaining strength, at least in the two-dimensional plane, and the ability to take load from the fagade.
- the top surface of the at least one arm comprises an indent. This may aid with the prevention of fire, whilst keeping the masonry support element simple to manufacture and assemble.
- a fire barrier or fire prevention material sits within the indent, such that the fire barrier is positioned between the at least one arm and the cavity tray.
- the fire barrier may therefore be securely attached without requiring further means of attachment such as adhesive etc.
- a fire barrier is positioned between the cavity tray and the at least one arm. This may help prevent the spread of fire, especially between floors.
- a fire barrier is positioned atop the cavity tray. This may make assembly simple.
- an intumescent rigid structure is positioned atop the cavity tray. This may allow for the masonry support element to be retrofitted with existing fire prevention materials.
- a wall tie attached to the masonry support bracket, optionally attached to the second column of the masonry support bracket.
- the wall tie is attached to a slot within the masonry support bracket, allowing the height of the wall tie to be adjusted. This reduces the complexity of assembly/construction.
- the cavity tray comprises a metal sheet, preferably of a thickness of up to 2mm, preferably wherein the thickness is 0.5mm. This may reduce mass of the masonry support element.
- the cavity tray is angled relative to the horizontal, preferably wherein the angle is between 3 and 10 degrees, and preferably wherein the angle is 5 degrees. This may aid the passage of water along the cavity tray.
- the cavity tray further comprises a second angled section at a greater angle to the horizontal than the rest of the cavity tray, wherein the second angled section is positioned adjacent the first column, optionally wherein the greater angle is 50 degrees from horizontal.
- This may aid with attachment of the cavity tray to the masonry support bracket as it is simpler for the two to be married in this position.
- the second angled portion comprises the attachment point to attach the cavity tray to the masonry support bracket.
- the cavity tray extends to overlie at least a portion of the first column of the masonry support bracket. This may enable the cavity to intercept any moisture travelling down the internal building structure.
- the cavity tray overhangs the end of the at least one arm, and the second column. This may be highly advantageous as this allows moisture to drop from the cavity tray to an intended location. This may reduce the mass of the cavity tray as it need not extend further.
- the cavity tray comprises a lip. This may direct the falling moisture droplets to the intended position.
- the lip extends downwards, optionally vertically down parallel to the internal building structure. This may guide the moisture droplets directly downwards.
- the cavity tray is attached to the masonry support bracket by one of a mechanical join, an adhesive join or a welded join.
- the cavity tray is attached to the masonry support bracket by an attachment element as set out in the fourth aspect.
- the masonry support angle comprises an upstanding element such that the upstanding is attached to the at least one arm and/or second column of the masonry support bracket. This may provide strength, and may prevent splash from the masonry support angle going back into the cavity.
- the upstanding element extends at least 50mm from the horizontal plane of the portion of the masonry support angle that extends into the fagade, further optionally wherein this extension is at least 100mm.
- the 50mm length may provide sufficient strengthening (and 70mm, or 90mm may provide further strengthening), whilst the 100mm length may ensure regulatory compliance. 50mm may be advantageous as it may reduce the mass of the masonry support.
- the upstanding element is perpendicular to the portion of the masonry support angle configured to extend into the fagade. This may strengthen the masonry support angle.
- the upstanding comprises a cut-out at the top edge of the upstanding, wherein the cut-out is positioned in line with the central void of the first column.
- this may be highly advantageous, and may be advantageous separately to the features of the first aspect (that is this feature may offer further advantages to the system of the first aspect, or may on its own offer an advantageous feature).
- This may allow access to the lower section of the central void of the first column, and so may allow further bolts or other attachments to be inserted into this void, that otherwise would be difficult to reach. This therefore improves the efficiency of assembly on a construction site.
- a cover to cover the cut-out of the upstanding when installed. This may ensure the upstanding reaches a pre-set level, for example to comply with regulatory guidance/guidelines.
- a primary attachment between the masonry support bracket and the internal building structure, and optionally the internal building structure is positioned at the top of the first column. This may ensure that the connection between the masonry support bracket and the internal building structure is strong, and may prevent rotation and the like.
- the first column comprises a central void. This may reduce the mass of the masonry support bracket.
- the primary attachment is through the central void of the first column, optionally at the top of the central void. This may provide a centralised (width-wise) connection to ensure even distribution of load.
- At the top comprises within 45mm of the top of the central void. This may provide a secure and stable connection that is simple to fit in construction.
- a secondary attachment between the masonry support bracket and the internal building structure may further secure the masonry support bracket.
- the secondary attachment is through the central void of the first column. This may distribute the load evenly.
- the secondary attachment is within 75mm of the primary attachment. This may make the attachment particularly strong, and may be simple to fit.
- the secondary attachment is positioned at the bottom of the first column.
- at the bottom of the central void optionally wherein at the bottom comprises within 45mm of the bottom of the central void.
- one or both of the primary and secondary attachments are in the form of a bolt into the internal building structure.
- a side of the cavity tray, parallel to the at least one arm, comprises a lip, optionally wherein both sides parallel to the at least one arm comprise a lip. This may prevent water from passing off of the side of the tray, and may help channel the water over the overhang of the cavity tray.
- the lip rises from the cavity tray to prevent water from passing to the side and off of the cavity tray.
- the at least one arm, or the second column comprises a slot into which the upstanding of the masonry support angle is positioned. This may allow the masonry support angle and the masonry support bracket to be mechanically joined, and may reduce the mass of the masonry support element.
- the first column comprises a notch, such that there is an offset from a first portion of the column to a second portion. This may allow the masonry support element to sit flush against an internal building structure comprising a notch.
- each masonry support bracket comprises a pair of brackets attached to a single masonry support angle. This may mean that a single masonry support angle is attached to two masonry support brackets. This may increase the strength of the masonry support element, and may reduce the time taking during construction to fit a plurality of masonry support elements.
- each of the masonry support brackets are positioned angled to one another, optionally perpendicular to one another. This may allow a masonry support angle to extend around a corner.
- the masonry support angle comprises a first section and a second section are angled to one another, optionally perpendicular to one another. This may allow a masonry support angle to extend around a corner.
- the cavity tray comprises a first and second section angled to one another, optionally perpendicular to one another. This may allow a masonry support angle to extend around a corner.
- the masonry support element is configured to attach as a single unit around an external/internal corner of the internal building structure.
- a masonry support bracket for transferring the load of a building fagade to the internal building structure
- the masonry support bracket comprises: a first column, and at least one arm extending perpendicular to the first column away from the internal building structure and towards the fagade; wherein the first column is configured to lie parallel with the interna l building structure; wherein the first column is configured to attach to the internal building structure.
- such an arrangement ensures an effective force transmitting arrangement from the building fagade to the internal structure as it utilises a sufficiently large surface area (the first column) abutting the internal building structure.
- the masonry support bracket of the second aspect is the masonry support bracket of the first aspect.
- the optional features, and their advantages, relating to the masonry support bracket of the first aspect apply to the masonry support bracket of the second aspect.
- the masonry support bracket attaches onto a masonry support angle; wherein the masonry support bracket is configured to transfer the load from the masonry support angle to the internal building structure; wherein the masonry support angle is configured to extend into the fagade, and to take the load of the fagade and transfer this load to the masonry support bracket; wherein the masonry support angle is the masonry support angle of the first aspect.
- such an arrangement may see the masonry support angle attach to the second column of a masonry support bracket. This may allow the masonry support angle to abut the second column and therefore make manufacture less complex as many simple joins may be used between the two elements.
- a cavity tray comprisi ng: a tray section configured to extend at least partially between an inner cavity wall and an outer cavity wall; a fire prevention structure, wherein the fire prevention structure is configured to be positioned below the tray section, and to comprise a front face, wherein the front face is configured to face the outer cavity wall during use, and an inner face, wherein the inner face is configured to face the inner cavity wall during use; wherein both the front face and rear face comprise a fire prevention material.
- the fire prevention structure may be advantageous for reducing the spread of flames, fire, and slowing the rate of temperature increase. This is because it acts to reduce the flow of gas from below the cavity tray to above the cavity tray, and because the front face and the rear face provide means for prohibiting the spread of fire across a large section of the underside of the tray.
- fire prevention material covering at least a portion of the tray section, preferably wherein the fire prevention material covers the portion of the tray section configured to be positioned closest to the outer cavity wall during use.
- this covers the top of the tray section this may be advantageous as it may prevent flames, or a rise in temperature, from spreading or hastening in the event of fire. This is because it acts to limit the air flow between the cavity tray and the space above it - i.e. to the next cavity tray on the floor above.
- a lip extending from the edge of the tray section that is configured to be closest to the outer cavity wall during use, preferably wherein the lip extends at an angle to the tray section, further preferably wherein the lip is angled further downwards as compared to the tray section.
- the lip may be advantageous as it may further prohibit the movement of flames or the passage of heated air through the cavity. In particular, in the event of fire the lip may prohibit the spread of flames through any gap between the cavity tray section and the outer wall of the cavity.
- the lip is hinged with the end of the tray section, or with the fire prevention material covering the tray section. This may allow the lip to close the gap to the outer cavity wall when needed, but allow water to pass from the cavity tray to a tray beneath when not needed.
- the lip is configured such that when heat and an associated increase in pressure occurs below the tray section, the lip moves about the hinge so as to block at least a portion of any gap between the end of the tray section and the outer cavity wall. This may advantageously seal the gap, or part of the gap, between the tray section and the outer cavity wall. In the event of a fire this may prevent the spread.
- the lip extends between 40-50mm beyond the edge of the tray section, preferably wherein this distance is 45mm. This may allow the lip to mitigate against the spread of fire for the majority of the gap between the tray section and the outer cavity wall.
- the lip is configured to aid in the direction of water off of the tray section, such that water passing off of the tray section is directed onto a further tray below.
- the cavity tray is already designed such that water is configured to be directed in this manner.
- the lip may further aid with the passage of water as at least some water may travel along the lip and then drop to the designated surface below.
- the lip is formed of non-expansive fire prevention material. This may allow it to retain its structure in the event of a fire and function in the hinged manner detailed above.
- the fire prevention structure comprises an intermediate portion situated between the front face and the rear face. This may ensure that the front and rear faces act as intended, and that the joining portion does not present an opportunity for the spread of fire.
- the fire prevention material is an intumescent material.
- This may be highly advantageous. This may mean that the material atop the tray section may expand vertically upwards towards the tray above -and so limit the ability of fire to spread in this direction.
- the front face may expand to the outer cavity wall also, in conjunction with the rear face expanding towards the inner cavity wall so that together they form a barrier.
- the fire prevention structure comprises a first outer layer of intumescent material forming the front face, and a second outer layer of intumescent material forming the rear face, with a layer of alternative fire prevention material situated therebetween, preferably wherein the alternative fire prevention material is mineral wool.
- the alternative fire prevention material is mineral wool.
- the alternative fire prevention material may allow these front and rear faces to be connected together, whilst minimising the spread of fire through such a connection. It is noted that in some embodiments the alternative fire prevention material may be replaced by a divider forming part of the cavity tray.
- the tray section comprises a divider configured to extend downwards in the cavity, and wherein the front and rear surface separated by the divider.
- This may advantageously provide a surface for the fire prevention structure to be situated onto without comprising the structure of the cavity tray.
- the divider may also aid in the direction of water onto a tray situated below.
- the alternative fire prevention material is situated adjacent the divider and the rear face.
- This may allow the alternative fire prevention material, such as mineral wool, to attach to the rear side of the divider. This may simplify manufacture, and ensure the fire prevention structure is efficient at reducing the spread of fire.
- the divider is non-continuous such that it is castellated. This may reduce the cost of manufacture (for example two dividers may be produced that approximately tessellate with one another to minimise wasted material), and the weight of the cavity tray. This may also reduce the energy needed for transport and increase ease of installation.
- a jointing structure attaches the fire prevention structure to the cavity tray. This may allow the fire prevention structure to be securely attached to the cavity tray.
- the jointing structure comprises rivets.
- rivets may prevent hot air from passing from one side of a join to the other and therefore may aid in the prevention of fire.
- rivets are configured to protrude through the divider and at least one of the front face and/or rear face, and optionally wherein the rivets protrude through both the front face and rear face. This may be advantageous as the tray section is unencumbered to the attachment and so is of optimal strength in the case of fire.
- the rivets are configured to protrude through the tray section and into the intermediate portion. This may mean that a divider is not needed, and so reduce the weight and complexity of the cavity tray.
- washers are used to hold rivets, optionally wherein said washers are situated within the intermediate portion. This may keep the attachment strong and reliable.
- the divider is absent when the tray section is used as the point of connection between the fire prevention structure and the cavity tray. This may reduce the weight of the tray and so improve ease of installation. It may also reduce complexity of manufacture.
- the rightmost and/or leftmost portion of the fire prevention structure terminates prior to the rightmost and/or leftmost portion of the tray section such that a gap is left at the rightmost and/or leftmost end of the fire prevention structure, optionally wherein said gap is to enable adjacent cavity trays to be fitted with an overlapping section, optionally wherein said gap is 50mm.
- This may be advantageous as cavity trays are configured to overlap.
- the tray section is flexible enough to allow such overlap, but the additional width of the fire prevention structure would not accommodate such overlap in some cases. Therefore, the provision of a gap in the fire prevention structure at the point of overlap enables the assembly of the cavity trays to be simpler on a building site.
- the rightmost and/or leftmost portion of the fire prevention structure comprises a fire prevention material situated at the end face, optionally wherein the fire prevention material is intumescent material.
- the fire prevention material is intumescent material. This may allow the fire prevention material to prevent any fire or hot air from passing through the gap. For example in the case of intumescent material in the event of fire this will expand to fill any remaining gap and therefore limit the spread of fire.
- tray section further comprising an attachment surface, attached to the tray section, and configured to attach the tray section to an external component during use. This may allow the tray to be attached to external elements during installation without the need for welding or the like.
- the external component is a masonry support element or the inner cavity wall.
- This may allow the cavity tray to be installed with ease, whilst being in a set position that is strong and stable.
- a masonry support element comprising: a masonry support bracket; a masonry support angle; a cavity tray as set out in accordance with the third aspect; wherein the masonry support angle is configured to extend into the outer cavity wall, and to take the load of the outer cavity wall and transfer this load to the masonry support bracket; wherein the masonry support bracket is configured to be attached to the inner cavity wall, and is configured to transfer the load from the masonry support angle to the inner cavity wall; wherein the cavity tray is configured to sit above the masonry support angle such that water passing across the cavity tray drops down onto the masonry support angle.
- a masonry support comprising the cavity tray as this provides a single element that both provides structural support to the outer cavity wall, and is configured to manage the movement of water within the cavity. Additionally this element is configured to reduce the risk of the spread of fire. This may allow the masonry support angle to function as a second cavity tray to direct the water out of the cavity.
- a masonry support element comprising: a masonry support bracket; a masonry support angle; a fire prevention structure; wherein the masonry support angle is configured to extend into the outer cavity wall, and to take the load of the outer cavity wall and transfer this load to the masonry support bracket; wherein the masonry support bracket is configured to be attached to the inner cavity wall, and is configured to transfer the load from the masonry support angle to the inner cavity wall; wherein the fire prevention structure comprises a front face, wherein the front face is configured to face the outer cavity wall during use, and an inner face, wherein the inner face is configured to face the inner cavity wall during use; wherein both the front face and rear face comprise a fire prevention material.
- This may be advantageous as it provides a masonry support element that reduces the risk of the spread of fire through a high rise building.
- the fire prevention material is an intumescent material. This is advantageous it is will expand in the event of fire to create a barrier to prevent the spread of fire.
- a cavity tray wherein the cavity tray is configured to sit above the masonry support angle such that water passing across the cavity tray drops down onto the masonry support angle, preferably wherein the cavity tray is the cavity tray in accordance with the third aspect. This may allow the passage of water within the cavity to be managed.
- the fire prevention structure is configured to sit above or on a portion of the masonry support bracket. This may provide space for the fire prevention structure to function in.
- the masonry support bracket is formed from an arm extending from the inner cavity wall to the outer cavity wall, and wherein the fire prevention structure is configured to sit on or above the arm. This may provide an unobstructed volume in which the fire prevention structure may function.
- the masonry support bracket is formed from a first column parallel to the inner cavity wall, an arm extending from the inner cavity wall to the outer cavity wall, and a second column at the end of the arm, wherein the fire prevention structure is configured to sit on or above the second column. This may provide an unobstructed volume in which the fire prevention structure may function.
- the volume between the inner cavity wall and the rear face of the fire prevention structure is kept clear of any obstructions, preferably wherein a layer of insulation is positioned on the surface of the inner cavity wall.
- no portion of the masonry support bracket is configured to be situated between the rear face of the fire prevention structure and the inner cavity wall.
- the masonry support bracket comprises a first column configured to lie parallel with the internal cavity wall, and at least one arm extending away from the internal building structure and towards the outer cavity wall.
- This may provide a mass efficient means of providing support to the outer cavity wall. The reduction in mass may make installation and manufacture of the masonry support element simpler and less costly.
- the cavity tray is configured to overlie the at least one arm of the masonry support bracket. This may enable the cavity tray to intercept any moisture travelling down the internal building structure.
- the arm forms a first portion and a second portion that are angled to one another, wherein the first portion emanates from the attachment surface of the cavity tray, and the second portion extends towards the masonry support angle.
- the angle between the first portion and the second portion of the arm is the same as the angle between the attachment surface and the tray portion.
- the first portion emanates from the attachment surface of the cavity tray, and the second portion extends towards the masonry support angle.
- a second column attached to the other end of the at least one arm, wherein the fire prevention structure is situated above the second column.
- the second column may offer structural support to the at least one arm.
- the position of the fire prevention structure above the second column means that the portion of the tray portion closest the outer cavity wall is raised above the masonry support bracket.
- a wall tie attached to the masonry support bracket. This offers a further point of attachment to the fagade and helps reduce movement between the fagade and the support element.
- a masonry support bracket comprising: a first column configured to lie parallel to the inner cavity wall; a first arm extending from the first column towards the outer cavity wall; wherein the first arm comprises a first portion and a second portion that are angled relative to one another. This may allow for fire prevention material to be so positioned as to reduce the risk of fire. Moreover, the bracket also serves to convey the weight of the outer cavity wall to the internal building structure.
- a second column wherein the second portion of the arm terminates at the second column, wherein the second column is configured to be attached to a masonry support angle.
- This may provide means for transferring the weight from the outer cavity wall to the masonry support bracket.
- the first portion of the arm is configured to be attached to a cavity tray, such that in use the cavity tray is positioned above the second portion of the arm.
- This may allow the water within the cavity to be managed such that it does not cause damage to any of the internal structure within the cavity. This may also improve the lifespan of the masonry support bracket.
- a fire prevention structure configured to be attached on to or above the second portion of the arm or the second column. This may prevent the spread of fire when combined with the structure of the masonry support bracket as detailed above which provides a volume for the fire prevention structure to occupy in the presence of heat.
- a cavity tray and fire barrier configured to sit in a cavity between an internal building structure and a fagade; wherein the cavity tray is configured to collect moisture within the cavity, and to provide an alternative path for said water to take across the cavity tray; wherein the fire barrier is configured to be positioned either: atop the cavity tray; or beneath the cavity tray.
- the fire barrier is configured to be positioned atop the cavity tray through a mechanical attachment. Positioning the fire barrier atop the cavity tray utilises gravity to ensure the fire barrier is passively in contact with and sits on top of the cavity tray even without attachment means. This is especially useful in the event of a fire should the mechanical attachments fail. Additionally, the fire barrier doesn't need to be held in place whilst fixing to the tray. This may be more convenient to the assembler. Moreover, if the fire barrier is formed from intumescent material, the cavity tray may act to aid with the directional distribution of the expanded material.
- the mechanical attachment is one of: rivets, bolts, crimping or clips.
- These listed attachment means are both easy to implement and may ensure a secure attachment.
- the fire barrier is a strip.
- the strip may be conveniently cut to a range of sizes.
- the strip refers to a regular width of fire barrier and therefore may be assembled side-by-side with many strips to increase width of fire barrier coverage in a controlled fashion (incrementally and discretely).
- the strip of fire barrier is dimensioned to cover either a portion or all of the cavity tray surface to which it is attached.
- a benefit of covering only a portion of the surface is to complement the existing fire prevention structures or insulation material that also occupy space on the cavity tray themselves. This arrangement may save material cost by not excessively placing the fire barrier where it is not needed as much, i.e. underneath the fire prevention structures or insulation material.
- the fire safety may be more robust simply by virtue of increasing the amount of fire barrier used.
- each strip of fire barrier is configured to be attached to the cavity tray by at least two mechanical attachments. This provides a securement means in the event that one attachment fails.
- the mechanical attachments are positioned longitudinally separated from one another on each strip of fire barrier such that the fire barrier is constrained to the cavity tray along its length.
- such an arrangement provides a more secure attachment as compared to a single fixture, as well as multiple attachment means concentrated at one longitudinal location on the fire barrier.
- the fire barrier is configured to cover a portion of the total area of a cavity tray surface onto which it is attached, optionally wherein the cavity tray surface is the top surface.
- the fire barrier is configured to cover a portion of the total width of the cavity tray surface spanning from its distal end towards the proximal end, wherein the distal end is the end of the cavity tray configured to be adjacent the fagade and wherein the proximal end is configured to be adjacent the internal building structure.
- the fire barrier is configured to cover the very distal end of the cavity tray surface to which it is attached.
- this minimises the probability of clashing with the fire prevention structures or insulation material found at the proximal end.
- the distal end is also more likely to be 'free' from obstruction and therefore allow the intumescent material of the fire barrier to expand more freely.
- one strip of fire barrier may be dimensioned to the required width.
- the desired width may be achieved by placing multiple strips side by side. Both these approaches are very convenient to implement in practice.
- the fire barrier is configured to cover the majority of the length of the cavity tray surface, wherein length is defined in the longitudinal direction of the cavity tray. This is advantageous as it allows the fire barrier to function more effectively and efficiently.
- the intumescent material of the fire barrier will be able to fill the cavity space above (or below) the cavity tray quicker should it cover a greater length of said cavity tray. Filling this cavity quickly is an important feature of the fire barrier.
- the cavity tray surface is covered in the longitudinal direction by either one strip of fire barrier or a plurality of strips of fire barriers arranged adjacent one another in the longitudinal direction.
- the option of not being limited to using one fire barrier per tray is more convenient for the assembler. Strips that may accidentally be dimensioned too short of the length of the cavity tray will still be effective. This arrangement is also more sustainable as it utilises fire barrier strips that otherwise would be discarded for being too short.
- a gap is left between longitudinally adjacent fire barriers.
- a passage for the moisture collected on the cavity tray is formed. This allows the moisture to fall off the cavity tray in a controlled manner.
- Such an arrangement strikes a balance between maintaining a good lengthwise coverage of fire barriers on the cavity tray and the effective flow of water off of the cavity tray.
- a fire prevention structure or insulation material is configured to be positioned atop the cavity tray, optionally wherein the fire prevention structure or insulation material comprise mineral wool.
- the fire prevention structure or insulation material comprise mineral wool.
- such an arrangement allows the cavity tray and fire barrier to not only accommodate but complement existing fire prevention structures or insulation material to provide a more complete fire protection. This may be through full coverage of the width of the cavity tray with fire prevention means (barriers and structures or insulation).
- the upper surface of the cavity tray uncovered by the fire prevention structure or insulation material is configured to be covered by the fire barrier, optionally wherein a portion of the upper surface of the cavity tray is left exposed.
- the fire barrier is an intumescent material.
- this is particularly favourable in filling up the cavity space in a short period of time.
- a side of the cavity tray comprises a lip
- both sides of the cavity tray comprise a lip
- the lip rises from the cavity tray to prevent water from passing to the side and off of the cavity tray. This may channel the water and direct it towards the weep holes in the masonry fagade.
- angle of the lip relative to the horizontal is between 10° to 90°.
- a 90° angle ensures that the lip protrudes vertically above the fire barrier strips to channel the water effectively.
- Lower angles within the range may allow for a more slender side profile of the tray.
- a first cavity tray is configured to lay longitudinally adjacent a second cavity tray, optionally wherein a portion of one tray overlies a portion of a second tray such that there is no passage for water in between cavity trays.
- a portion of one tray overlies a portion of a second tray such that there is no passage for water in between cavity trays.
- the cavity tray is configured to be attached to the internal building structure
- the cavity tray is configured to be attached to a load carrying feature in connection with the internal building structure.
- attaching directly to the building may aid in collecting water running down the surface of the internal building structure more efficiently. Attaching to a load carrying feature may be a more convenient attachment means or utilise existing cavity infrastructure.
- the cavity tray is configured to attach to the internal building structure by one of: a mechanical join, an adhesive join, a welded join or an attachment element. All of these attachments are convenient to implement in a tight cavity with limited skill required.
- the load carrying feature is a masonry support bracket.
- the cavity tray is attached to the masonry support bracket by one of a mechanical join, an adhesive join or a welded join, optionally wherein the cavity tray is attached to the masonry support bracket by an attachment element.
- the cavity tray comprises a metal sheet, preferably of a thickness of up to 2mm, preferably wherein the thickness is 0.5mm. This may reduce mass of the cavity tray.
- the cavity tray is configured to be angled relative to the horizontal, preferably wherein the angle is between 3 and 10 degrees, and preferably wherein the angle is 5 degrees. This may aid the passage of water along the cavity tray.
- the cavity tray further comprises a second angled section at a greater angle to the horizontal than the rest of the cavity tray, wherein the second angled section is configured to be positioned adjacent the internal building structure, optionally wherein the second angle is 50 degrees from the horizontal, optionally wherein the second angled portion comprises an attachment means.
- This may aid with attachment of the cavity tray to the internal building structure or load carrying feature as it is simpler for the two to be married in this position.
- the cavity tray comprises a lip at its distal end, optionally wherein the lip extends downwards, optionally vertically down and parallel to the internal building structure. This may direct the falling moisture droplets to the intended position.
- an attachment element configured to attach to a secondary element
- the attachment element comprising: a proximal arm; a distal arm; a channel between the proximal arm and the distal arm; the channel leading to a first recess positioned below the proximal arm and a second recess positioned below the distal arm; and a tooth positioned within the second recess.
- the attachment element is positioned on a masonry support element, such as a masonry support bracket, and is configured to attach to a building structure. It is advantageous to provide the attachment means on a masonry support element such as a masonry support bracket. Where the secondary element is a cavity tray the attachment means may provide a quick and easy to use means of attachment. This reduces time installing the masonry support element and the cavity tray, and therefore improves the efficiency of the building process.
- the proximal arm is located on the masonry support element. This may make manufacture and installation simpler and require less assembly.
- the distal arm is located on the masonry support element. This may make manufacture and installation simpler and require less assembly.
- the second recess is divided by the tooth into a first passage adjacent the channel and the anterior of the tooth, and a second passage adjacent the posterior of the tooth.
- the second passage can be used as the end point of the path of a bar for attachment of a secondary element. This secures the bar effectively, and makes it highly unlikely for the bar to slip out of the attachment means.
- the anterior side of the tooth is angled relative to the underside of the distal arm. This may allow a bar to pivot during the insertion to form a path that the bar cannot re-traverse without human intervention.
- the angle between the anterior side of the tooth and the distal arm is between 5 and 20 degrees, optionally wherein the angle is between 14 to 18 degrees, and further optionally wherein the angle is 16 degrees.
- This angular range, and this angle in particular have been found to optimise the amount of pivoting available, whilst reducing the use of material, and making the attachment secure.
- the arms of the attachment element are angled with respect to the vertical of the masonry support element. This may allow the bar to sit at an angle, which may conform with the shape of the secondary element, particularly if the secondary element is a cavity tray.
- proximal arm extends from a position above the distal arm. This may provide ease of access to the channel.
- the top side of the distal arm and the top side of the proximal arm are parallel. This may make moving the bar simpler, and reduce the risk of the bar unexpectedly catching a surface during attachment.
- the top side of the distal arm is parallel to the bottom side of the distal arm. This allows the second recess to be shaped to provide an advantageous pathway for the secondary element.
- the bottom side of the proximal arm is angled with respect to the top side of the proximal arm. This may provide a second point at which to pivot the secondary element, and so may aid with attachment.
- the angle between the top side of the proximal arm and the bottom side of the proximal arm is between 5 and 20 degrees, optionally wherein the angle is between 14 to 18 degrees, and further optionally wherein the angle is 16 degrees.
- This angular range, and this angle in particular have been found to optimise the amount of pivoting available, whilst reducing the use of material, and making the attachment secure.
- the angle between the top side of the proximal arm and the bottom side of the proximal arm is the same as the angle between the anterior side of the tooth and the distal arm. This may improve the ease of attachment by making it simpler to slide a secondary element from the anterior side of the distal tooth to the bottom side of the proximal arm.
- first recess and the second recess are joined to form a single cavity.
- first recess and second recess share a base.
- the base is parallel with the posterior side of the tooth.
- This may be advantageous as the void of the second passageway may be cuboid in shape - and therefore make the insertion of the bar of the secondary element simpler.
- the base is parallel with the top of the distal arm. This helps with creating the multiple stage pathway.
- the base is parallel with the top of the proximal arm.
- distance between the base and the underside of the proximal arm is less than the distance between the base and the underside of the distal arm. This may be highly advantageous as this may allow a bar resting on the top of the distal arm to slide through the channel and under the underside of the proximal arm.
- the distance between the base and the top of the proximal arm is less than the distance between the base and the underside of the distal arm. This may help the bar slide through the channel by sliding along the top of the distal arm and then under the proximal arm and in the first recess.
- the distal arm is shaped as an elongate bar in cross section.
- the secondary element comprises an attachment bar. This may advantageously fit into the pathway of the attachment element.
- the attachment bar forms part of a cavity tray. This may be advantageous for the construction of masonry support elements where a cavity tray attaches to a masonry bracket.
- the bar is flat, such that the length and width of the bar are greater than the depth of the bar, optionally wherein the depth of the bar is 0.5mm.
- either side of the bar is a void, and wherein the voids are at least a distance x in length, optionally where x is 8mm to 12mm, and further optionally wherein x is 10mm. This may advantageously make it simpler to manoeuvre the bar into place.
- the distance between the base and the top of the proximal arm is less than the distance between the base and the underside of the distal arm, and wherein the difference between these distances is equal to the depth of the bar optionally wherein equal includes an additional tolerance, for example of 0.1mm. This may advantageously allow the bar to slide into the first recess in a simple manner.
- the second passage has a depth equal to the depth of the bar, optionally wherein equal includes an additional tolerance, for example of 0.1mm. This may allow the second passage to engage with the bar in a friction fit to keep the bar in place.
- the width of the bar is greater than the width of the channel. This may allow the bar to enter by sliding, rather than by initially being angled and pivoting into a recess as per other solutions.
- the length of the distal arm is 0.5mm greater than the width of the bar. This may make ease of attachment simpler.
- the length of the second passage is at least half the width of the bar. This may provide a particularly secure attachment.
- the length of the base to the entrance of the second passage is at least 0.5mm greater than the width of the bar. This may make attachment simpler.
- the distance between the end of the proximal arm and the tooth is at least half of the width of the bar. This may make progress of the bar through the pathway simple.
- the length of the top side of the distal arm is at least 1mm smaller than x. This may make manoeuvring the cavity tray simpler.
- the length of tooth to the rear of the distal arm is at least 1mm smaller than x. This may make manoeuvring the cavity tray simpler.
- a cavity tray comprising a first sheet comprising a plurality of edges; at a first edge there is a first void extending from the edge towards the interior of the sheet; at the end of the first void is a bar of material such that a first side of the bar is adjacent the first void; adjacent the second side of the bar is a second void, wherein the second void is entirely surrounded by material of the sheet.
- This may co-operate with the attachment element of the fourth aspect (in a plug-socket type arrangement). This may allow the cavity tray to be efficiently and securely fastened, therefore increasing the efficiency of building.
- the bar has a width of between 3mm and 7mm, preferably 5mm.
- the void extends between 8mm and 12mm into the interior of the cavity, preferably wherein it extends 10mm.
- the relative dimensions of the width to the void may be particularly preferable as this provides ease of use during installation.
- the second void extends away from the bar for a distance of at least 8mm to 12mm, optionally 10mm.
- the cavity tray further comprises: at the first edge, or an edge adjacent the first edge, a third void extending from the edge towards the interior of the sheet; at the end of the third void a second bar of material such that a first side of the second bar is adjacent the third void; adjacent the second side of the second bar a fourth void, wherein the fourth void is entirely surrounded by material of the sheet.
- Having two bars may be particularly advantageous. This may allow a single cavity tray to be attached to two attachment elements. This may allow the cavity tray two points of attachment to a single masonry support bracket/element, or a single point of attachment to two masonry support brackets/elements. This secures the cavity tray may securely, and may enable flexibility in construction.
- an assembly comprising the attachment element of the fourth aspect incorporated into a masonry support bracket, and a cavity tray of the fifth aspect.
- This combination may provide a particularly efficient means of forming a masonry support element within a cavity.
- a masonry support element comprising the attachment means of the first aspect.
- the masonry support element is a masonry support bracket.
- a building comprising: an internal building structure; a masonry fagade; a masonry support element as recited in the first aspect; wherein the masonry support element is connected between the masonry fagade and the internal building structure.
- This building may transfer the load from the masonry fagade to the building structure, and may have improved moisture management within the cavity between the fagade and the internal building structure. In some embodiments fire management may also be improved.
- weep vents positioned at the end of the masonry support angle such that water is expelled from the building via the weep vents. This may allow water flowing onto the masonry support angle to pass through the weep vents and be expelled from the cavity of the building.
- a high rise building comprising a plurality of floors, and an inner cavity wall and an outer cavity wall with a cavity therebetween; and a cavity tray in accordance with the third aspect, wherein the cavity tray is situated at a first floor of the high rise building, and within the cavity between the inner cavity wall and the outer cavity wall.
- the cavity tray is situated at a first floor of the high rise building, and within the cavity between the inner cavity wall and the outer cavity wall.
- This may provide a building at less risk of fire.
- the fire prevention material covering at least a portion of the tray section is configured to expand towards the second cavity tray in the event of fire. Therefore less hot air and fewer flames (and potentially none in some circumstances) will pass between the floors, and therefore the risk of the spread of fire is reduced.
- a fourteenth aspect there is described a method of installing the masonry support element of the first aspect, the method comprising the steps of: positioning a first masonry support bracket and angle at an intended position adjacent the internal building structure; positioning a second masonry support bracket and angle adjacent the position of the first masonry support element, and adjacent the internal building structure; attaching both the first masonry support bracket and angle and the second masonry support bracket and angle to the internal building structure; positioning a first cavity tray over the at least one arm of the first masonry support bracket; attaching the first cavity tray to the first masonry support bracket.
- This method may allow an efficient method for installing the masonry support angle within a cavity. This may therefore take less time and resources during the construction process.
- first infill cavity tray over a portion of the first masonry support angle and a portion of the second masonry support angle, attaching the first infill cavity tray to the first masonry support angle and the second masonry support angle. This may aid with the direction of water on the masonry support angle.
- the first cavity tray extends over at least a portion of the second masonry support bracket. This may make it simple to install multiple masonry support elements together, particularly around corners.
- positioning the first masonry support bracket and angle comprises positioning the first masonry support bracket and angle one side of an external/internal corner of the building structure, wherein positioning the second masonry support bracket and angle comprises positioning the second masonry support bracket and angle the other side of the external/internal corner of the building structure to the first masonry support bracket and angle.
- positioning the first cavity tray over the at least one arm of the masonry support bracket comprises the cavity tray extending around the external/internal corner of the internal building structure. This may make it simpler to join the two masonry support brackets together.
- positioning a first infill cavity tray comprises positioning the infill cavity tray over the external/internal corner of the internal building structure. This may prohibit ingress of water at the corner point.
- attaching the first masonry support bracket to the internal building structure comprises securing a first bolt through a central void in the first column of the masonry support bracket, and said bolt attaching to the internal building structure. This may provide a secure connection and ensure load is transferred to the internal building structure.
- the first bolt is positioned at the top of the central void. This may help distribute the load evenly.
- securing further comprises securing a second bolt through the central void in the first column of the masonry support bracket, and said second bolt attaching to the internal building structure. This may provide an improved attachment that is more secure.
- attaching the second bolt comprises providing leverage through a cut-out in the first masonry support angle, wherein the cut-out is aligned with the central void of the first column of the masonry support bracket. This may allow the secondary attachment to be situated at a preferred position that may otherwise be inaccessible to the worker assembling and installing the masonry support element.
- a method of installing a cavity tray in accordance with the third aspect comprising the steps of: providing a first cavity tray in accordance with the third aspect; cutting the rightmost and/or leftmost end of the fire prevention structure to remove a pre-set length of the fire prevention structure; providing a second cavity tray in accordance the first aspect; overlapping the first cavity tray and the second tray by the pre-set length.
- a method comprises attaching the fire barrier to the cavity tray.
- this may be done prior to fitting in the cavity so that it is more convenient for the assembler.
- attaching the fire barrier to the cavity tray comprises: positioning the fire barrier on the cavity tray at a predetermined location; placing a first mechanical attachment at a first longitudinal and transverse location on the fire barrier; optionally wherein the mechanical attachment extends through the fire barrier and cavity tray arrangement; optionally wherein the first transverse location is preferably the midpoint of the width of the fire barrier strip.
- attaching the fire barrier to the cavity tray further comprises: placing a second mechanical attachment on the fire barrier, optionally wherein the second mechanical attachment extends through the fire barrier and cavity tray arrangement; wherein the second longitudinal location is separated from the first longitudinal location so as to constrain the fire barrier to the cavity tray along its length; optionally wherein the second mechanical attachment is positioned at the first transverse location and a second longitudinal location; optionally wherein the second mechanical attachment is a rivet.
- This method may provide an efficient means for securing the elements together which therefore may improve the construction process as a whole. It also ensures a uniform method for conducting the attachment.
- the method comprises attaching the cavity tray to the internal building structure.
- the cavity tray is attached to the internal building structure by one of: a mechanical join, an adhesive join, a welded join, or an attachment element.
- a mechanical join an adhesive join
- a welded join an attachment element
- the fire barrier is attached to the cavity tray prior to attaching the cavity tray to the internal building structure. This is more convenient for the assembler as it can be supplied to the consumer site pre-assembled.
- a method of attaching the attachment element of the first aspect, with a secondary element comprising an elongate flat bar comprising: positioning the bar on the top of the proximal arm; sliding the bar into the first passage below and parallel the distal arm; pivoting the bar such that the base is parallel with the anterior side of the tooth; sliding the bar into the first recess below and parallel the proximal arm; pivoting the bar to be parallel with the base.
- This method may provide an efficient means for securing the elements together which therefore may improve the construction process as a whole.
- the secondary element comprises a cavity tray
- the attachment element is attached to a masonry support element
- the method is a method of attaching a cavity tray to a masonry support element.
- the cavity tray is the cavity tray of the second aspect.
- Figure 1 shows a cross section of a masonry support element.
- Figure 2 shows two masonry support elements of Figure 1 joined together.
- Figure 3 shows a masonry bracket with an indent to house a fire barrier.
- Figures 4a-d show various positions of fire barriers, or equivalents in relation to the masonry support element.
- Figure 5 shows a side lip of a cavity tray.
- Figures 6a and 6b show two steps in the installation of masonry support elements around an external corner.
- Figures 7a and 7b show two further steps of installing the masonry support elements of Figure 6 around an external corner.
- Figure 8 shows a final installation step in the method shown in Figures 6 and 7.
- Figure 9 shows an installation step for installing a one-piece masonry support element around an external corner.
- Figure 10 shows a masonry support element in cross section in which the first column comprises a notch.
- Figures 11a and lib show a masonry support element with only one arm.
- Figures 12a and 12b show a masonry support element in which the masonry support angle comprises a cut-out.
- Figure 13 shows an embodiment of a masonry support angle in which the masonry support bracket comprises a slot into which the masonry support angle is housed.
- Figure 14 shows a close up of an attachment element.
- Figure 15 is a perspective view of a first embodiment of a cavity tray and fire barrier seen through a masonry fagade.
- Figure 16 is a cross sectional view of a first embodiment of a cavity tray and fire barrier.
- Figure 17 is a perspective view of a second embodiment of a cavity tray and fire barrier seen through a masonry fagade.
- Figure 18 is a cross sectional view of a second embodiment of a cavity tray and fire barrier.
- Figure 19 is a cross sectional view of a third embodiment of a cavity tray and fire barrier wherein the fire barrier is positioned beneath the cavity tray.
- Figure 20 is a cross sectional view of a fourth embodiment of a cavity tray and fire barrier wherein the fire barrier wraps around the cavity tray.
- Figure 21 is a perspective view of a fifth embodiment of a cavity tray and fire barrier.
- Figure 22 is a cross sectional view of a fifth embodiment of a cavity tray and fire barrier.
- Figure 23a shows an embodiment of a cavity tray comprising a fire prevention structure in a perspective view.
- Figure 23b shows the cavity tray of Figure 23a in a side view.
- Figure 24a shows a perspective view of a masonry support element comprising a cavity tray comprising a fire prevention structure.
- Figure 24b shows the masonry support element of Figure 24a in a side view.
- Figure 24c shows the masonry support of Figure 24a in a front view.
- Figure 25a shows an alternative embodiment of the masonry support element in a side view.
- Figure 25b shows a further alternative embodiment of the masonry support element in a side view.
- Figure 26 shows the underlying masonry support structure (with fire prevention material removed) present in figures 24a-c.
- Figure 27 shows a flow chart for a method of preparing the cavity tray for installation.
- Figure 28 shows the attachment element in cross section.
- Figure 29 shows a cavity tray with means for attachment to the attachment element.
- Figure 30 shows a close up of the attachment means of the cavity tray.
- Figure 31a is a close up of the attachment means of the cavity tray from above.
- Figure 31b is a view of the cavity tray from above.
- Figure 32 shows the attachment means of the cavity tray attached to the attachment element.
- Figure 33 shows one step in the process of attaching the cavity tray to the attachment element.
- Figure 34 shows a further step of the method of Figure 33.
- Figure 35 shows a further step of the method of Figures 33 and 34.
- Figure 36 shows a further step of the method shown in Figures 33 to 35.
- a masonry support element configured to sit in a cavity between an internal building structure and a fagade, and to transfer the load of the fagade to the internal building structure
- the masonry support element comprising, a masonry support bracket, a masonry support angle, a cavity tray, wherein the masonry support angle is configured to extend into the fagade, and to take the load of the fagade and transfer this load to the masonry support bracket, wherein the masonry support bracket is configured to be attached to the internal building structure, and is configured to transfer the load from the masonry support angle to the internal building structure, wherein the masonry support bracket comprises a first column configured to lie parallel with the internal building structure, and at least one arm extending perpendicular to the column away from the internal building structure and towards the fagade, wherein the masonry support angle is attached to the masonry support bracket, wherein the cavity tray is configured to overlie the at least one arm of the masonry support bracket, wherein the cavity tray is configured to collect moisture within the cavity,
- Figure 1 shows a cross section of a masonry support element 1.
- This comprises a masonry support bracket 7, a masonry support angle 19 and a cavity tray 23.
- the masonry support element is positioned within a cavity between a masonry fagade 5 and an internal building structure 3.
- the masonry support angle 19 is configured to extend into the masonry fagade 5.
- the masonry support angle 19 is configured to transfer the load from the masonry fagade 5 to the masonry support bracket 7.
- the masonry support bracket 7 is in turn attached to the internal building structure 3 (this may be directly or through an intervening element) and to transfer the load from the masonry support angle 19 to the internal building structure 3. As such the load of the masonry fagade 5 is held by the internal building structure 3.
- the masonry support bracket 7 has a structure that is weight saving, whilst maintaining strength in the plane (the plane of the first arm 11) configured to transfer the load of the masonry fagade 5.
- Shown in Figure 1 is the structure of the masonry support bracket 7 in side view. This shows a first column 9, a first arm 11, a second arm 13, and a second column 15. There is also a central void 17 between the first arm 11 and the second arm 13. The central void is fully enclosed in the plane of the first arm.
- the proximal end of the first arm 11 and second arm 13 are attached to the first column 9 in Figure 1.
- the distal ends of the first arm 11 and second arm 13 are attached to the second column 15 in Figure 1.
- first column 9 is perpendicular the cross section of Figure 1, and is flush and/or parallel with the internal building structure. This portion of the first column 9 is perpendicular to the plane of the first arm 11.
- the central void 17 may reduce the weight of the masonry support bracket.
- the strength of the masonry support bracket in the plane of the first arm (the plane that can be seen in Figure 1) is maintained. This is maintained by the two arms 11 and 13, and the second column 15. These elements together distribute the load, and enable it to be transferred.
- the portion of first column 9 visible in Figure 1 is optional, and all of the first column 9 may be perpendicular to the view shown in Figure 1. However, the section of the first column 9 is also advantageous for receiving the load from the arms 11 and 13 and transferring this to the portion of the first column 9 not visible in Figure 1 and then onto the internal building structure 3.
- the second column is in two-dimensional plane of the first arm 11.
- the second column extends downwards (in this case vertically downwards, but other angles may be used).
- the second column is shown as being parallel in this view to the masonry fagade. This may enable load to be transferred and carried efficiently by the masonry support bracket, whilst minimising the mass of the masonry bracket required.
- first column, first arm, second arm, and second column may all be formed of a sheet-like material. This may be a metal such as stainless steel. These elements (the portion visible in the case of the first column 9) are therefore thin in the directions perpendicular to this viewpoint. These elements may for example be 0.5mm in the other perpendicular views.
- This enables the mass of the first column 9, second column 15, first arm 11 and second arm 13 to be reduced significantly.
- the strength of the masonry support bracket in the plane of the first arm 11 is not affected, and is sufficient to transfer the load of the masonry fagade 5. However, the strength in the other two directions perpendicular to the view of Figure 1 is much lower. Having one plane of far greater strength and load bearing capacity allows the mass of the masonry support bracket 7 to be minimised, whilst not affecting the function the masonry support bracket 7 in the plane of the arm 11.
- the first arm 11 is shown as being angled relative to the second column 15 (rather than being perpendicular). In some embodiments the arm 11 may be perpendicular to the second column 15. The arm 11 is angled such that the cavity tray 23 sitting atop the arm 11 is also angled. The arm however may be flat and the cavity tray 23 angled in an alternative manner. Angled may include the arm extending from the first column 9 towards the masonry fagade 5, and the second column extending down from the first arm 11. The second column 15 may be approximately parallel the masonry fagade 5 (as shown in Figure 1). The angle between the arm 11 and the second column 15 may be equal to 90 degrees plus the angle of the cavity tray relative to the horizontal (in the case of Figure 1 approximately 5 degrees).
- the cavity tray overlies the at least on arm and extends through the plane visible in Figure 1.
- the cavity tray spans the majority of the cavity between the internal building 3 and the masonry fagade 5.
- the function of the cavity tray 23 is to capture moisture in the cavity (e.g. condensing from the cavity onto the cavity tray 23, or passing down the internal building structure 3).
- the cavity tray 23 is angled to cause moisture collecting on the cavity tray 23 to pass towards the masonry fagade 5. This angle may be between 3 and 10 degrees and preferably is 5 degrees. This may prevent pooling, whilst reducing the amount of mass needed to form the cavity tray 23.
- At the end of the cavity tray 23 the moisture will drop off of the cavity tray 23.
- the end of the cavity tray features a lip 31 (purely optional).
- the cavity tray may comprise a metal sheet, and may have a thickness of up to 2mm, and preferably 0.5mm to reduce weight.
- the moisture will then fall on the masonry support angle 19.
- the water will then pass along the masonry support angle 19 and out of the cavity.
- the masonry fagade 5 may contain weep holes positioned adjacent the masonry support angle 19 to enable the moisture to leave the cavity and the building entirely.
- the masonry support angle 19 is shown as being entirely flat in the horizontal, however it may have a slight angle to encourage water flow out of the cavity. It is noted that a single masonry support angle may be connected to two masonry support brackets 7 within a single masonry support element 1.
- the cavity tray 23 may be attached to the masonry support bracket 7 by any means such as by a mechanical join, adhesive or by welding.
- the cavity tray 23 comprises a second angled section 27, that is angled at a greater angle than the rest of the slope of the cavity tray 23. This may be angled at 50 degrees from the horizontal in this example (other angles may be used). This may allow the cavity tray to attach to an attachment element 29 positioned at the top of the first column/ first arm 11.
- the second angled section 27 may make it simpler for a user to make the connection between the cavity tray 23 and the attachment element 29.
- the cavity tray may be optional for some embodiments.
- the masonry support bracket 7 may be used as a standalone element with the masonry support angle 19. This may still provide a reduced mass masonry support element 1 for transferring the load form the masonry fagade 5 to the internal building structure 3. Other means may then be used to control moisture and fluid flow within the cavity.
- the wall tie 33 may offer a second point of attachment between the masonry support element 1 and the masonry fagade. This may help with alignment during installation, and to prevent slippage during use.
- the wall tie is shown as being attached to the second column 15 of the masonry support bracket 7.
- the wall tie 33 may also be attached to the first arm 11.
- the wall tie 33 may be directly attached by any means.
- the wall tie sits within a slot 35.
- the slot may be positioned on either the second column 15 or the first arm 11.
- the slot 35 may allow some tolerance and adjustability of the height of the wall tie. This may make installation significantly simpler as the slot 35 may make allowances for any inaccuracies in installation.
- the masonry support angle 19 comprises an upstanding 21.
- the upstanding may project upwards from the portion of the masonry support angle 19 that extends into the fagade 5 during use.
- the two portions of the masonry support angle 19 may be perpendicular to each other as shown in Figure 1.
- the upstanding may be 50mm, 70mm, or 90mm in height above the other portion of the masonry support angle.
- a lower height e.g. 50mm
- a larger upstanding may be used in some embodiments where greater strength is required.
- Current UK regulations dictate a minimum upstanding of 100mm.
- the first column (portion shown only) 9, second column 15, first arm 11 and second arm 13 may be known as a single sheet with a central window 17. This separate interpretation confers the same structure shown in Figure 1.
- a second structure much like that shown in Figure 1 may be attached in parallel to that shown in Figure 1, where both are connected via the first column 9.
- the third and fourth arms may form a second two-dimensional plane that is parallel to the two-dimensional plane of the first and second arms 11, 13. There may be a central void between the third and fourth arms.
- a building comprising an internal building structure 3, a masonry fagade 5, and a masonry support element (such as the one shown and described in Figure 1, or with respect to any other Figures or embodiments described herein) may have the masonry support element 1 connected between the masonry fagade and the internal building structure 3.
- a masonry support element such as the one shown and described in Figure 1, or with respect to any other Figures or embodiments described herein
- the masonry support element 1 may have the masonry support element 1 connected between the masonry fagade and the internal building structure 3.
- weep vents adjacent the masonry support angle 19 such that water carried along the masonry support angle 19 may exit the building via the weep holes.
- Figure 2 shows two masonry support elements of Figure 1 conjoined.
- Figure 2 shows a first masonry support bracket 7a, a second masonry support bracket 7b, a first cavity tray 23a, a second cavity tray 23b, a first masonry support angle 19a, a second masonry support angle 19b.
- two masonry support brackets 7a are attached to a single masonry support angle 19a.
- the second masonry support bracket 7a is entirely optional.
- infill tray 37 This joins the first masonry support angle 19a with the second masonry support angle 19b. This prevents the join being a weak point structurally, and prevents water ingress.
- the infill tray 37 and join between the two masonry support elements is shown as being at a straight point in the structure. Alternatively, this may at an internal or external corner.
- Figure 3 shows a masonry bracket with an indent 37 to house a fire barrier 25.
- the masonry support element 1 may serve yet another purpose as it may reduce the spread of fire in a building, particularly reducing the spread of fire from floor to floor.
- Shown in Figure 3 is a masonry support bracket 7, a masonry support angle 19 an indent 37 on the masonry support bracket 7, and a fire barrier 25.
- the indent sits at the top of the first arm 11.
- the notch 37 allows the fire barrier to sit between the first arm 11 and the cavity tray 23 as shown in Figure 1.
- the fire barrier 25 may be any suitable fire prevention material, such as intumescent material, or fire prevention material.
- Figures 4a-d show various positions of fire barriers, or equivalents in relation to the masonry support element.
- the cavity trays may also be used with the fire barriers independently without any further portion of masonry support.
- Figure 4a shows a different view of Figure 3 in which the notch 37 at the top of the first arm 11 allows the fire barrier to sit between the first arm 11 and the cavity, whilst in a mechanical hold of the indent 37.
- the cavity tray overlies the fire barrier 25.
- Figure 4b shows an alternative embodiment in which no notch is present. Instead the fire barrier sits atop the first arm 11 (it may be joined to the first arm by alternative means such as tape or adhesive). The cavity tray 23 then overlies the fire barrier.
- Figure 4c shows an alternative in which the fire barrier 25 is placed atop the cavity tray 23.
- Figure 4d shows an intumescent rigid structure 39 positioned atop the cavity tray 23. This may allow the masonry support element 1 to cooperate with legacy fire prevention systems.
- Figure 5 shows a side lip of a cavity tray.
- Figure 5 shows a cavity tray 23 with a slide lip 41 and a masonry support bracket 7.
- a side lip 41 may be on either side (one, or the other, or both) of the cavity tray.
- the sides run parallel with the first arm 11 of the masonry support bracket 7.
- the side lips may prevent water from passing off of the side of the cavity tray. This in turn may allow the amount of water on each cavity tray to regular (similar to the groynes on a beach keeping sand distribution equal).
- the side lip 41 may extend upwards, and may be vertically upwards from the cavity tray 23.
- Figures 6a and 6b show two steps in the installation of masonry support elements around an external corner.
- Figure 6a show a first step of positioning a masonry support element 1 at a selected position relative to the internal building structure 3 and the masonry fagade 5.
- the masonry fagade may be built around the masonry support angle 19 after the masonry support element 1 has been installed.
- the masonry support element comprises two masonry support brackets 7a (one of which is entirely optional) and a masonry support angle 19a.
- the masonry support element 1 in this example is positioned on one side of an external angle. This same process may be used adjacent an internal corner.
- Figure 6b shows a second step of the method shown in Figure 6a.
- a second masonry support element comprising masonry support bracket 7b, and masonry support angle 19b is positioned at a second selected position.
- This selected position is the other side of the external corner to the first selected position of the first masonry support element 1.
- the masonry support elements may be attached to the internal building structure. Alternatively, this attachment may take place later in the method.
- Figures 7a and 7b show two further steps of installing the masonry support elements of Figure 6 around an external corner.
- Figure 7a shows the first masonry support element and second masonry support element as shown in figure 6b.
- an infill tray 37 has been positioned at the join between the first masonry support element and the second masonry support element. This may improve the structural performance of the masonry support elements, and prevent water ingress.
- the infill tray is positioned at the apex of the external corner (and may be positioned at the apex of an internal corner in a corresponding embodiment).
- the infill tray 37 may be attached to the first masonry support angle 19a and the secondary masonry support angle 19b at this stage, or this may be attached later in the method.
- Figure 7b shows the elements of figure 7b with an additional cavity tray 23a installed.
- the cavity tray 23a is positioned to overlie the first masonry support bracket 7a.
- the cavity tray does not overlie the second masonry support element 7b (however in alterative embodiments it may well do).
- the cavity tray extends around the external corner such that is sits above at least a portion of both the first masonry support angle 19a and a portion of the secondary masonry support angle 19b.
- Figure 8 shows a final installation step in the method shown in Figures 6 and 7.
- This shows the elements of Figure 7b and an additional second cavity tray 23b.
- This overlies the second masonry support bracket 7b and a portion of the second masonry support angle 19b. It is adjacent the first cavity tray 23a.
- the join may be left as is, or may have tape or other mechanical or adhesive join made between them.
- the cavity trays 23a and 23b may be attached to the masonry support brackets at this stage.
- the cavity trays 23a and 23b may further be directly attached to the internal building structure to prevent movement.
- Figure 9 shows an installation step for installing a one-piece masonry support element around an external corner. This is an alternative to figures 6-8. In cases where the dimensions of the corner are small, or where there are access problems it may be simpler to fit a one-piece masonry support element that contains a corner, rather than using two straight sections of masonry support element to form a corner (as shown in Figures 6-8). A cavity tray may then be added as per any suitable method of attachment.
- Figure 9 shows a single masonry support element with a first masonry support bracket 7a at an angle to a second masonry support bracket 7n.
- the masonry support angle 19 comprises two sections at an angle to one another.
- a cavity tray overlying the masonry support brackets would also comprise two sections at an angle to one another. Such an arrangement may also be used for internal corners.
- Figure 10 shows a masonry support element in cross section in which the first column comprises a notch.
- Figure 10 shows an internal building structure comprising a notch 45.
- a notch 45 may also be formed from other elements or members attached to the internal building structure 3 that are to be navigated by the masonry support element 1.
- the masonry support bracket 7 therefore includes a notch 43. This notch allows the first column 9 of the masonry support bracket 7 to lie adjacent (in this case parallel and flush to) the internal building structure 1.
- the notch 43 consists of a horizontal displacement of the column at a point along its length.
- the two sections of the first column 9 either side of the notch 43 are parallel and connected to one another. However, there is in effect a chicane like connecting portion that comprises the notch 43.
- the notch 43 may be rounded, or may be squared as shown in the Figure.
- first column 9 may not have a back plate flush to the internal building structure below the notch. Instead the side portion of first column 9 (the portion visible in Figure 1 for example) may extend below the notch and there may be a void adjacent the internal building structure 3.
- Figures 11a and lib show a masonry support element with only one arm.
- the masonry bracket 7 comprises a first column 9, and an arm 11.
- the arm shown comprises no central void (although one may be present). Such an arm may be used in dual arm embodiments.
- only one full arm emanates from the first column 9, and only one arm 11 is secured to the masonry support angle 19 (two masonry support brackets are shown, which whilst advantageous is optional).
- the at least one arm provides sufficient load bearing means to support the masonry fagade.
- Element 47 is optional and comprises a shortened arm or stump. This allows the proximal end of the masonry support bracket to have a C-shaped profile when viewed from above. This is stronger than an L-shaped profile if the stump 47 is removed. The stump 47 is therefore advantageous for increasing load bearing capacity.
- Figures 12a and 12b show a masonry support element in which the masonry support angle comprises a cut-out.
- Figure 12a shows masonry support elements 7 overlaid by a cavity tray 23 as per previous embodiments.
- a masonry support angle 19 is connected to the masonry support brackets as per the previous embodiments.
- the first column 9 of the masonry support bracket 7 comprises a central void 57. This is shown and described in greater detail with reference to Figure 14.
- bolts that attach the masonry support bracket to the internal building structure 3 may be positioned in the central void 57.
- a cut-out 51 is also shown in Figure 12a.
- the cut-out is at the uppermost edge of the upstanding 21.
- the cut-out 51 allows a bolt to be positioned in either the central void 57 or a secondary void (e.g. within 75mm of an upper primary bolt) of the first column 9, and for a user to be able to apply leverage to said bolt in a simple manner. This makes assembly simpler, more efficient, and allows greater flexibility in bolt positioning to enhance the connection between the masonry support element 1 and the internal building structure 3.
- a user may drill into the building structure to create a hole for the bolt to enter. This hole may be aligned with the cut-out, and the drill bit may access the position of the hole (so as to drill the hole) through the cut out.
- a socket may then be used to tighten the bolt nut into place. The socket may be accessed via the cu- out to improve access in some embodiments.
- Figure 12b is the same as Figure 12a, with only one difference. This is shown in zoomed in portion which shows a cover element 53.
- the cover element is positioned over the cut-out 51 so that it is not visible. This may help with restoring the strength properties of the masonry support angle. Moreover, this may allow the cut-out compliance with UK construction regulations. It is noted that the cover is optional and the cut-out may be left uncovered.
- cut-out may be used with any masonry support element in which an upstanding (for example forming part of a masonry support angle) is used. This cut-out is not tied to any masonry support angle shown in this application.
- Figure 13 shows an embodiment of a masonry support angle in which the masonry support bracket comprises a slot into which the masonry support angle is housed.
- the masonry support element of Figure 13 comprises a masonry support angle 19 and a masonry support bracket 7 (of which only the arms 11 are shown).
- the arms 11 are shown as omitting a central void which may beneficial in this embodiment. However, it is possible to incorporate a central void into this embodiment if required.
- a slot 55 is present in the arms 11 shown.
- the upstanding 21 of the masonry support angle 19 fits into the slot 55 of the arms 11.
- the masonry support angle is therefore mechanically joined to the masonry bracket 7 through the slot. This may reduce the need for welding in the construction process, and may decrease the mass of the masonry support element 1. It is noted this slot may be used with any masonry support element comprising a bracket and a masonry support angle comprising an upstanding.
- an attachment element configured to attach to a secondary element, the attachment element comprising a proximal arm, a distal arm, a channel between the proximal arm and the distal arm, the channel leading to a first recess positioned below the proximal arm and a second recess positioned below the distal arm, and a tooth positioned within the second recess.
- Figure 14 shows a close up of an attachment element.
- a masonry support element as detailed in the embodiments described above.
- a masonry bracket 7 and a masonry support angle 19 are shown.
- a central void 57 is also shown in the first column 9 in the side flush to the internal building structure 3 during use. Attachment means such as bolts may protrude through the central void 57 and may attach the masonry support bracket to the internal building structure 3.
- a primary attachment means may be positioned near the top of the first column 9 within the central void 57. Near the top may comprise within 45mm of the top of the first column 9.
- a secondary attachment means may be located further down (for example within 75mm of the primary attachment means, and/or within 45mm of the bottom of the first column).
- the secondary attachment means may either be located within the central void, or within a second void in the first column 9 (the second void is not shown). This may provide a secure attachment between the internal building structure and the internal building structure 3.
- attachment element 29 The close-up view on the right shows the attachment element 29.
- This attachment element may be used in any technical field, and may be divorced from this particular masonry support element, or from masonry support elements more generally. However, this attachment element is particularly advantageous for use in connecting a masonry support bracket to a cavity tray.
- the attachment element 29 is described with reference to the remaining Figures.
- attachment element and therefore the arms of the attachment element
- the proximal arm extends form a position above the distal arm.
- Figure 15 shows a cavity tray 23 and fire barrier 25 configured to sit in a cavity between an internal building structure 3 and a fagade 5; wherein the cavity tray 23 is configured to collect moisture within the cavity, and to provide an alternative path for said water to take across the cavity tray 23; wherein the fire barrier 25 is configured to be positioned either: atop the cavity tray 23; or beneath the cavity tray 23.
- the proximal end of the cavity tray 23 (the end of the cavity tray adjacent the internal building structure 3) attaches directly onto the internal building structure 3, whilst the distal end of the cavity tray 23 is adjacent the masonry fagade 5.
- the attachment between the cavity tray 23 and the internal building structure 3 is via nuts and bolts 59 in Figures 15 and 16, however other mechanical, adhesive and welded joins are entirely possible, as is a separate attachment element.
- the cavity tray 23 may optionally attach onto a load carrying feature, connected to the internal building structure 3, in the same manner (not shown).
- the load carrying feature may be an attachment element specifically designed to connect the cavity tray 23 to the internal building structure 3.
- the load carrying feature may have other primary functionality and be adapted to accommodate the cavity tray 23.
- the load carrying feature may be the masonry support bracket 11 as described thus far above and connect to the cavity tray 23 in this alternate manner.
- the cavity tray 23 shown in Figures 15 and 16 spans the majority of the cavity between the internal building 3 and the masonry fagade 5.
- the function of the cavity tray 23 is to capture moisture in the cavity (e.g. condensing from the cavity onto the cavity tray 23, or passing down the internal building structure 3).
- the cavity tray 23 is angled to cause moisture collecting on the cavity tray 23 to pass towards the masonry fagade 5. This angle may be between 3 and 10 degrees and preferably is 5 degrees. This may prevent pooling, whilst reducing the amount of mass needed to form the cavity tray 23.
- the cavity tray 23 has a second angled section 27 located at its proximal end.
- This second angled section 27 is 90 degrees to the horizontal and is seen best in Figure 15.
- the orthogonality of this second angled section 27 may be beneficial in maintaining a preferred first section angle of 5 degrees to the horizontal and achieve flush abutment with the internal building structure 3 wall for attachment.
- the second angled section 27 may alternatively be any other angle greater than the first section angle and is not limited by this square requirement.
- the second angled section 27 may be 50 degrees.
- other angles may be used for both the first and second angled sections 27.
- the end of the cavity tray features a lip 31 (purely optional).
- the lip 31 extends vertically down and is parallel the internal building structure 3, but other angles may be used, for example, a slight angle towards the masonry fagade 5.
- This lip 31 may guide the moisture so that the moisture falling from the cavity tray 23 takes a predictable path.
- the moisture will then fall on the masonry support angle 19 (for embodiments in which this element is present).
- the water will then pass along the masonry support angle 19 and out of the cavity.
- the masonry fagade 5 may contain weep holes 60 (shown best in Figure 16) positioned adjacent the masonry support angle 19 to enable the moisture to leave the cavity and the building entirely.
- the masonry support angle 19 is shown as being entirely flat in the horizontal, however it may have a slight angle to encourage water flow out of the cavity.
- the cavity tray may comprise a lip at one, or both, of its sides.
- the side lip or lips may be raised from the cavity tray 23 to prevent water from passing to the side and off of the cavity tray 23.
- the angle of the lip(s) relative to the horizontal may be in the range of 10 to 90 degrees.
- a lip angle of 90 degrees ensures that the lips protrude above the fire barrier strips 25 to effectively channel the water.
- a lower lip angle may be advantageous in some embodiments as it achieves effective water confinement whilst maintaining a more-slender side profile with limited vertical protrusion as compared to higher side lip angles.
- the cavity tray 23 may comprise a metal sheet, and may have a thickness of up to 2mm, and preferably 0.5mm. Such construction may aid in keeping the mass of the cavity tray 23 low.
- the cavity tray 23 of Figures 15 and 16 is of largely similar construction to the cavity tray 23 described in embodiments forming part of a masonry support element 1. Slight adaptations are present in the current embodiment to better accommodate the attachment to the internal building structure 3 as opposed to a masonry support bracket 11. These adaptations are entirely optional features. Both the cavity tray 23 and the masonry support bracket 11 may be modified in a number of ways to form embodiments that either complement one another, or stay independent of one another, such that they can be used without the other present.
- Figure 15 shows a first cavity tray 23 laying longitudinally adjacent a second cavity tray 23, wherein the longitudinal direction is perpendicular the distance between the internal building structure 3 and the fagade 5.
- the cavity trays 23 are arranged side- by-side and in flush contact along their entire side edges such that there is no passage for water in between cavity trays 23.
- the cavity trays 23 may be arranged such that a portion of one tray 23 overlies a portion of a second tray 23 (not shown).
- Lower side lip angles (given sufficient vertical protrusion above the fire barrier strips 25) in the range provided may aid in minimising the vertical displacement, and therefore slanting, of the top tray 23 in an overlying arrangement as compared to higher lip angles.
- Both Figures 15 and 16 show a strip of fire barrier 25 positioned atop an upper surface of a cavity tray 23.
- the strip of fire barrier 25 covers a portion of the cavity tray's 23 upper surface and is located at its distal end. The majority of the upper surface is left uncovered by the fire barrier 25.
- the uncovered portion may be covered by a fire prevention structure such as mineral wool (not shown).
- a fire prevention structure already present in the cavity predefines a portion of the cavity tray 23 to be covered by a fire barrier strip 25.
- the fire barrier 25 may then be dimensioned accordingly.
- the fire prevention structure may be a structure specifically implemented in the cavity to provide protection from fire.
- the fire prevention structure may be an insulation material implemented primarily for its thermal properties yet provides fire prevention as its secondary functionality. This may be due to the insulation material being incombustible.
- the insulation material may also comprise mineral wool.
- the fire barrier 25 it is entirely possible to place the fire barrier 25 on the lower surface of the cavity tray 23.
- placing the fire barrier 25 on the upper surface is advantageous as the fire barrier 25 is kept in position on the cavity tray 23 by gravity in addition to the attachment means. This is particularly useful in case of a fire should the attachment means fail under extreme heat.
- the fire barrier 25 described is intended to be an intumescent material as this is preferred. Nevertheless, other embodiments may utilise other types of fire barrier 25 construction.
- one fire barrier 25 is positioned at the very distal end of the cavity tray 23.
- This fire barrier 25 only covers a portion of the total width of the cavity tray 23 surface spanning from its distal end.
- the width of the cavity tray 23 is defined as the distance between its proximal and distal ends. Since the fire barrier 25 is a strip of an intumescent material that can be easily dimensioned to a range of widths, the width of the cavity tray 23 covered from the distal end can be conveniently varied.
- the amount of fire barrier 25 coverage required may be dictated by legislation or, as already mentioned, by the fire prevention structures or insulation material (not shown) already in place on the cavity tray 23.
- Such fire barriers 25 may be positioned adjacent one another transversely (width wise) on the cavity tray 23.
- the transverse direction is the direction between the internal building structure 3 and the masonry fagade 5 (the width wise direction).
- the fire barrier strips 25 may be positioned at any transverse location on the cavity tray 23 and are not limited to being positioned at the distal end alone. Positioning at the very distal end (the leading edge of the cavity tray 23 adjacent the masonry fagade 5) may be advantageous in terms of ensuring adequate fire safety since most fire prevention structures or insulation material are situated at the proximal end of the cavity tray 23. This would minimise the risk of the fire barriers 25 being positioned underneath a fire prevention structure or insulation material, which may reduce the effectiveness of the intumescent material.
- Figure 15 shows an arrangement wherein the fire barriers 25 are positioned such that one fire barrier strip 25 covers the entire length of a cavity tray 23.
- the length of the cavity tray 23 is defined by its longest dimension i.e. distance in the longitudinal direction described above.
- the fire barrier 25 may be arranged such that it only covers a majority of the length of cavity tray 23, and not its whole length.
- 'Majority' in this context referring to a sufficient length of the cavity tray 23 being covered by the fire barrier 25 such that the fire barrier 25, optionally an intumescent material strip, is effective in its function. This may be more than half the length of the cavity tray 23.
- the cavity tray 23 surface may be covered in the longitudinal direction by either one strip of fire barrier 25, as seen in Figure 15, or a plurality of fire barriers 25 arranged adjacent one another in the longitudinal direction (not shown). For both arrangements, it may be advantageous to leave gaps (not shown) between adjacent fire barriers 25 to allow for water/moisture to pass through onto the distal edge of the cavity tray 23 from which it may drop off. These gaps may be in between fire barriers 25 placed on the same cavity tray 23 or adjacent trays.
- Each strip of fire barrier 25 attaches onto the cavity tray 23 by at least two mechanical attachment means (not shown).
- the mechanical attachment means may be rivets, bolts, crimping or clips, as well as other means not named here.
- the mechanical attachments are placed such that they are longitudinally separated from one another on each strip of fire barrier 25. This ensures that the fire barrier is adequately constrained to the cavity tray 23 along its length.
- This attachment may be achieved preferably by rivets. Rivets ensure a tight friction attachment yet allow some clearance in between attachment points for the flow of water beneath the fire barrier 25 to aid the cavity tray in its function.
- the at least two mechanical attachments may be positioned such that they are at the same transverse location on the cavity tray 23/fire barrier 25, preferably at the fire barrier's 25 midpoint. This may ensure a uniform attachment that is easy to replicate, therefore improving efficiency and consistency during the assembly process.
- the mechanical attachments may be positioned at different transverse locations to one another, for example, on diagonally opposite strip 25 corners. Further optionally, they may be placed at any arbitrary transverse locations in relation to one another so long as the mechanical attachments are longitudinally separated.
- Figures 17 and 18 show an embodiment of the cavity tray 23 and fire barrier 25 described in Figures 15 and 16 in which the fire barrier 25 covers the total area of the upper surface of the cavity tray 23.
- the fire barrier 25 may cover the total area of the lower surface of the cavity tray 23. This complete coverage may be particularly useful in embodiments where the fire barrier 25 is the only fire safety measure present in the cavity. That being said, it may also have some benefits when fitting into cavities alongside fire prevention structures or insulation material too. As there is no requirement to dimension the fire barrier 25 strip in accordance with any space limitations (since all the surface is covered regardless), time is saved in the initial strip sizing step. The full coverage of the upper (or lower surface) may also provide better fire protection due to the additional volume of the intumescent material as well as having no gaps between the fire barrier strip 25 and the fire prevention structures or insulation material.
- Figure 19 shows an embodiment of the cavity tray 23 and fire barrier 25 described in Figures 17 and 18 in which the fire barrier 25 covers the total area of the lower surface of the cavity tray 23.
- Positioning the fire barrier 25 beneath the cavity tray 23, as shown, may be advantages should the upper surface of the cavity tray 23 be utilised by other infrastructure. Additionally, the surface of the intumescent material that forms the fire barrier 25 may be ridged and not substantially flat. Therefore, placing the fire barrier 25 beneath the cavity tray 23 allows for an unobstructed flow of water on the upper surface of the cavity tray 23. This may allow for more effective moisture removal from within the cavity.
- Figure 20 shows a circular embodiment of a fire barrier 25 wrapped around a cavity tray 23, seen from a side-on cross section view.
- the circular shape allows the fire barrier 25 to wrap-a-around the cavity tray 23 and therefore attach onto both the upper and lower surfaces.
- This fire barrier 25 shape may be beneficial in terms of additional fire safety as it covers both the tray 23 surfaces. It may also be more convenient to position a fire barrier 25 of this shape onto the cavity tray 23 for attachment as it may naturally sit and 'hug' the cavity tray 23 in the desired position without falling away from the tray 23. Therefore, posing less dexterity challenges for the assembler.
- Figures 21 and 22 show an embodiment in which the fire barrier 25 is positioned onto the masonry fagade facing surface of the vertical upstanding 21.
- the vertical upstanding 21 may function as a cavity tray 23 by collecting the moisture in the cavity through condensation and allowing it to flow onto the masonry support angle 19.
- Figure 23a shows a cavity tray comprising: a tray section configured to extend at least partially between an inner cavity wall and an outer cavity wall, a fire prevention structure, wherein the fire prevention structure is configured to be positioned below the tray section, and to comprise a front face, wherein the front face is configured to face the outer cavity wall during use, and an inner face, wherein the inner face is configured to face the inner cavity wall during use, wherein both the front face and rear face comprise a fire prevention material.
- Figure 23a shows a cavity tray 23 in accordance with an embodiment. This is an embodiment that is particularly adept at mitigating the risk of the spread of fire.
- the cavity tray itself comprises a tray section 61 and an attachment surface 63. In Figure 23a these are shown at an angle to one another.
- the cavity tray may also comprise a divider emanating from the end of the tray section 61 downwards. This is an optional feature. In this embodiment the divider is situated within the fire prevention structure 69.
- a fire prevention material 65 is atop a portion of the tray section 61 .
- a fire prevention material 65 is atop a portion of the tray section 61 .
- a lip 67 is also formed of fire prevention material (not necessarily the same material - but often these are integral with one another). The lip is optional.
- the fire prevention structure 69 Beneath the tray section 61 is the fire prevention structure 69.
- This comprises a front face 71 and a rear face 73.
- the front face 71 and rear face 75 are formed of a fire prevention material.
- the portion 75 is formed of an alternative fire prevention material in some embodiments.
- the fire prevention material 65 positioned atop the tray section 61 is formed of intumescent material, as is the lip 67, and front face 71 and rear face 73. This means that in response to heat and/or fire the intumescent material will rapidly expand so as to prevent oxygen from reaching flames, in order to curtail the progress of the fire.
- the fire prevention material 65 (which may be referred to as a fire barrier) atop the tray section 61 may expand vertically upwards to fill the cavity above the tray section 61. This may reach, or go towards the tray on the floor above. This may therefore reduce the chance of the fire spreading between floors.
- the front face 71 and rear face 73 may both expand.
- the front face may expand until it reaches the outer cavity wall, and the rear face may expand until it reaches the inner cavity wall. Therefore the front and rear faces together may form a barrier to prevent the spread of fire.
- the intermediate portion 75 formed from alternative fire prevention material which may be mineral wool, or other equivalent fire resistant materials, and may prevent fire, or hot air, from moving between the gap between the front and rear face.
- the front and rear faces may be directly attached to the divider 31 and so the alternative fire prevention material 75 may be removed.
- the intermediate portion 75 may aid in ensuring that the rear face expands to reach the inner cavity wall, or insulation abutting the inner cavity wall, and does not fall short.
- the intermediate portion may position the rear face 73 closer to the inner cavity wall to ensure this occurs. Moreover the thickness of the rear face is therefore not increased.
- a thickness of the intermediate portion 75 of 35mm may be suitable for this purpose.
- the masonry support bracket may be designed such that there are no obstructions between the rear face of the fire prevention structure and the inner cavity wall (save as for some insulation which may be placed on the inner cavity wall). This may ensure that a barrier to fire and hot gases is created.
- the lip may not be formed from intumescent material. Instead the lip may be formed from an alternative fire prevention material. This may be a flexible material that holds it shape, and that optionally has a density lower than that of intumescent material.
- the lip may be attached to the fire barrier 65 atop the tray portion 61, or may be directly attached to the tray portion 61. The lip may be hinged about this connection.
- the lip may be configured in normal circumstances without fire to hang down at an angle, for example approximately 45 degrees. In the event of fire below the tray section 61 there will likely be a heat gradient within the cavity. Associated with the heat below the cavity there is also likely to be an increased pressure (due to any combustion - and due to the gases heating up and expanding).
- the lip may move to seal the gap between the end of the tray section 61 and the outer cavity wall. This may limit, or prevent, hot gases from passing from below the tray section to above the tray section. Sealing the gap may occur when the lip is parallel with the extent of the tray section 61. This may be the furthest that the hinge allows the lip to rotate in response to the increased pressure.
- the lip may be formed from a foil, or from glass fibres or the like. The lip may extend by 40-50mm, preferably 45mm so that the majority/all of the distance to the outer cavity wall is filled by the lip once the lip has rotated - this reduces any gap between the end of the tray portion and the outer wall of the cavity.
- the lip could be formed from intumescent material.
- the lip 67 may expand towards the outer cavity wall, and up, effectively expanding into the space between that filled by the front surface and the fire prevention material 65 on the tray section 61.
- the lip 67 may form a barrier in the gap between the cavity tray 23 and the outer cavity wall.
- the lip may be optional.
- the fire prevention material atop the tray section 61 may similarly be removed.
- the end of the fire prevention structure 69 is shown as being approximately flush with the end of the tray section 61. This may be the case in some embodiments. In others, a section adjacent the edge (either right most of left most) may be removed such that there is a gap. This may facilitate the overlapping of the cavity trays, and reduce the amount of work involved at site in the installation process. By leaving a small gap, such as 50mm at the edge of the fire prevention structure this may allow the cavity tray to be overlapped with an adjacent cavity tray. In some embodiments in which a gap is left the side face of the fire prevention structure 69 directly adjacent the gap may be covered by a fire prevention material, such as an intumescent material. This may then expand into the gap in the event of fire - such that the gap does not increase the risk of the spread of fire in any way.
- a fire prevention material such as an intumescent material
- Figure 23b shows the embodiment of Figure 23a in side view. This shows the cavity tray 23 formed of the tray section 61, and the attachment surface 63 (and optionally the divider 31 not shown).
- the fire prevention material 65 atop the tray portion 61, the lip 67, and the fire prevention structure formed of a front face 71, a rear face 73, and optionally the intermediate portion 75.
- Figure 24a shows a masonry support element comprising a masonry support bracket, a masonry support angle, a cavity tray as shown in figure 23a -c, wherein the masonry support angle is configured to extend into the outer cavity wall, and to take the load of the outer cavity wall and transfer this load to the masonry support bracket, wherein the masonry support bracket is configured to be attached to the inner cavity wall, and is configured to transfer the load from the masonry support angle to the inner cavity wall, wherein the cavity tray is configured to sit above the masonry support angle such that water passing across the cavity tray drops down onto the masonry support angle.
- the masonry support bracket and angle may be similar in structure to those shown in Figures 1-21, and the features disclosed in those Figures may be used in combination with those disclosed herein (with the exception only of those that are contradictory).
- Figure 24a shows a cavity tray 23 attached to a masonry support element comprising a masonry support bracket 7 and a masonry support angle 19.
- the cavity tray i s attached to the masonry support element by attachment element 29.
- Attachment element 29 may be any suitable attachment element - such as that shown in Figure 14. In other embodiments the cavity tray may attach directly to the inner wall of the cavity.
- the cavity tray 23 comprises a tray section 61, an attachment surface 63, a fire prevention material 65 situated atop the tray section 61, a lip 67 formed of fire prevention material, and a fire prevention structure with a front face 71 and a rear face 73.
- An intermediate portion 75 between the front face 71 and the rear face 73 is also shown - although this is entirely optional.
- element 7 is the masonry support bracket. Whilst some of the structure of this element is visible a lot is not and is it is not annotated in any detail. This is shown in more detail in figure 24b. It is noted however that in some embodiments a pair of first arms and/or second arms extends from a single first column.
- the masonry support angle 19 is shown. This is configured to extend into the outer wall of the cavity. This provides support to the outer cavity wall such that the weight of the outer cavity wall is supported by the masonry support angle 19. This transfers this weight through the masonry support bracket to the inner cavity wall, or the internal building structure. Additionally the masonry support angle is configured to be positioned below the cavity tray 23 and for water passing over the cavity tray 23 to pass on to the masonry support angle 19 below. This may then exit the outer cavity wall through weep holes or the like.
- the cavity tray is principally designed to cause the water to pass to the masonry support angle 19. Additionally the lip 67 may further aid in this direction of water passing across the cavity tray.
- Wall ties are also shown - and these are optional.
- the wall ties may provide a further fixation point between the masonry support bracket 7 and the outer cavity wall. This may prevent movement of the masonry support bracket relative to the outer cavity wall, and may aid in the transfer of weight to the masonry support bracket.
- Figure 24b shows a side on view of the masonry support of Figure 24a.
- the cavity tray 23 is shown comprising the tray section 61 and attachment surface 63.
- the attachment surface 63 is attached to the masonry support bracket 7 by the attachment element 29.
- the fire prevention structure below the tray portion 61 is also shown. This is formed from the front surface 71, the rear face 73 and the intermediate portion 75 (optional).
- the masonry support bracket 7 comprises an arm 11, a first column 9, a second column 15, a first arm 11, a second arm 13, and a central void 17. It is noted that in some embodiments the second arm may not be present. In others the void may not be present and may be infilled. A portion of the first column may extend across - perpendicular to the portion shown in Figure 24b.
- the central void may be advantageous for saving weight so that it is simpler to install the masonry support bracket 7, as well as being cheaper to produce.
- the arm 11 forming two portions that are angled to one another allows the tray portion 61 to be separated from the top edge of the arm. This in turn enables the fire prevention structure to be positioned between the tray portion 61 and the arm 11. In the event of a fire this provides additional protection to prevent the spread as discussed above in relation to Figure 23.
- the first portion and second portion of the arm are joined at an elbow such that they are angled relative to one another. This angle is the same (or similar) to the angle between the tray portion 61 and the attachment surface 63 of the cavity tray.
- the fire prevention structure is positioned above the second column 15 of the masonry support bracket 7, and optionally above a portion of the masonry support angle 19.
- Figure 24c shows the front view of the masonry support. This shows the attachment surface 63, the fire prevention material 65, the lip 67, the fire prevention structure 68, and the masonry support angle 19.
- the masonry support bracket 7 is also shown. This shows the additional portion of the first column 9.
- the portion of the first column 15 visible in Figure 24c is perpendicular to the portion of the first column 15 visible in Figure 24b.
- Figure 25a shows an additional alternative embodiment of the masonry support element 7.
- the cavity tray is unchanged as compared to that shown in Figure 24.
- the first arm is once again formed of two portions. However, the first arm comprises a shoulder portion configured for a portion of the tray portion 61 of the cavity tray 23 to sit on. This may secure the position of the cavity tray, and prevent and oscillations of the tray if there is a large force associated with the movement of air within the cavity.
- Figure 25b shows a further additional alternative embodiment of the masonry support element.
- the cavity tray 23 is once again unchanged with respect to Figure 24.
- the first arm in this embodiment is not formed of two portions, but instead of a single portion. This extends from the point at which the cavity tray 23 attaches to the masonry support bracket 7, to the end of the arm, where a second column is positioned in this embodiment. The end of the arm sits below the fire prevention structure.
- either the arm or the second column comprises a flat surface that the base of the fire prevention structure sits on.
- the fire prevention structure is attached directly to the masonry support bracket 7 at this point. Any suitable attachment may be used such as the rivets discussed above.
- a divider may extend from the arm or second column up and within the fire prevention structure. The fire prevention structure may then be secured to the divider. In some embodiments the fire prevention structure may be secured both to the cavity tray 23 and to the masonry support bracket 7, although in others it may be secured to only one of these two elements.
- Figure 26 shows the structure of the masonry support and the cavity tray without the fire prevention structure or fire prevention material present.
- the masonry support element, or the masonry support bracket alone, may be sold without the fire prevention structure, or the fire prevention material, or intumescent material in some circumstances. This may then be retrofitted on if the owner desires.
- the fire prevention structure may therefore also form a self-contained product in its own right. Therefore, the divider 31 is visible. This extends down from the tray portion 61. It is noted that in this embodiment it extends form the end of the tray portion 61, but it may extend below the tray portion 61 at a position that is not at the very end of the tray portion 61.
- the divider may be used to attach the fire prevention structure 69 to the cavity tray 23.
- the front face 71 may directly attach to the divider 31.
- the rear face 73 may also directly attach to the divider 31.
- an intermediate portion may be positioned between the divider and one of these faces, such as the rear face 73.
- the divider may attach to the fire prevention surface by any suitable jointing means.
- rivets may be used so that no hot air can pass through the jointing means in the case of fire.
- Rivets may be positioned through the front face 71 and through the divider 31, and/or through the rear face 73 and through the divider 31. In cases where an intermediate portion 75 is also used rivets would pass through the intermediate portion 75 as well.
- the divider may be castellated.
- the divider may form a non- continuous structure, such that form above/below it appears as a dashed line. This may reduce the weight associated with the divider, and therefore the weight of the cavity tray.
- the divider may be removed.
- the fire prevention structure 69 may be attached to the cavity tray 23 by rivets that attach through the tray portion 61. These rivets may also pass through the fire prevention material 65 in some embodiments.
- the rivets may pass into the intermediate portion 75. Washers may be used to secure the rivets in the intermediate portion 75 if needed. For example if mineral wool is used in intermediate portion 75 then this may keep the fire prevention structure 69 in a secure position.
- the cavity tray or masonry support may be installed in a building, such as a high rise building comprising more than 18 stories or floors.
- a cavity tray may be installed on one floor (for example the ninth floor), and a second cavity tray may be installed at the floor above (in this case the tenth floor).
- This may be particularly advantageous if the second tray is above the first so that in the event of fire the fire prevention material 65 atop the tray section 71 on the first tray on the ninth floor expands towards the second cavity tray on the tenth floor. This then reduces the air between the two trays - making it difficult for the fire to spread between the floors, and therefore slowing the fires progress.
- Figure 27 shows the steps of a method for preparing the cavity tray (or masonry support) as shown in Figures 23-25 for installation.
- the fire prevention structure extends so that it is approximately flush with the rightmost and/or leftmost portions of the tray portion 61.
- the fire prevention structure 69 is thicker than the tray portion 61 and therefore modification is needed to enable overlap in some cases.
- the first step therefore comprises providing a first cavity tray 81. At least one end of the fire prevention structure 69 is then trimmed by cutting the rightmost and/or leftmost end of the fire prevention structure 83. This removes a pre-set length of the fire prevention structure (for example 50mm).
- a second tray is then provided 85. This is then overlapped with the first tray by the pre-set length 87. Alternatively the fire prevention structure on both trays may be trimmed by a portion such that the total timed is equal to the pre-set length.
- Figure 28 shows the attachment element in cross section.
- the attachment element comprises a proximal arm 89, a distal arm 91.
- a first recess 93 Below the proximal arm is a first recess 93.
- a second recess 95 Below the distal arm 91 is a second recess 95.
- Within the second recess 95 is a tooth 97.
- the tooth 97 divides the second passage 95 into a first passage and a second passage 99.
- the first passage is adjacent the anterior side 115 of the tooth, and the second passage is adjacent the posterior 113 side of the tooth.
- FIG. 28 Also shown in Figure 28 are the top surface of the proximal arm 107, and the underside of the proximal arm 105. Similarly, the top side of the distal arm 111 and the underside of the distal arm 109 are also shown. The anterior side of the tooth 115 and the posterior side of the tooth 113 are also shown.
- the second recess 95 being below the distal arm 91 comprises the second recess 95 being adjacent the underside 109 of the distal arm 91.
- the first recess 93 and the second recess 95 are shown as being joined together to form a single void.
- the first recess 93 and second recess 95 share a base 103.
- the tooth 97 is positioned within the second recess 95. It is noted that in other embodiments the tooth 97 rests directly on top of the base 103. However, in the embodiment shown in Figure 28 the tooth 97 is elevated above the base 103 such that second passage 99 is formed. The second passage is positioned between the posterior side of the tooth 113 and the base 103.
- a channel is also shown in Figure 1. This is the space between the proximal arm 89 and the distal arm 91.
- the channel connects the first recess 93 and second recess 91 with the outside environment.
- the anterior side of the tooth 115 is angled relative to the underside of the distal arm 109.
- the underside of the proximal arm 105 is angled relative to the base 103.
- the angle may be between 5 and 20 degrees (relative to one another).
- This angle may preferably be between 14 and 18 degrees, and most optimally may be 16 degrees.
- This angular range may make the secondary element simple to fit to the attachment element 29.
- the two angles may be the same to enable the secondary element to slide form the anterior side of the tooth 115 to the underside of the proximal arm 105 easily during installation.
- the posterior side of the tooth 113 is parallel with the base 103 such that the passage 99 is approximately cuboidal.
- the underside of the distal arm 109 is further from the base than the underside of the proximal arm 105. Indeed, the underside of the distal arm 109 is further from the base 103 than the top side of the proximal arm 107.
- the distal arm forms an elongate bar as the top side 111 and underside 109 are parallel. These surfaces are parallel to both the top side of the proximal arm and the base 103, and the posterior side of the tooth 113.
- a secondary element may co-operate with the attachment element to couple together. An element may slide along the top surface of the proximal arm 107, and then onto the underside of the distal arm 109 (passing across the channel 101 whilst doing so). Once inside the second recess 95 the secondary device may be pivoted onto the anterior surface of the tooth 115, and then slid onto the underside of the proximal arm 105 in the first recess 93. The secondary element may then be further pivoted to be flush with the base 103. Optionally the secondary element may then be slid into the passage 99.
- Figure 29 shows a cavity tray with means for attachment to the attachment element.
- the cavity tray may be used in the masonry support element 1 as described in the above figures.
- the cavity tray 23 comprises a bar 117.
- the bar may act as the secondary element to co-operate with the attachment element 29.
- Either side of the bar 117 are voids 119, 121.
- the first void 119 extends from the bar 117 to the first edge of the cavity tray.
- the bar 117 therefore makes up a portion of the perimeter of the cavity tray 23.
- the second void 121 extends from the bar towards the interior of the cavity tray 23.
- the second void 121 is therefore surrounded by material of the cavity tray 23.
- the voids 119, 121 may be used to provide space for manoeuvring the bar through the attachment element 29.
- the voids may be 8-12mm in length (that is the dimension perpendicularly away from the bar). A distance of 10mm may be particularly advantageous.
- first void 119 there are two sets of bar 117, first void 119, and second void 121 close together to form a pair. This may be useful in creating a secure attachment between a masonry support element and the cavity tray.
- an attachment element may be situated above two arms of a masonry support element, either side of the first column 9.
- the bar 117 has a width of between 3mm and 7mm, and preferably 5mm. This may fit particularly well with the attachment element 29.
- Figure 29 there are two pairs of bars 117. This may provide a particularly secure attachment between a cavity tray 23 and a masonry support element 1, particularly a masonry support element 1 containing two brackets 7.
- Figure 30 shows a close up of the attachment means of the cavity tray.
- This shows the bar 117, first void 119 and second void 121 in more detail.
- the bar is approximately flat with a thickness significantly smaller than tis length or width.
- the bar may have a thickness or depth of approximately 0.5mm.
- the first void 119 is shown as being longer than the second void 121. This may allow the bar to be offset from the top of the cavity tray such that it is simpler to manoeuvre the cavity tray during installation.
- the first void 119 may be 12mm long, and the second void 121 may be 8mm long in this embodiment.
- Figure 31a is a close up of the attachment means of the cavity tray from above. This shows the bar 117, first void 119 and second void 121 in more detail.
- Figure 31b is a view of the cavity tray from above. This shows that the bar 117, first void 119, and second void 121 may all be positioned on a raised secondary angled section 27 of the cavity tray.
- the length of the first and second voids may be 1mm longer than the length of the top side of the distal arm in some embodiments, and may be 1mm longer than the distance between the rear of the distal arm and the tooth.
- Figure 32 shows the attachment means of the cavity tray attached to the attachment element. This shows the cavity tray 23 within the attachment means 29. This is in the final position once the two are attached.
- the bar 117 is shown as being held within the second passage 99, below the tooth 97.
- the second passage may have a depth approximately equal to the depth of the bar - however the second passage may comprise an additional tolerance to ensure the bar fits within the second passage. This tolerance may be 0.1mm for example.
- the distance between the base 103 and the top of the proximal arm 107 is less than the distance between the base 103 and the underside of the distal arm 109, and wherein the difference between these distances is equal to the depth of the bar.
- This distance may also include an additional tolerance, for example of 0.1mm.
- the width of the bar 117 may be wider than the channel 101, such that the bar 117 may only enter the channel at a specific angle.
- Figure 33 shows one step in the process of attaching the cavity tray to the attachment element. This is shown from above ( Figure 33A), cross section ( Figure 33B), and perspective view ( Figure 33C). It is noted that a first step may include sliding the bar 117 along the top surface of the proximal arm 107. However, this first step is not essential in all configurations and so is omitted from the drawings herein.
- This stage shows the bar 117 being positioned under the underside of the distal arm 109. The bar is shown within the second recess 95. To get to this position the bar 117 may have passed through the channel 101.
- This embodiment shows that the length of the distal arm is optionally 0.5mm (or more) greater than the width of the bar 117. This may provide space to make it simple to pivot the bar 117 (the next step shown in Figure 34).
- This embodiment may also show that the distance between the end of the proximal arm and the tooth is at least half of the width of the bar. This is entirely optional, and may simply make the pivoting of the bar simpler. However, if this is not the case whilst the pivoting may be less ergonomic for the user, it can still be done to fit the bar to the attachment element.
- Figure 34 shows a further step of the method of Figure 33.
- Figure 34 shows the bar 117 being pivoted within the second recess 95. The bar then sits on the anterior surface of the tooth 115.
- Figure 35 shows a further step of the method of Figures 33 and 34.
- the same perspectives as used in Figures 33 and 34 are used in Figure 35.
- Figure 35 (as compared with figure 34) shows the bar 117 slid into the first recess 93 to the underside of the proximal arm 105.
- the length of the base to the entrance of the second passage 99 is at least 0.5mm greater than the width of the bar. This may make it simple to pivot the bar during installation (in particular the second pivoting action described below) - however shorter measurements may also be used.
- Figure 36 shows a further step of the method shown in Figures 33 to 35.
- Figure 36 (as compared to Figure 35) shows the bar 117 having been pivoted to be flush with the base 103.
- An optional step is also shown in which the bar 117 is slid into the second passage 99 between the base 103 and the posterior of the tooth 113. This final entry into the second passage 99 is optional, but may advantageously secure the bar 117 in place such that without human intervention it is extremely unlikely to move.
- the length of the second passage 99 is at least half of the width of the bar. This means that half of the bar is contained within the second passage 99 in order to secure the bar 117. As stated above the second passage is entirely optional, and some embodiments may have a shorter passage for manufacturing purposes (although this may make the bar 117 less secure in use).
- a method of making the above described devices may include welding, forming, casting or any other suitable equivalent process.
- one or more memory elements can store data and/or program instructions used to implement manufacture of devices described herein.
- Embodiments of the disclosure provide tangible, non -transitory storage media comprising program instructions operable to program a processor to said manufacture method and/or claimed herein.
- the processor of such manufacturing apparatus may be implemented with fixed logic such as assemblies of logic gates or programmable logic such as software and/or computer program instructions executed by a processor.
- Other kinds of programmable logic include programmable processors, programmable digital logic (e.g. a field programmable gate array (FPGA), an erasable programmable read only memory (EPROM), an electrically erasable programmable read only memory (EEPROM), an application specific integrated circuit (ASIC) or any other kind of digital logic, software, code, electronic instructions, flash memory, optical disks, CD-ROMs, DVD ROMs, magnetic or optical cards, other types of machine-readable mediums suitable for storing electronic instructions, or any suitable combination thereof.
- Such data storage media may also provide the data storage of the manufacturing device.
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Abstract
There is disclosed a masonry support element configured to sit in a cavity between an internal building structure and a façade, and to transfer the load of the façade to the internal building structure, the masonry support element comprising: a masonry support bracket; a masonry support angle; a cavity tray; wherein the masonry support angle is configured to extend into the façade, and to take the load of the façade and transfer this load to the masonry support bracket; wherein the masonry support bracket is configured to be attached to the internal building structure, and is configured to transfer the load from the masonry support angle to the internal building structure; wherein the masonry support bracket comprises a first column configured to lie parallel with the internal building structure, and at least one arm extending perpendicular to the column away from the internal building structure and towards the façade, wherein the masonry support angle is attached to the masonry support bracket; wherein the cavity tray is configured to overlie the at least one arm of the masonry support bracket; wherein the cavity tray is configured to collect moisture within the cavity, and to provide an alternative path for said water to take across the cavity tray; wherein the cavity tray sits above the masonry support angle such that water passing across the cavity tray drops down onto the masonry support angle.
Description
A Cavity Tray and Masonry Support Element
Field of Invention
The present invention is in the field of cavity trays and masonry support elements. Masonry support elements serve to transfer loads from external building facades to internal building structures. Cavity trays may be used to passively remove moisture within the cavity. Fire prevention structures and barriers may be used alongside both these to help reduce the risk of fire. The present invention in particular relates to the attachment of a fire prevention structure and a fire barrier onto a cavity tray, masonry support element, or masonry support bracket and of a cavity tray to a masonry support element.
Background
Modern building techniques utilise an internal building structure to which a masonry fagade is attached. There is often a gap between the internal building structure and the masonry fagade. Masonry support elements may be used to transfer the load of the masonry fagade to the internal building structure. The masonry support elements may also sit within the gap (known as a cavity) between the masonry fagade and the internal building structure.
Such a cavity may be prone to moisture accumulation which can lead to issues relating to damp and mould. The cavity area may also be utilised effectively from a fire safety perspective. Therefore, there is a need in some implementations for the masonry support elements to provide secondary functionality in line with these issues, such as collecting any moisture running down the internal building structure, and aiding in the prevention of fire.
Currently masonry support elements are bulky and heavy items that can be difficult to install. Therefore, a problem to be addressed includes reducing the mass of the masonry support element, and making installation simpler. Installation issues are also seen with cavity trays and fire barriers.
Additionally, cavity trays and fire barriers are independent instruments to one another and therefore can be complicated to implement together. There is also a consensus that these two additions are disparate from the current infrastructure commonly found in cavities, such as mineral wool and the masonry support elements themselves.
The cavity tray and fire barrier arrangement as disclosed in this application is an integrated solution to the issues mentioned and one that compliments the cavity- found infrastructure used in industry today. This makes their implementation much more convenient in practice.
There are many forms of attachment mechanism between two objects. For example, adhesives, mechanical attachment, and other such techniques may be used. There is a need to provide a simple to use, mechanical attachment. In particular, this may be useful in the installation of a masonry support element.
Summary of Invention
Aspects of the invention are set out in the independent claims and optional features are set out in the dependent claims.
In accordance with a first aspect there is described a masonry support element configured to sit in a cavity between an internal building structure and a fagade, and to transfer the load of the fagade to the internal building structure, the masonry support element comprising: a masonry support bracket; a masonry support angle; a cavity tray; wherein the masonry support angle is configured to extend into the fagade, and to take the load of the fagade and transfer this load to the masonry support bracket; wherein the masonry support bracket is configured to be attached to the internal building structure, and is configured to transfer the load from the masonry support angle to the internal building structure; wherein the masonry support bracket comprises a first column configured to lie parallel with the internal building structure, and at least one arm extending perpendicular to the column away from the internal building structure and towards the fagade, wherein the masonry support angle is attached to the masonry support bracket; wherein the cavity tray is configured to overlie the at least one arm of the masonry support bracket; wherein the cavity tray is configured to collect moisture within the cavity, and to provide an alternative path for said water to take across the cavity tray; wherein the cavity tray sits above the masonry support angle such that water
passing across the cavity tray drops down onto the masonry support angle. The cavity tray sitting above the masonry support angle may be advantageous. This may allow the masonry support angle to function as a second cavity tray to direct the water out of the cavity. This may reduce the overall mass of the masonry support element (as well as increasing the efficiency of removing moisture), and therefore make the element simpler to manufacture, fit and transport. This may also help reduce load on the internal building structure.
It is also noted that the cavity tray of the first aspect may be optional in some embodiments in which the movement of water is not required. For example, the masonry support element may comprise the masonry support bracket and the masonry support angle as described below without the cavity tray.
Optionally, further comprising a second column attached to the other end of the at least one arm, wherein the second column is perpendicular to the first column and is angled relative to the at least one arm. The second column may offer structural support to the at least one arm.
Optionally, angled to comprises the arm extending from the first column towards the fagade, and the second column extending from the first arm downwards, approximately parallel to the fagade. This may provide particularly efficient structural support.
Optionally, the arm is a sheet, and is in a two dimensional plane, and wherein the second column is in the same two-dimensional plane. This may provide particularly efficient structural support. This may be because being in the same plane as the at least on arm means load can be transferred directly through the at least one arm and the second column. This dimensional plane may be perpendicular to the load that is being transferred from the masonry fagade, and so the strength in the two- dimensional plane of the second column and at least one arm is high, despite the mass of the second column and at least one arm being relatively low. It is strength in this plane, perpendicular to the load, that allows it to be transferred to the internal building structure.
Optionally, wherein the masonry support angle being attached to the masonry support bracket comprises the masonry support angle being attached to the second column of the masonry support bracket. This may allow the masonry support angle to abut the second column and therefore make manufacture less complex as many simple joins may be used between the two elements.
Optionally, the at least one arm comprises two arms extending from the first column, such that the proximal end of the arms are attached to the first column. The use of two arms may increase the strength of the masonry support bracket, whilst minimising the mass of the masonry support bracket. This is especially the case where the arms are in the same two-dimensional plane.
Optionally, the distal ends of both the first arm and the second arm are attached to the second column. This may increase the strength of the masonry support bracket, especially in the two dimensional plane.
Optionally, there is a void between the first and second arms. This may enable the mass of the masonry support bracket to be reduced.
Optionally, the first arm emanates from the top of the first column, and the second arm emanates from the bottom of the first column. This arrangement may increase the length of the column taking load, and therefore the strength of the bracket may be increased.
Optionally, the masonry support bracket comprises a second pair of arms, the third arm and fourth arm, that extend from the first column. This may further increase the strength of the masonry support bracket.
Optionally, wherein the third arm and fourth arm are parallel to the first arm and second arm. Further optionally the third and fourth arms may be offset from the first and second arms. The parallel relationship enables the load to be born symmetrically and reduce risk of failure over time.
Optionally, wherein the third arm and fourth arm are both joined to a third column. The third column may offer structural support to the at third and fourth arms.
Optionally, the third column is perpendicular the first column, and is parallel to the second column.
Optionally, the third column is angled relative to the third arm and the fourth arm, wherein the third and fourth arm extend from the first column towards the fagade, and wherein the third column extends downwardly approximately parallel the fagade. This may offer structural support to the masonry bracket.
Optionally, the arm is a sheet, and is in a two dimensional plane, and wherein the third column is in the same two-dimensional plane. This may allow the two dimensional plane to have a great deal of strength. Moreover, in the case where the
first and second arms are parallel with the third and fourth arms the two two- dimensional planes are parallel and therefore together may be able to take a significant amount of load, despite the relative low mass of the masonry support bracket.
Optionally, there is a void between the third arm and the fourth arm. This may reduce the mass of the masonry support bracket.
Optionally, the first column comprises a sheet of material, preferably metal, preferably stainless steel. This may reduce the mass of the masonry support bracket, whilst maintaining strength.
Optionally, the at least one arm comprises a sheet of material, preferably metal, preferably stainless steel. This may reduce the mass of the masonry support bracket, whilst maintaining strength, at least in the two-dimensional plane, and the ability to take load from the fagade.
Optionally, the top surface of the at least one arm comprises an indent. This may aid with the prevention of fire, whilst keeping the masonry support element simple to manufacture and assemble.
Optionally, a fire barrier or fire prevention material sits within the indent, such that the fire barrier is positioned between the at least one arm and the cavity tray. The fire barrier may therefore be securely attached without requiring further means of attachment such as adhesive etc.
Optionally, a fire barrier is positioned between the cavity tray and the at least one arm. This may help prevent the spread of fire, especially between floors.
Optionally, a fire barrier is positioned atop the cavity tray. This may make assembly simple.
Optionally, wherein an intumescent rigid structure is positioned atop the cavity tray. This may allow for the masonry support element to be retrofitted with existing fire prevention materials.
Optionally, further comprising a wall tie attached to the masonry support bracket, optionally attached to the second column of the masonry support bracket. This offers a further point of attachment to the fagade and helps reduce movement between the fagade and the support element.
Optionally, the wall tie is attached to a slot within the masonry support bracket, allowing the height of the wall tie to be adjusted. This reduces the complexity of assembly/construction.
Optionally, the cavity tray comprises a metal sheet, preferably of a thickness of up to 2mm, preferably wherein the thickness is 0.5mm. This may reduce mass of the masonry support element.
Optionally, the cavity tray is angled relative to the horizontal, preferably wherein the angle is between 3 and 10 degrees, and preferably wherein the angle is 5 degrees. This may aid the passage of water along the cavity tray.
Optionally, wherein the cavity tray further comprises a second angled section at a greater angle to the horizontal than the rest of the cavity tray, wherein the second angled section is positioned adjacent the first column, optionally wherein the greater angle is 50 degrees from horizontal. This may aid with attachment of the cavity tray to the masonry support bracket as it is simpler for the two to be married in this position.
Optionally, the second angled portion comprises the attachment point to attach the cavity tray to the masonry support bracket.
Optionally, the cavity tray extends to overlie at least a portion of the first column of the masonry support bracket. This may enable the cavity to intercept any moisture travelling down the internal building structure.
Optionally, the cavity tray overhangs the end of the at least one arm, and the second column. This may be highly advantageous as this allows moisture to drop from the cavity tray to an intended location. This may reduce the mass of the cavity tray as it need not extend further.
Optionally, at the end of the overhang of the cavity tray the cavity tray comprises a lip. This may direct the falling moisture droplets to the intended position.
Optionally, the lip extends downwards, optionally vertically down parallel to the internal building structure. This may guide the moisture droplets directly downwards.
Optionally, the cavity tray is attached to the masonry support bracket by one of a mechanical join, an adhesive join or a welded join.
Optionally, the cavity tray is attached to the masonry support bracket by an attachment element as set out in the fourth aspect.
Optionally, the masonry support angle comprises an upstanding element such that the upstanding is attached to the at least one arm and/or second column of the masonry support bracket. This may provide strength, and may prevent splash from the masonry support angle going back into the cavity.
Optionally, wherein the upstanding element extends at least 50mm from the horizontal plane of the portion of the masonry support angle that extends into the fagade, further optionally wherein this extension is at least 100mm. The 50mm length may provide sufficient strengthening (and 70mm, or 90mm may provide further strengthening), whilst the 100mm length may ensure regulatory compliance. 50mm may be advantageous as it may reduce the mass of the masonry support.
Optionally, the upstanding element is perpendicular to the portion of the masonry support angle configured to extend into the fagade. This may strengthen the masonry support angle.
Optionally, the upstanding comprises a cut-out at the top edge of the upstanding, wherein the cut-out is positioned in line with the central void of the first column. It is noted that this may be highly advantageous, and may be advantageous separately to the features of the first aspect (that is this feature may offer further advantages to the system of the first aspect, or may on its own offer an advantageous feature). This may allow access to the lower section of the central void of the first column, and so may allow further bolts or other attachments to be inserted into this void, that otherwise would be difficult to reach. This therefore improves the efficiency of assembly on a construction site.
Optionally, further comprising a cover to cover the cut-out of the upstanding when installed. This may ensure the upstanding reaches a pre-set level, for example to comply with regulatory guidance/guidelines.
Optionally, a primary attachment between the masonry support bracket and the internal building structure, and optionally the internal building structure is positioned at the top of the first column. This may ensure that the connection between the masonry support bracket and the internal building structure is strong, and may prevent rotation and the like.
Optionally, the first column comprises a central void. This may reduce the mass of the masonry support bracket.
Optionally, wherein the primary attachment is through the central void of the first column, optionally at the top of the central void. This may provide a centralised (width-wise) connection to ensure even distribution of load.
Optionally, wherein at the top comprises within 45mm of the top of the central void. This may provide a secure and stable connection that is simple to fit in construction.
Optionally, further comprising a secondary attachment between the masonry support bracket and the internal building structure. This may further secure the masonry support bracket.
Optionally, the secondary attachment is through the central void of the first column. This may distribute the load evenly.
Optionally, wherein the secondary attachment is within 75mm of the primary attachment. This may make the attachment particularly strong, and may be simple to fit.
Optionally, the secondary attachment is positioned at the bottom of the first column. Optionally, at the bottom of the central void, optionally wherein at the bottom comprises within 45mm of the bottom of the central void.
Optionally, one or both of the primary and secondary attachments are in the form of a bolt into the internal building structure.
Optionally, a side of the cavity tray, parallel to the at least one arm, comprises a lip, optionally wherein both sides parallel to the at least one arm comprise a lip. This may prevent water from passing off of the side of the tray, and may help channel the water over the overhang of the cavity tray.
Optionally, the lip rises from the cavity tray to prevent water from passing to the side and off of the cavity tray.
Optionally, the at least one arm, or the second column, comprises a slot into which the upstanding of the masonry support angle is positioned. This may allow the masonry support angle and the masonry support bracket to be mechanically joined, and may reduce the mass of the masonry support element.
Optionally, the first column comprises a notch, such that there is an offset from a first portion of the column to a second portion. This may allow the masonry support element to sit flush against an internal building structure comprising a notch.
Optionally, each masonry support bracket comprises a pair of brackets attached to a single masonry support angle. This may mean that a single masonry support angle is attached to two masonry support brackets. This may increase the strength of the masonry support element, and may reduce the time taking during construction to fit a plurality of masonry support elements.
Optionally, each of the masonry support brackets are positioned angled to one another, optionally perpendicular to one another. This may allow a masonry support angle to extend around a corner.
Optionally, the masonry support angle comprises a first section and a second section are angled to one another, optionally perpendicular to one another. This may allow a masonry support angle to extend around a corner.
Optionally, the cavity tray comprises a first and second section angled to one another, optionally perpendicular to one another. This may allow a masonry support angle to extend around a corner.
Optionally, the masonry support element is configured to attach as a single unit around an external/internal corner of the internal building structure.
In accordance with a second aspect of invention there is disclosed a masonry support bracket for transferring the load of a building fagade to the internal building structure, wherein the masonry support bracket comprises: a first column, and at least one arm extending perpendicular to the first column away from the internal building structure and towards the fagade; wherein the first column is configured to lie parallel with the interna l building structure; wherein the first column is configured to attach to the internal building structure. Advantageously, such an arrangement ensures an effective force transmitting arrangement from the building fagade to the internal structure as it utilises a sufficiently large surface area (the first column) abutting the internal building structure.
It is understood that the masonry support bracket of the second aspect is the masonry support bracket of the first aspect. Hence the optional features, and their advantages, relating to the masonry support bracket of the first aspect apply to the masonry support bracket of the second aspect.
Optionally, wherein the masonry support bracket attaches onto a masonry support angle; wherein the masonry support bracket is configured to transfer the load from the masonry support angle to the internal building structure; wherein the masonry support angle is configured to extend into the fagade, and to take the load of the fagade and transfer this load to the masonry support bracket; wherein the masonry support angle is the masonry support angle of the first aspect. Advantageously, such an arrangement may see the masonry support angle attach to the second column of a masonry support bracket. This may allow the masonry support angle to abut the second column and therefore make manufacture less complex as many simple joins may be used between the two elements.
In accordance with a third aspect there is disclosed a cavity tray comprisi ng: a tray section configured to extend at least partially between an inner cavity wall and an outer cavity wall; a fire prevention structure, wherein the fire prevention structure is configured to be positioned below the tray section, and to comprise a front face, wherein the front face is configured to face the outer cavity wall during use, and an inner face, wherein the inner face is configured to face the inner cavity wall during use; wherein both the front face and rear face comprise a fire prevention material. The fire prevention structure may be advantageous for reducing the spread of flames, fire, and slowing the rate of temperature increase. This is because it acts to reduce the flow of gas from below the cavity tray to above the cavity tray, and because the front face and the rear face provide means for prohibiting the spread of fire across a large section of the underside of the tray.
Optionally, further comprising fire prevention material covering at least a portion of the tray section, preferably wherein the fire prevention material covers the portion of the tray section configured to be positioned closest to the outer cavity wall during use. As this covers the top of the tray section this may be advantageous as it may prevent flames, or a rise in temperature, from spreading or hastening in the event of fire. This is because it acts to limit the air flow between the cavity tray and the space above it - i.e. to the next cavity tray on the floor above.
Optionally, further comprising a lip extending from the edge of the tray section that is configured to be closest to the outer cavity wall during use, preferably wherein the lip extends at an angle to the tray section, further preferably wherein the lip is angled further downwards as compared to the tray section. The lip may be advantageous as it may further prohibit the movement of flames or the passage of heated air through the cavity. In particular, in the event of fire the lip may prohibit the spread of flames through any gap between the cavity tray section and the outer wall of the cavity.
Optionally, wherein the lip is hinged with the end of the tray section, or with the fire prevention material covering the tray section. This may allow the lip to close the gap to the outer cavity wall when needed, but allow water to pass from the cavity tray to a tray beneath when not needed.
Optionally, wherein the lip is configured such that when heat and an associated increase in pressure occurs below the tray section, the lip moves about the hinge so as to block at least a portion of any gap between the end of the tray section and the outer cavity wall. This may advantageously seal the gap, or part of the gap, between the tray section and the outer cavity wall. In the event of a fire this may prevent the spread.
Optionally, wherein the lip extends between 40-50mm beyond the edge of the tray section, preferably wherein this distance is 45mm. This may allow the lip to mitigate against the spread of fire for the majority of the gap between the tray section and the outer cavity wall.
Optionally, wherein the lip is configured to aid in the direction of water off of the tray section, such that water passing off of the tray section is directed onto a further tray below. The cavity tray is already designed such that water is configured to be directed in this manner. The lip may further aid with the passage of water as at least some water may travel along the lip and then drop to the designated surface below.
Optionally, wherein the lip is formed of non-expansive fire prevention material. This may allow it to retain its structure in the event of a fire and function in the hinged manner detailed above.
Optionally, wherein the fire prevention structure comprises an intermediate portion situated between the front face and the rear face. This may ensure that the front
and rear faces act as intended, and that the joining portion does not present an opportunity for the spread of fire.
Optionally, wherein the fire prevention material is an intumescent material. This may be highly advantageous. This may mean that the material atop the tray section may expand vertically upwards towards the tray above -and so limit the ability of fire to spread in this direction. The front face may expand to the outer cavity wall also, in conjunction with the rear face expanding towards the inner cavity wall so that together they form a barrier. Each of these features alone, as well as these features in combination, represents an advantage in limiting the spread of fire.
Optionally, wherein the fire prevention structure comprises a first outer layer of intumescent material forming the front face, and a second outer layer of intumescent material forming the rear face, with a layer of alternative fire prevention material situated therebetween, preferably wherein the alternative fire prevention material is mineral wool. This be form a particularly effective fire prevention structure. In the event of fire the expanded front and rear surfaces may together form a barrier to hot air from travelling from below the cavity tray to above and vice versa. As multiple trays are intended to be situated next to one another this would form a barrier across the entire cavity. The alternative fire prevention material may allow these front and rear faces to be connected together, whilst minimising the spread of fire through such a connection. It is noted that in some embodiments the alternative fire prevention material may be replaced by a divider forming part of the cavity tray.
Optionally, wherein the tray section comprises a divider configured to extend downwards in the cavity, and wherein the front and rear surface separated by the divider. This may advantageously provide a surface for the fire prevention structure to be situated onto without comprising the structure of the cavity tray. The divider may also aid in the direction of water onto a tray situated below.
Optionally, wherein the alternative fire prevention material is situated adjacent the divider and the rear face. This may allow the alternative fire prevention material, such as mineral wool, to attach to the rear side of the divider. This may simplify manufacture, and ensure the fire prevention structure is efficient at reducing the spread of fire.
Optionally, wherein the divider is non-continuous such that it is castellated. This may reduce the cost of manufacture (for example two dividers may be produced
that approximately tessellate with one another to minimise wasted material), and the weight of the cavity tray. This may also reduce the energy needed for transport and increase ease of installation.
Optionally, wherein a jointing structure attaches the fire prevention structure to the cavity tray. This may allow the fire prevention structure to be securely attached to the cavity tray.
Optionally, wherein the jointing structure comprises rivets. This may be advantageous as rivets may prevent hot air from passing from one side of a join to the other and therefore may aid in the prevention of fire.
Optionally, wherein rivets are configured to protrude through the divider and at least one of the front face and/or rear face, and optionally wherein the rivets protrude through both the front face and rear face. This may be advantageous as the tray section is unencumbered to the attachment and so is of optimal strength in the case of fire.
Optionally, wherein the rivets are configured to protrude through the tray section and into the intermediate portion. This may mean that a divider is not needed, and so reduce the weight and complexity of the cavity tray.
Optionally, wherein washers are used to hold rivets, optionally wherein said washers are situated within the intermediate portion. This may keep the attachment strong and reliable.
Optionally, wherein the divider is absent when the tray section is used as the point of connection between the fire prevention structure and the cavity tray. This may reduce the weight of the tray and so improve ease of installation. It may also reduce complexity of manufacture.
Optionally, wherein the rightmost and/or leftmost portion of the fire prevention structure terminates prior to the rightmost and/or leftmost portion of the tray section such that a gap is left at the rightmost and/or leftmost end of the fire prevention structure, optionally wherein said gap is to enable adjacent cavity trays to be fitted with an overlapping section, optionally wherein said gap is 50mm. This may be advantageous as cavity trays are configured to overlap. The tray section is flexible enough to allow such overlap, but the additional width of the fire prevention structure would not accommodate such overlap in some cases.
Therefore, the provision of a gap in the fire prevention structure at the point of overlap enables the assembly of the cavity trays to be simpler on a building site.
Optionally, wherein the rightmost and/or leftmost portion of the fire prevention structure comprises a fire prevention material situated at the end face, optionally wherein the fire prevention material is intumescent material. This may allow the fire prevention material to prevent any fire or hot air from passing through the gap. For example in the case of intumescent material in the event of fire this will expand to fill any remaining gap and therefore limit the spread of fire.
Optionally, further comprising an attachment surface, attached to the tray section, and configured to attach the tray section to an external component during use. This may allow the tray to be attached to external elements during installation without the need for welding or the like.
Optionally, wherein the external component is a masonry support element or the inner cavity wall. This may allow the cavity tray to be installed with ease, whilst being in a set position that is strong and stable.
In accordance with a fourth aspect there is provided a masonry support element comprising: a masonry support bracket; a masonry support angle; a cavity tray as set out in accordance with the third aspect; wherein the masonry support angle is configured to extend into the outer cavity wall, and to take the load of the outer cavity wall and transfer this load to the masonry support bracket; wherein the masonry support bracket is configured to be attached to the inner cavity wall, and is configured to transfer the load from the masonry support angle to the inner cavity wall; wherein the cavity tray is configured to sit above the masonry support angle such that water passing across the cavity tray drops down onto the masonry support angle. It may be advantageous to provide a masonry support comprising the cavity tray as this provides a single element that both provides structural support to the outer cavity wall, and is configured to manage the movement of water within the cavity. Additionally this element is configured to reduce the risk of the spread of fire. This may allow the masonry support angle to function as a second cavity tray to direct the water out of the cavity.
Similarly in accordance with a fifth aspect there is provided a masonry support element comprising: a masonry support bracket; a masonry support angle; a fire prevention structure; wherein the masonry support angle is configured to extend into the outer cavity wall, and to take the load of the outer cavity wall and transfer this load to the masonry support bracket; wherein the masonry support bracket is configured to be attached to the inner cavity wall, and is configured to transfer the load from the masonry support angle to the inner cavity wall; wherein the fire prevention structure comprises a front face, wherein the front face is configured to face the outer cavity wall during use, and an inner face, wherein the inner face is configured to face the inner cavity wall during use; wherein both the front face and rear face comprise a fire prevention material. This may be advantageous as it provides a masonry support element that reduces the risk of the spread of fire through a high rise building.
It is noted that all features listed below as optional are optional for both the second and third aspects.
Optionally, wherein the fire prevention material is an intumescent material. This is advantageous it is will expand in the event of fire to create a barrier to prevent the spread of fire.
Optionally, further comprising a cavity tray, wherein the cavity tray is configured to sit above the masonry support angle such that water passing across the cavity tray drops down onto the masonry support angle, preferably wherein the cavity tray is the cavity tray in accordance with the third aspect. This may allow the passage of water within the cavity to be managed.
Optionally, wherein the fire prevention structure is configured to sit above or on a portion of the masonry support bracket. This may provide space for the fire prevention structure to function in.
Optionally, wherein the masonry support bracket is formed from an arm extending from the inner cavity wall to the outer cavity wall, and wherein the fire prevention structure is configured to sit on or above the arm. This may provide an unobstructed volume in which the fire prevention structure may function.
Optionally, wherein the masonry support bracket is formed from a first column parallel to the inner cavity wall, an arm extending from the inner cavity wall to the outer cavity wall, and a second column at the end of the arm, wherein the fire prevention structure is configured to sit on or above the second column. This may provide an unobstructed volume in which the fire prevention structure may function.
Optionally, wherein the volume between the inner cavity wall and the rear face of the fire prevention structure is kept clear of any obstructions, preferably wherein a layer of insulation is positioned on the surface of the inner cavity wall.
Optionally, wherein no portion of the masonry support bracket is configured to be situated between the rear face of the fire prevention structure and the inner cavity wall.
Optionally, wherein the masonry support bracket comprises a first column configured to lie parallel with the internal cavity wall, and at least one arm extending away from the internal building structure and towards the outer cavity wall. This may provide a mass efficient means of providing support to the outer cavity wall. The reduction in mass may make installation and manufacture of the masonry support element simpler and less costly.
Optionally, wherein the cavity tray is configured to overlie the at least one arm of the masonry support bracket. This may enable the cavity tray to intercept any moisture travelling down the internal building structure.
Optionally, wherein the arm forms a first portion and a second portion that are angled to one another, wherein the first portion emanates from the attachment surface of the cavity tray, and the second portion extends towards the masonry support angle.
Optionally, wherein the angle between the first portion and the second portion of the arm is the same as the angle between the attachment surface and the tray portion.
Optionally, wherein the first portion emanates from the attachment surface of the cavity tray, and the second portion extends towards the masonry support angle.
Optionally, further comprising a second column attached to the other end of the at least one arm, wherein the fire prevention structure is situated above the second
column. The second column may offer structural support to the at least one arm. The position of the fire prevention structure above the second column means that the portion of the tray portion closest the outer cavity wall is raised above the masonry support bracket.
Optionally, further comprising a wall tie attached to the masonry support bracket. This offers a further point of attachment to the fagade and helps reduce movement between the fagade and the support element.
In accordance with a sixth aspect there is provided a masonry support bracket comprising: a first column configured to lie parallel to the inner cavity wall; a first arm extending from the first column towards the outer cavity wall; wherein the first arm comprises a first portion and a second portion that are angled relative to one another. This may allow for fire prevention material to be so positioned as to reduce the risk of fire. Moreover, the bracket also serves to convey the weight of the outer cavity wall to the internal building structure.
Optionally, further comprising a second column, wherein the second portion of the arm terminates at the second column, wherein the second column is configured to be attached to a masonry support angle. This may provide means for transferring the weight from the outer cavity wall to the masonry support bracket.
Optionally, wherein the first portion of the arm is configured to be attached to a cavity tray, such that in use the cavity tray is positioned above the second portion of the arm. This may allow the water within the cavity to be managed such that it does not cause damage to any of the internal structure within the cavity. This may also improve the lifespan of the masonry support bracket.
Optionally, further comprising a fire prevention structure configured to be attached on to or above the second portion of the arm or the second column. This may prevent the spread of fire when combined with the structure of the masonry support bracket as detailed above which provides a volume for the fire prevention structure to occupy in the presence of heat.
In accordance with a seventh aspect of invention there is provided a cavity tray and fire barrier configured to sit in a cavity between an internal building structure and a fagade; wherein the cavity tray is configured to collect moisture within the cavity,
and to provide an alternative path for said water to take across the cavity tray; wherein the fire barrier is configured to be positioned either: atop the cavity tray; or beneath the cavity tray. Advantageously, it has been found that such an arrangement is a substantially convenient way to implement a cavity tray and fire barrier into a cavity. By attaching together a fire barrier and cavity tray, a solution to two common issues of moisture accumulation and inadequate fire measures are overcome in a simple manner. Additionally, such is the simplicity of the invention that modifications can readily be made to accommodate pre-existing cavity infrastructure.
Optionally, wherein the fire barrier is configured to be positioned atop the cavity tray through a mechanical attachment. Positioning the fire barrier atop the cavity tray utilises gravity to ensure the fire barrier is passively in contact with and sits on top of the cavity tray even without attachment means. This is especially useful in the event of a fire should the mechanical attachments fail. Additionally, the fire barrier doesn't need to be held in place whilst fixing to the tray. This may be more convenient to the assembler. Moreover, if the fire barrier is formed from intumescent material, the cavity tray may act to aid with the directional distribution of the expanded material.
Optionally, wherein the mechanical attachment is one of: rivets, bolts, crimping or clips. These listed attachment means are both easy to implement and may ensure a secure attachment.
Optionally, wherein the fire barrier is a strip. Advantageously, the strip may be conveniently cut to a range of sizes. The strip refers to a regular width of fire barrier and therefore may be assembled side-by-side with many strips to increase width of fire barrier coverage in a controlled fashion (incrementally and discretely).
Optionally, wherein the strip of fire barrier is dimensioned to cover either a portion or all of the cavity tray surface to which it is attached. A benefit of covering only a portion of the surface is to complement the existing fire prevention structures or insulation material that also occupy space on the cavity tray themselves. This arrangement may save material cost by not excessively placing the fire barrier where it is not needed as much, i.e. underneath the fire prevention structures or insulation material. Alternatively, by covering the entire surface of the cavity tray with fire barriers, irrespective of whether the fire prevention structures or insulation material are present, the fire safety may be more robust simply by virtue of increasing the amount of fire barrier used.
Optionally, wherein each strip of fire barrier is configured to be attached to the cavity tray by at least two mechanical attachments. This provides a securement means in the event that one attachment fails.
Optionally, wherein the mechanical attachments are positioned longitudinally separated from one another on each strip of fire barrier such that the fire barrier is constrained to the cavity tray along its length. Advantageously, such an arrangement provides a more secure attachment as compared to a single fixture, as well as multiple attachment means concentrated at one longitudinal location on the fire barrier.
Optionally, wherein the fire barrier is configured to cover a portion of the total area of a cavity tray surface onto which it is attached, optionally wherein the cavity tray surface is the top surface.
Optionally, wherein the fire barrier is configured to cover a portion of the total width of the cavity tray surface spanning from its distal end towards the proximal end, wherein the distal end is the end of the cavity tray configured to be adjacent the fagade and wherein the proximal end is configured to be adjacent the internal building structure. As mentioned, a benefit of covering only a portion of the surface i s to complement the existing fire prevention structures or insulation material that occupy an area themselves on the cavity tray surface. By only covering the exposed portions of the cavity tray (exposed by virtue of not being covered by the fire prevention structure or insulation material) this arrangement may save material. Such an arrangement is therefore a well balanced approach that minimises cost and maintains effectiveness. Spanning an area from the distal end is beneficial since most of the mentioned fire prevention structures or insulation material are present at the proximal end of the cavity tray.
Optionally, wherein the fire barrier is configured to cover the very distal end of the cavity tray surface to which it is attached. Advantageously, this minimises the probability of clashing with the fire prevention structures or insulation material found at the proximal end. The distal end is also more likely to be 'free' from obstruction and therefore allow the intumescent material of the fire barrier to expand more freely.
Optionally, wherein the cavity tray surface is covered in the transverse direction by either one strip of fire barrier or a plurality of strips of fire barriers arranged adjacent
one another. As mentioned, one strip may be dimensioned to the required width. Alternatively, the desired width may be achieved by placing multiple strips side by side. Both these approaches are very convenient to implement in practice.
Optionally, wherein the fire barrier is configured to cover the majority of the length of the cavity tray surface, wherein length is defined in the longitudinal direction of the cavity tray. This is advantageous as it allows the fire barrier to function more effectively and efficiently. The intumescent material of the fire barrier will be able to fill the cavity space above (or below) the cavity tray quicker should it cover a greater length of said cavity tray. Filling this cavity quickly is an important feature of the fire barrier.
Optionally, wherein the cavity tray surface is covered in the longitudinal direction by either one strip of fire barrier or a plurality of strips of fire barriers arranged adjacent one another in the longitudinal direction. The option of not being limited to using one fire barrier per tray is more convenient for the assembler. Strips that may accidentally be dimensioned too short of the length of the cavity tray will still be effective. This arrangement is also more sustainable as it utilises fire barrier strips that otherwise would be discarded for being too short.
Optionally, wherein a gap is left between longitudinally adjacent fire barriers. By leaving gaps between fire barriers a passage for the moisture collected on the cavity tray is formed. This allows the moisture to fall off the cavity tray in a controlled manner. Such an arrangement strikes a balance between maintaining a good lengthwise coverage of fire barriers on the cavity tray and the effective flow of water off of the cavity tray.
Optionally, wherein a fire prevention structure or insulation material is configured to be positioned atop the cavity tray, optionally wherein the fire prevention structure or insulation material comprise mineral wool. Advantageously, such an arrangement allows the cavity tray and fire barrier to not only accommodate but complement existing fire prevention structures or insulation material to provide a more complete fire protection. This may be through full coverage of the width of the cavity tray with fire prevention means (barriers and structures or insulation).
Optionally, wherein the upper surface of the cavity tray uncovered by the fire prevention structure or insulation material is configured to be covered by the fire
barrier, optionally wherein a portion of the upper surface of the cavity tray is left exposed. An advantage of this arrangement is that the entire surface area of the tray and therefore a majority of the cavity width is covered by fire prevention means.
Optionally, wherein the fire barrier is an intumescent material. Advantageously, this is particularly favourable in filling up the cavity space in a short period of time.
Optionally, wherein a side of the cavity tray comprises a lip, optionally wherein both sides of the cavity tray comprise a lip, optionally wherein the lip rises from the cavity tray to prevent water from passing to the side and off of the cavity tray. This may channel the water and direct it towards the weep holes in the masonry fagade.
Optionally, wherein the angle of the lip relative to the horizontal is between 10° to 90°. A 90° angle ensures that the lip protrudes vertically above the fire barrier strips to channel the water effectively. Lower angles within the range may allow for a more slender side profile of the tray.
Optionally, wherein a first cavity tray is configured to lay longitudinally adjacent a second cavity tray, optionally wherein a portion of one tray overlies a portion of a second tray such that there is no passage for water in between cavity trays. Such an arrangement ensures the water is directed as required and doesn't fall to areas that may be damaged by moisture.
Optionally, wherein the cavity tray is configured to be attached to the internal building structure, optionally wherein the cavity tray is configured to be attached to a load carrying feature in connection with the internal building structure. Advantageously, attaching directly to the building may aid in collecting water running down the surface of the internal building structure more efficiently. Attaching to a load carrying feature may be a more convenient attachment means or utilise existing cavity infrastructure.
Optionally, wherein the cavity tray is configured to attach to the internal building structure by one of: a mechanical join, an adhesive join, a welded join or an attachment element. All of these attachments are convenient to implement in a tight cavity with limited skill required.
Optionally, wherein the load carrying feature is a masonry support bracket.
Optionally, wherein the cavity tray is attached to the masonry support bracket by one of a mechanical join, an adhesive join or a welded join, optionally wherein the cavity tray is attached to the masonry support bracket by an attachment element.
Optionally, wherein the cavity tray comprises a metal sheet, preferably of a thickness of up to 2mm, preferably wherein the thickness is 0.5mm. This may reduce mass of the cavity tray.
Optionally, wherein the cavity tray is configured to be angled relative to the horizontal, preferably wherein the angle is between 3 and 10 degrees, and preferably wherein the angle is 5 degrees. This may aid the passage of water along the cavity tray.
Optionally, wherein the cavity tray further comprises a second angled section at a greater angle to the horizontal than the rest of the cavity tray, wherein the second angled section is configured to be positioned adjacent the internal building structure, optionally wherein the second angle is 50 degrees from the horizontal, optionally wherein the second angled portion comprises an attachment means. This may aid with attachment of the cavity tray to the internal building structure or load carrying feature as it is simpler for the two to be married in this position.
Optionally, wherein the cavity tray comprises a lip at its distal end, optionally wherein the lip extends downwards, optionally vertically down and parallel to the internal building structure. This may direct the falling moisture droplets to the intended position.
In accordance with an eighth aspect there is described an attachment element configured to attach to a secondary element, the attachment element comprising: a proximal arm; a distal arm; a channel between the proximal arm and the distal arm; the channel leading to a first recess positioned below the proximal arm and a second recess positioned below the distal arm; and a tooth positioned within the second recess. This is highly advantageous as the channel, first recess, second recess, and tooth together form a path for a bar of the secondary element to take when the secondary element is being attached to the
attachment means. This path enables ease of attachment for a user - whilst ensuring the secondary element is securely attached to the attachment means.
Optionally, the attachment element is positioned on a masonry support element, such as a masonry support bracket, and is configured to attach to a building structure. It is advantageous to provide the attachment means on a masonry support element such as a masonry support bracket. Where the secondary element is a cavity tray the attachment means may provide a quick and easy to use means of attachment. This reduces time installing the masonry support element and the cavity tray, and therefore improves the efficiency of the building process.
Optionally, the proximal arm is located on the masonry support element. This may make manufacture and installation simpler and require less assembly.
Optionally, the distal arm is located on the masonry support element. This may make manufacture and installation simpler and require less assembly.
Optionally, the second recess is divided by the tooth into a first passage adjacent the channel and the anterior of the tooth, and a second passage adjacent the posterior of the tooth. This is highly advantageous as the second passage can be used as the end point of the path of a bar for attachment of a secondary element. This secures the bar effectively, and makes it highly unlikely for the bar to slip out of the attachment means.
Optionally, the anterior side of the tooth is angled relative to the underside of the distal arm. This may allow a bar to pivot during the insertion to form a path that the bar cannot re-traverse without human intervention.
Optionally, the angle between the anterior side of the tooth and the distal arm is between 5 and 20 degrees, optionally wherein the angle is between 14 to 18 degrees, and further optionally wherein the angle is 16 degrees. This angular range, and this angle in particular have been found to optimise the amount of pivoting available, whilst reducing the use of material, and making the attachment secure.
Optionally, the arms of the attachment element are angled with respect to the vertical of the masonry support element. This may allow the bar to sit at an angle, which may conform with the shape of the secondary element, particularly if the secondary element is a cavity tray.
Optionally, wherein the proximal arm extends from a position above the distal arm. This may provide ease of access to the channel.
Optionally, the top side of the distal arm and the top side of the proximal arm are parallel. This may make moving the bar simpler, and reduce the risk of the bar unexpectedly catching a surface during attachment.
Optionally, wherein the top side of the distal arm is parallel to the bottom side of the distal arm. This allows the second recess to be shaped to provide an advantageous pathway for the secondary element.
Optionally, the bottom side of the proximal arm is angled with respect to the top side of the proximal arm. This may provide a second point at which to pivot the secondary element, and so may aid with attachment.
Optionally, the angle between the top side of the proximal arm and the bottom side of the proximal arm is between 5 and 20 degrees, optionally wherein the angle is between 14 to 18 degrees, and further optionally wherein the angle is 16 degrees. This angular range, and this angle in particular have been found to optimise the amount of pivoting available, whilst reducing the use of material, and making the attachment secure.
Optionally, the angle between the top side of the proximal arm and the bottom side of the proximal arm is the same as the angle between the anterior side of the tooth and the distal arm. This may improve the ease of attachment by making it simpler to slide a secondary element from the anterior side of the distal tooth to the bottom side of the proximal arm.
Optionally, the first recess and the second recess are joined to form a single cavity.
Optionally, wherein the first recess and second recess share a base.
Optionally, wherein the base is parallel with the posterior side of the tooth. This may be advantageous as the void of the second passageway may be cuboid in shape - and therefore make the insertion of the bar of the secondary element simpler.
Optionally, the base is parallel with the top of the distal arm. This helps with creating the multiple stage pathway.
Optionally, the base is parallel with the top of the proximal arm.
Optionally, distance between the base and the underside of the proximal arm is less than the distance between the base and the underside of the distal arm. This may be highly advantageous as this may allow a bar resting on the top of the distal arm to slide through the channel and under the underside of the proximal arm.
Optionally, the distance between the base and the top of the proximal arm is less than the distance between the base and the underside of the distal arm. This may help the bar slide through the channel by sliding along the top of the distal arm and then under the proximal arm and in the first recess.
Optionally, the distal arm is shaped as an elongate bar in cross section.
Optionally, the secondary element comprises an attachment bar. This may advantageously fit into the pathway of the attachment element.
Optionally, the attachment bar forms part of a cavity tray. This may be advantageous for the construction of masonry support elements where a cavity tray attaches to a masonry bracket.
Optionally, the bar is flat, such that the length and width of the bar are greater than the depth of the bar, optionally wherein the depth of the bar is 0.5mm.
Optionally, either side of the bar is a void, and wherein the voids are at least a distance x in length, optionally where x is 8mm to 12mm, and further optionally wherein x is 10mm. This may advantageously make it simpler to manoeuvre the bar into place.
Optionally, the distance between the base and the top of the proximal arm is less than the distance between the base and the underside of the distal arm, and wherein the difference between these distances is equal to the depth of the bar optionally wherein equal includes an additional tolerance, for example of 0.1mm. This may advantageously allow the bar to slide into the first recess in a simple manner.
Optionally, the second passage has a depth equal to the depth of the bar, optionally wherein equal includes an additional tolerance, for example of 0.1mm. This may allow the second passage to engage with the bar in a friction fit to keep the bar in place.
Optionally, the width of the bar is greater than the width of the channel. This may allow the bar to enter by sliding, rather than by initially being angled and pivoting into a recess as per other solutions.
Optionally, the length of the distal arm is 0.5mm greater than the width of the bar. This may make ease of attachment simpler.
Optionally, the length of the second passage is at least half the width of the bar. This may provide a particularly secure attachment.
Optionally, the length of the base to the entrance of the second passage is at least 0.5mm greater than the width of the bar. This may make attachment simpler.
Optionally, the distance between the end of the proximal arm and the tooth is at least half of the width of the bar. This may make progress of the bar through the pathway simple.
Optionally, the length of the top side of the distal arm is at least 1mm smaller than x. This may make manoeuvring the cavity tray simpler.
Optionally, the length of tooth to the rear of the distal arm is at least 1mm smaller than x. This may make manoeuvring the cavity tray simpler.
In accordance with a ninth aspect there is described a cavity tray comprising a first sheet comprising a plurality of edges; at a first edge there is a first void extending from the edge towards the interior of the sheet; at the end of the first void is a bar of material such that a first side of the bar is adjacent the first void; adjacent the second side of the bar is a second void, wherein the second void is entirely surrounded by material of the sheet. This may co-operate with the attachment element of the fourth aspect (in a plug-socket type arrangement). This may allow the cavity tray to be efficiently and securely fastened, therefore increasing the efficiency of building.
Optionally, the bar has a width of between 3mm and 7mm, preferably 5mm.
Optionally, the void extends between 8mm and 12mm into the interior of the cavity, preferably wherein it extends 10mm. The relative dimensions of the width to the void may be particularly preferable as this provides ease of use during installation.
Optionally, the second void extends away from the bar for a distance of at least 8mm to 12mm, optionally 10mm.
Optionally, the cavity tray further comprises: at the first edge, or an edge adjacent the first edge, a third void extending from the edge towards the interior of the sheet; at the end of the third void a second bar of material such that a first side of the second bar is adjacent the third void; adjacent the second side of the second bar a fourth void, wherein the fourth
void is entirely surrounded by material of the sheet. Having two bars may be particularly advantageous. This may allow a single cavity tray to be attached to two attachment elements. This may allow the cavity tray two points of attachment to a single masonry support bracket/element, or a single point of attachment to two masonry support brackets/elements. This secures the cavity tray may securely, and may enable flexibility in construction.
In accordance with a tenth aspect there is described an assembly comprising the attachment element of the fourth aspect incorporated into a masonry support bracket, and a cavity tray of the fifth aspect. This combination may provide a particularly efficient means of forming a masonry support element within a cavity.
In accordance with a eleventh aspect there is described a masonry support element comprising the attachment means of the first aspect.
Optionally, wherein the masonry support element is a masonry support bracket.
In accordance with a twelfth aspect there is described a building comprising: an internal building structure; a masonry fagade; a masonry support element as recited in the first aspect; wherein the masonry support element is connected between the masonry fagade and the internal building structure. This building may transfer the load from the masonry fagade to the building structure, and may have improved moisture management within the cavity between the fagade and the internal building structure. In some embodiments fire management may also be improved.
Optionally, further comprising weep vents positioned at the end of the masonry support angle such that water is expelled from the building via the weep vents. This may allow water flowing onto the masonry support angle to pass through the weep vents and be expelled from the cavity of the building.
In accordance with a thirteenth aspect there is disclosed a high rise building comprising a plurality of floors, and an inner cavity wall and an outer cavity wall with a cavity therebetween; and a cavity tray in accordance with the third aspect, wherein the cavity tray is situated at a first floor of the high rise building, and within the cavity between the inner cavity wall and the outer cavity wall. This may provide a building at less risk of fire.
Optionally, further comprising a second cavity tray situated one floor above the first cavity tray. This may advantageously control the movement of water within the cavity and prevent water passing through multiple floors, and may reduce the risk of the spread of fire.
Optionally, wherein the fire prevention material covering at least a portion of the tray section is configured to expand towards the second cavity tray in the event of fire. Therefore less hot air and fewer flames (and potentially none in some circumstances) will pass between the floors, and therefore the risk of the spread of fire is reduced.
In accordance with a fourteenth aspect there is described a method of installing the masonry support element of the first aspect, the method comprising the steps of: positioning a first masonry support bracket and angle at an intended position adjacent the internal building structure; positioning a second masonry support bracket and angle adjacent the position of the first masonry support element, and adjacent the internal building structure; attaching both the first masonry support bracket and angle and the second masonry support bracket and angle to the internal building structure; positioning a first cavity tray over the at least one arm of the first masonry support bracket; attaching the first cavity tray to the first masonry support bracket. This method may allow an efficient method for installing the masonry support angle within a cavity. This may therefore take less time and resources during the construction process.
Optionally, further comprising positioning a first infill cavity tray over a portion of the first masonry support angle and a portion of the second masonry support angle, attaching the first infill cavity tray to the first masonry support angle and the second masonry support angle. This may aid with the direction of water on the masonry support angle.
Optionally, the first cavity tray extends over at least a portion of the second masonry support bracket. This may make it simple to install multiple masonry support elements together, particularly around corners.
Optionally, further comprising positioning a second cavity tray extending over at least a portion of the second masonry support bracket.
Optionally, further comprising attaching the second cavity tray to the second masonry support bracket. This may prohibit moisture from following an unwanted path.
Optionally, positioning the first masonry support bracket and angle comprises positioning the first masonry support bracket and angle one side of an external/internal corner of the building structure, wherein positioning the second masonry support bracket and angle comprises positioning the second masonry support bracket and angle the other side of the external/internal corner of the building structure to the first masonry support bracket and angle. This may allow a simple and effective technique to be used such that a corner may be navigated through the use of straight masonry support elements alone. This may make manufacture and tooling of the manufacture facility considerably more efficient.
Optionally, positioning the first cavity tray over the at least one arm of the masonry support bracket comprises the cavity tray extending around the external/internal corner of the internal building structure. This may make it simpler to join the two masonry support brackets together.
Optionally, positioning a first infill cavity tray comprises positioning the infill cavity tray over the external/internal corner of the internal building structure. This may prohibit ingress of water at the corner point.
Optionally, attaching the first masonry support bracket to the internal building structure comprises securing a first bolt through a central void in the first column of the masonry support bracket, and said bolt attaching to the internal building structure. This may provide a secure connection and ensure load is transferred to the internal building structure.
Optionally, the first bolt is positioned at the top of the central void. This may help distribute the load evenly.
Optionally, securing further comprises securing a second bolt through the central void in the first column of the masonry support bracket, and said second bolt attaching to the internal building structure. This may provide an improved attachment that is more secure.
Optionally, attaching the second bolt comprises providing leverage through a cut-out in the first masonry support angle, wherein the cut-out is aligned with the central void of the first column of the masonry support bracket. This may allow the secondary
attachment to be situated at a preferred position that may otherwise be inaccessible to the worker assembling and installing the masonry support element.
Optionally, further comprising attaching a cover to cover the cut-out after the second bolt is attached. This may allow the upstanding to be in line with UK guidelines.
In accordance with a fifteenth aspect there is disclosed a method of installing a cavity tray in accordance with the third aspect, the method comprising the steps of: providing a first cavity tray in accordance with the third aspect; cutting the rightmost and/or leftmost end of the fire prevention structure to remove a pre-set length of the fire prevention structure; providing a second cavity tray in accordance the first aspect; overlapping the first cavity tray and the second tray by the pre-set length.
This may allow cavity trays where there is no gap in the fire prevention structure at the point of overlap to be efficiently modified and fitted on site depending on the length of overlap required.
In accordance with a sixteenth aspect of invention there is disclosed a method comprises attaching the fire barrier to the cavity tray. Advantageously, this may be done prior to fitting in the cavity so that it is more convenient for the assembler.
Optionally, wherein attaching the fire barrier to the cavity tray comprises: positioning the fire barrier on the cavity tray at a predetermined location; placing a first mechanical attachment at a first longitudinal and transverse location on the fire barrier; optionally wherein the mechanical attachment extends through the fire barrier and cavity tray arrangement; optionally wherein the first transverse location is preferably the midpoint of the width of the fire barrier strip.
Optionally, wherein attaching the fire barrier to the cavity tray further comprises: placing a second mechanical attachment on the fire barrier, optionally wherein the second mechanical attachment extends through the fire barrier and cavity tray arrangement; wherein the second longitudinal location is separated from the first longitudinal location so as to constrain the fire barrier to the cavity tray along its length; optionally wherein the second mechanical attachment is positioned at the first transverse location and a second longitudinal location; optionally wherein the second mechanical attachment is a rivet. This method may provide an efficient means for securing the elements together which therefore may improve the construction process as a whole. It also ensures a uniform method for conducting the attachment.
Optionally, wherein the method comprises attaching the cavity tray to the internal building structure.
Optionally, wherein the cavity tray is attached to the internal building structure by one of: a mechanical join, an adhesive join, a welded join, or an attachment element. These attachment means are easy to implement in a tight space.
Optionally, wherein the fire barrier is attached to the cavity tray prior to attaching the cavity tray to the internal building structure. This is more convenient for the assembler as it can be supplied to the consumer site pre-assembled.
In accordance with a seventeenth aspect there is described a method of attaching the attachment element of the first aspect, with a secondary element comprising an elongate flat bar, the method comprising: positioning the bar on the top of the proximal arm; sliding the bar into the first passage below and parallel the distal arm; pivoting the bar such that the base is parallel with the anterior side of the tooth; sliding the bar into the first recess below and parallel the proximal arm; pivoting the bar to be parallel with the base. This method may provide an efficient means for securing the elements together which therefore may improve the construction process as a whole.
Optionally, further comprising the step of sliding the bar into the second passage. This may provide a more secure attachment.
Optionally, the secondary element comprises a cavity tray, the attachment element is attached to a masonry support element, and the method is a method of attaching a cavity tray to a masonry support element.
Optionally, the cavity tray is the cavity tray of the second aspect.
Brief Description of Drawings
Figure 1 shows a cross section of a masonry support element.
Figure 2 shows two masonry support elements of Figure 1 joined together.
Figure 3 shows a masonry bracket with an indent to house a fire barrier.
Figures 4a-d show various positions of fire barriers, or equivalents in relation to the masonry support element.
Figure 5 shows a side lip of a cavity tray.
Figures 6a and 6b show two steps in the installation of masonry support elements around an external corner.
Figures 7a and 7b show two further steps of installing the masonry support elements of Figure 6 around an external corner.
Figure 8 shows a final installation step in the method shown in Figures 6 and 7.
Figure 9 shows an installation step for installing a one-piece masonry support element around an external corner.
Figure 10 shows a masonry support element in cross section in which the first column comprises a notch.
Figures 11a and lib show a masonry support element with only one arm.
Figures 12a and 12b show a masonry support element in which the masonry support angle comprises a cut-out.
Figure 13 shows an embodiment of a masonry support angle in which the masonry support bracket comprises a slot into which the masonry support angle is housed.
Figure 14 shows a close up of an attachment element.
Figure 15 is a perspective view of a first embodiment of a cavity tray and fire barrier seen through a masonry fagade.
Figure 16 is a cross sectional view of a first embodiment of a cavity tray and fire barrier.
Figure 17 is a perspective view of a second embodiment of a cavity tray and fire barrier seen through a masonry fagade.
Figure 18 is a cross sectional view of a second embodiment of a cavity tray and fire barrier.
Figure 19 is a cross sectional view of a third embodiment of a cavity tray and fire barrier wherein the fire barrier is positioned beneath the cavity tray.
Figure 20 is a cross sectional view of a fourth embodiment of a cavity tray and fire barrier wherein the fire barrier wraps around the cavity tray.
Figure 21 is a perspective view of a fifth embodiment of a cavity tray and fire barrier.
Figure 22 is a cross sectional view of a fifth embodiment of a cavity tray and fire barrier.
Figure 23a shows an embodiment of a cavity tray comprising a fire prevention structure in a perspective view.
Figure 23b shows the cavity tray of Figure 23a in a side view.
Figure 24a shows a perspective view of a masonry support element comprising a cavity tray comprising a fire prevention structure.
Figure 24b shows the masonry support element of Figure 24a in a side view.
Figure 24c shows the masonry support of Figure 24a in a front view.
Figure 25a shows an alternative embodiment of the masonry support element in a side view.
Figure 25b shows a further alternative embodiment of the masonry support element in a side view.
Figure 26 shows the underlying masonry support structure (with fire prevention material removed) present in figures 24a-c.
Figure 27 shows a flow chart for a method of preparing the cavity tray for installation. Figure 28 shows the attachment element in cross section.
Figure 29 shows a cavity tray with means for attachment to the attachment element.
Figure 30 shows a close up of the attachment means of the cavity tray.
Figure 31a is a close up of the attachment means of the cavity tray from above.
Figure 31b is a view of the cavity tray from above.
Figure 32 shows the attachment means of the cavity tray attached to the attachment element.
Figure 33 shows one step in the process of attaching the cavity tray to the attachment element.
Figure 34 shows a further step of the method of Figure 33.
Figure 35 shows a further step of the method of Figures 33 and 34.
Figure 36 shows a further step of the method shown in Figures 33 to 35.
Detailed Description of Drawings
Described herein is a masonry support element configured to sit in a cavity between an internal building structure and a fagade, and to transfer the load of the fagade to the internal building structure, the masonry support element comprising, a masonry support bracket, a masonry support angle, a cavity tray, wherein the masonry support angle is configured to extend into the fagade, and to take the load of the fagade and transfer this load to the masonry support bracket, wherein the masonry support bracket is configured to be attached to the internal building structure, and is configured to transfer the load from the masonry support angle to the internal building structure, wherein the masonry support bracket comprises a first column configured to lie parallel with the internal building structure, and at least one arm extending perpendicular to the column away from the internal building structure and towards the fagade, wherein the masonry support angle is attached to the masonry support bracket, wherein the cavity tray is configured to overlie the at least one arm of the masonry support bracket, wherein the cavity tray is configured to collect moisture within the cavity, and to provide an alternative path for said water to take across the cavity tray, wherein the cavity tray sits above the masonry support angle such that water passing across the cavity tray drops down onto the masonry support angle.
Figure 1 shows a cross section of a masonry support element 1. This comprises a masonry support bracket 7, a masonry support angle 19 and a cavity tray 23. The masonry support element is positioned within a cavity between a masonry fagade 5 and an internal building structure 3. The masonry support angle 19 is configured to extend into the masonry fagade 5. The masonry support angle 19 is configured to transfer the load from the masonry fagade 5 to the masonry support bracket 7. The masonry support bracket 7 is in turn attached to the internal building structure 3 (this may be directly or through an intervening element) and to transfer the load from the masonry support angle 19 to the internal building structure 3. As such the load of the masonry fagade 5 is held by the internal building structure 3.
The masonry support bracket 7 has a structure that is weight saving, whilst maintaining strength in the plane (the plane of the first arm 11) configured to transfer the load of the masonry fagade 5. Shown in Figure 1 is the structure of the masonry support bracket 7 in side view. This shows a first column 9, a first arm 11, a second arm 13, and a second column 15. There is also a central void 17 between the first arm 11 and the second arm 13. The central void is fully enclosed in the plane of the first arm. The proximal end of the first arm 11 and second arm 13 are attached to the first column 9 in Figure 1. The distal ends of the first arm 11 and second arm 13 are attached to the second column 15 in Figure 1.
The remainder of the first column 9 is perpendicular the cross section of Figure 1, and is flush and/or parallel with the internal building structure. This portion of the first column 9 is perpendicular to the plane of the first arm 11.
The central void 17 may reduce the weight of the masonry support bracket. The strength of the masonry support bracket in the plane of the first arm (the plane that can be seen in Figure 1) is maintained. This is maintained by the two arms 11 and 13, and the second column 15. These elements together distribute the load, and enable it to be transferred. The portion of first column 9 visible in Figure 1 is optional, and all of the first column 9 may be perpendicular to the view shown in Figure 1. However, the section of the first column 9 is also advantageous for receiving the load from the arms 11 and 13 and transferring this to the portion of the first column 9 not visible in Figure 1 and then onto the internal building structure 3.
The second column is in two-dimensional plane of the first arm 11. The second column extends downwards (in this case vertically downwards, but other angles may be used). The second column is shown as being parallel in this view to the masonry fagade. This may enable load to be transferred and carried efficiently by the masonry support bracket, whilst minimising the mass of the masonry bracket required.
It is noted that the first column, first arm, second arm, and second column may all be formed of a sheet-like material. This may be a metal such as stainless steel. These elements (the portion visible in the case of the first column 9) are therefore thin in the directions perpendicular to this viewpoint. These elements may for example be 0.5mm in the other perpendicular views. This enables the mass of the first column 9, second column 15, first arm 11 and second arm 13 to be reduced significantly. The strength of the masonry support bracket in the plane of the first arm 11 is not affected, and is sufficient to transfer the load of the masonry fagade 5. However, the strength in the other two directions perpendicular to the view of Figure 1 is much
lower. Having one plane of far greater strength and load bearing capacity allows the mass of the masonry support bracket 7 to be minimised, whilst not affecting the function the masonry support bracket 7 in the plane of the arm 11.
The first arm 11 is shown as being angled relative to the second column 15 (rather than being perpendicular). In some embodiments the arm 11 may be perpendicular to the second column 15. The arm 11 is angled such that the cavity tray 23 sitting atop the arm 11 is also angled. The arm however may be flat and the cavity tray 23 angled in an alternative manner. Angled may include the arm extending from the first column 9 towards the masonry fagade 5, and the second column extending down from the first arm 11. The second column 15 may be approximately parallel the masonry fagade 5 (as shown in Figure 1). The angle between the arm 11 and the second column 15 may be equal to 90 degrees plus the angle of the cavity tray relative to the horizontal (in the case of Figure 1 approximately 5 degrees).
The cavity tray overlies the at least on arm and extends through the plane visible in Figure 1. The cavity tray spans the majority of the cavity between the internal building 3 and the masonry fagade 5. The function of the cavity tray 23 is to capture moisture in the cavity (e.g. condensing from the cavity onto the cavity tray 23, or passing down the internal building structure 3). The cavity tray 23 is angled to cause moisture collecting on the cavity tray 23 to pass towards the masonry fagade 5. This angle may be between 3 and 10 degrees and preferably is 5 degrees. This may prevent pooling, whilst reducing the amount of mass needed to form the cavity tray 23. At the end of the cavity tray 23 the moisture will drop off of the cavity tray 23. The end of the cavity tray features a lip 31 (purely optional). This may guide the moisture so that the moisture falling from the cavity tray 23 takes a predictable path. In this case the lip 31 extends vertically down, but other angles may be used. The cavity tray may comprise a metal sheet, and may have a thickness of up to 2mm, and preferably 0.5mm to reduce weight.
The moisture will then fall on the masonry support angle 19. This makes use of the masonry support angle 19 as a secondary cavity tray. The water will then pass along the masonry support angle 19 and out of the cavity. The masonry fagade 5 may contain weep holes positioned adjacent the masonry support angle 19 to enable the moisture to leave the cavity and the building entirely. The masonry support angle 19 is shown as being entirely flat in the horizontal, however it may have a slight angle to encourage water flow out of the cavity. It is noted that a single masonry support angle may be connected to two masonry support brackets 7 within a single masonry support element 1.
The cavity tray 23 may be attached to the masonry support bracket 7 by any means such as by a mechanical join, adhesive or by welding. In this example the cavity tray 23 comprises a second angled section 27, that is angled at a greater angle than the rest of the slope of the cavity tray 23. This may be angled at 50 degrees from the horizontal in this example (other angles may be used). This may allow the cavity tray to attach to an attachment element 29 positioned at the top of the first column/ first arm 11. The second angled section 27 may make it simpler for a user to make the connection between the cavity tray 23 and the attachment element 29.
It is noted that the cavity tray may be optional for some embodiments. For example, the masonry support bracket 7 may be used as a standalone element with the masonry support angle 19. This may still provide a reduced mass masonry support element 1 for transferring the load form the masonry fagade 5 to the internal building structure 3. Other means may then be used to control moisture and fluid flow within the cavity.
Also shown in Figure 1 is a wall tie 33. The wall tie 33 may offer a second point of attachment between the masonry support element 1 and the masonry fagade. This may help with alignment during installation, and to prevent slippage during use. The wall tie is shown as being attached to the second column 15 of the masonry support bracket 7. The wall tie 33 may also be attached to the first arm 11. The wall tie 33 may be directly attached by any means. In this embodiment the wall tie sits within a slot 35. The slot may be positioned on either the second column 15 or the first arm 11. The slot 35 may allow some tolerance and adjustability of the height of the wall tie. This may make installation significantly simpler as the slot 35 may make allowances for any inaccuracies in installation.
The masonry support angle 19 comprises an upstanding 21. The upstanding may project upwards from the portion of the masonry support angle 19 that extends into the fagade 5 during use. The two portions of the masonry support angle 19 may be perpendicular to each other as shown in Figure 1. The upstanding may be 50mm, 70mm, or 90mm in height above the other portion of the masonry support angle. A lower height (e.g. 50mm) may be preferable to reduce the mass of the masonry support angle. However, a larger upstanding may be used in some embodiments where greater strength is required. Current UK regulations dictate a minimum upstanding of 100mm.
It is noted that the first column (portion shown only) 9, second column 15, first arm 11 and second arm 13 may be known as a single sheet with a central window 17. This separate interpretation confers the same structure shown in Figure 1.
Whilst not shown in Figure 1 (due to Figure 1 being a cross section), a second structure much like that shown in Figure 1 may be attached in parallel to that shown in Figure 1, where both are connected via the first column 9. In particular, there may be a third and fourth arm extending from the first column 9. These arms may be parallel to the first arm 11 and second arm 13, and the third and fourth arm may be joined by a third column, where said third column may be parallel to the second column 15, and perpendicular to the first column 9. The third and fourth arms may form a second two-dimensional plane that is parallel to the two-dimensional plane of the first and second arms 11, 13. There may be a central void between the third and fourth arms.
A building comprising an internal building structure 3, a masonry fagade 5, and a masonry support element (such as the one shown and described in Figure 1, or with respect to any other Figures or embodiments described herein) may have the masonry support element 1 connected between the masonry fagade and the internal building structure 3. Optionally in the masonry fagade there may be positioned weep vents adjacent the masonry support angle 19 such that water carried along the masonry support angle 19 may exit the building via the weep holes.
Figure 2 shows two masonry support elements of Figure 1 conjoined. Figure 2 shows a first masonry support bracket 7a, a second masonry support bracket 7b, a first cavity tray 23a, a second cavity tray 23b, a first masonry support angle 19a, a second masonry support angle 19b. In this example two masonry support brackets 7a are attached to a single masonry support angle 19a. However, the second masonry support bracket 7a is entirely optional.
Also shown herein is infill tray 37. This joins the first masonry support angle 19a with the second masonry support angle 19b. This prevents the join being a weak point structurally, and prevents water ingress. The infill tray 37 and join between the two masonry support elements is shown as being at a straight point in the structure. Alternatively, this may at an internal or external corner.
Figure 3 shows a masonry bracket with an indent 37 to house a fire barrier 25. The masonry support element 1 may serve yet another purpose as it may reduce the spread of fire in a building, particularly reducing the spread of fire from floor to floor.
Shown in Figure 3 is a masonry support bracket 7, a masonry support angle 19 an indent 37 on the masonry support bracket 7, and a fire barrier 25. The indent sits at the top of the first arm 11. There is a nodule shown at the d istal end of the first arm (nearest the masonry fagade 5 in use). This may support the fire barrier 25 and prevent slippage. It is noted that the nodule may be optional. Alternative fastenings such as adhesive may be used. The notch 37 allows the fire barrier to sit between the first arm 11 and the cavity tray 23 as shown in Figure 1.
The fire barrier 25 may be any suitable fire prevention material, such as intumescent material, or fire prevention material.
Figures 4a-d show various positions of fire barriers, or equivalents in relation to the masonry support element. The cavity trays may also be used with the fire barriers independently without any further portion of masonry support. Figure 4a shows a different view of Figure 3 in which the notch 37 at the top of the first arm 11 allows the fire barrier to sit between the first arm 11 and the cavity, whilst in a mechanical hold of the indent 37. The cavity tray overlies the fire barrier 25.
Figure 4b shows an alternative embodiment in which no notch is present. Instead the fire barrier sits atop the first arm 11 (it may be joined to the first arm by alternative means such as tape or adhesive). The cavity tray 23 then overlies the fire barrier.
Figure 4c shows an alternative in which the fire barrier 25 is placed atop the cavity tray 23.
Figure 4d shows an intumescent rigid structure 39 positioned atop the cavity tray 23. This may allow the masonry support element 1 to cooperate with legacy fire prevention systems.
Figure 5 shows a side lip of a cavity tray. Figure 5 shows a cavity tray 23 with a slide lip 41 and a masonry support bracket 7. A side lip 41 may be on either side (one, or the other, or both) of the cavity tray. The sides run parallel with the first arm 11 of the masonry support bracket 7. The side lips may prevent water from passing off of the side of the cavity tray. This in turn may allow the amount of water on each cavity tray to regular (similar to the groynes on a beach keeping sand distribution equal). The side lip 41 may extend upwards, and may be vertically upwards from the cavity tray 23.
Figures 6a and 6b show two steps in the installation of masonry support elements around an external corner. Figure 6a show a first step of positioning a masonry
support element 1 at a selected position relative to the internal building structure 3 and the masonry fagade 5. It is noted that the masonry fagade may be built around the masonry support angle 19 after the masonry support element 1 has been installed. The masonry support element comprises two masonry support brackets 7a (one of which is entirely optional) and a masonry support angle 19a. The masonry support element 1 in this example is positioned on one side of an external angle. This same process may be used adjacent an internal corner.
Figure 6b shows a second step of the method shown in Figure 6a. In this step a second masonry support element comprising masonry support bracket 7b, and masonry support angle 19b is positioned at a second selected position. This selected position is the other side of the external corner to the first selected position of the first masonry support element 1. At this point the masonry support elements may be attached to the internal building structure. Alternatively, this attachment may take place later in the method.
Figures 7a and 7b show two further steps of installing the masonry support elements of Figure 6 around an external corner. Figure 7a shows the first masonry support element and second masonry support element as shown in figure 6b. Additionally an infill tray 37 has been positioned at the join between the first masonry support element and the second masonry support element. This may improve the structural performance of the masonry support elements, and prevent water ingress. The infill tray is positioned at the apex of the external corner (and may be positioned at the apex of an internal corner in a corresponding embodiment). The infill tray 37 may be attached to the first masonry support angle 19a and the secondary masonry support angle 19b at this stage, or this may be attached later in the method.
Figure 7b shows the elements of figure 7b with an additional cavity tray 23a installed. The cavity tray 23a is positioned to overlie the first masonry support bracket 7a. In this embodiment the cavity tray does not overlie the second masonry support element 7b (however in alterative embodiments it may well do). The cavity tray extends around the external corner such that is sits above at least a portion of both the first masonry support angle 19a and a portion of the secondary masonry support angle 19b.
Figure 8 shows a final installation step in the method shown in Figures 6 and 7. This shows the elements of Figure 7b and an additional second cavity tray 23b. This overlies the second masonry support bracket 7b and a portion of the second masonry support angle 19b. It is adjacent the first cavity tray 23a. The join may be left as is,
or may have tape or other mechanical or adhesive join made between them. The cavity trays 23a and 23b may be attached to the masonry support brackets at this stage. The cavity trays 23a and 23b may further be directly attached to the internal building structure to prevent movement.
Figure 9 shows an installation step for installing a one-piece masonry support element around an external corner. This is an alternative to figures 6-8. In cases where the dimensions of the corner are small, or where there are access problems it may be simpler to fit a one-piece masonry support element that contains a corner, rather than using two straight sections of masonry support element to form a corner (as shown in Figures 6-8). A cavity tray may then be added as per any suitable method of attachment. Figure 9 shows a single masonry support element with a first masonry support bracket 7a at an angle to a second masonry support bracket 7n. The masonry support angle 19 comprises two sections at an angle to one another. A cavity tray overlying the masonry support brackets would also comprise two sections at an angle to one another. Such an arrangement may also be used for internal corners.
Figure 10 shows a masonry support element in cross section in which the first column comprises a notch. Figure 10 shows an internal building structure comprising a notch 45. A notch 45 may also be formed from other elements or members attached to the internal building structure 3 that are to be navigated by the masonry support element 1.
The masonry support bracket 7 therefore includes a notch 43. This notch allows the first column 9 of the masonry support bracket 7 to lie adjacent (in this case parallel and flush to) the internal building structure 1.
The notch 43 consists of a horizontal displacement of the column at a point along its length. The two sections of the first column 9 either side of the notch 43 are parallel and connected to one another. However, there is in effect a chicane like connecting portion that comprises the notch 43. The notch 43 may be rounded, or may be squared as shown in the Figure.
It is noted that in some embodiments in which a notch is present the first column 9 may not have a back plate flush to the internal building structure below the notch. Instead the side portion of first column 9 (the portion visible in Figure 1 for example) may extend below the notch and there may be a void adjacent the internal building structure 3.
Figures 11a and lib show a masonry support element with only one arm. The masonry bracket 7 comprises a first column 9, and an arm 11. The arm shown comprises no central void (although one may be present). Such an arm may be used in dual arm embodiments.
In this embodiment only one full arm emanates from the first column 9, and only one arm 11 is secured to the masonry support angle 19 (two masonry support brackets are shown, which whilst advantageous is optional). The at least one arm provides sufficient load bearing means to support the masonry fagade.
Element 47 is optional and comprises a shortened arm or stump. This allows the proximal end of the masonry support bracket to have a C-shaped profile when viewed from above. This is stronger than an L-shaped profile if the stump 47 is removed. The stump 47 is therefore advantageous for increasing load bearing capacity.
Figures 12a and 12b show a masonry support element in which the masonry support angle comprises a cut-out. Figure 12a shows masonry support elements 7 overlaid by a cavity tray 23 as per previous embodiments. A masonry support angle 19 is connected to the masonry support brackets as per the previous embodiments. It is noted that the first column 9 of the masonry support bracket 7 comprises a central void 57. This is shown and described in greater detail with reference to Figure 14. We note that bolts that attach the masonry support bracket to the internal building structure 3 may be positioned in the central void 57.
Also shown in Figure 12a is a cut-out 51. The cut-out is at the uppermost edge of the upstanding 21. The cut-out 51 allows a bolt to be positioned in either the central void 57 or a secondary void (e.g. within 75mm of an upper primary bolt) of the first column 9, and for a user to be able to apply leverage to said bolt in a simple manner. This makes assembly simpler, more efficient, and allows greater flexibility in bolt positioning to enhance the connection between the masonry support element 1 and the internal building structure 3.
For example, a user may drill into the building structure to create a hole for the bolt to enter. This hole may be aligned with the cut-out, and the drill bit may access the position of the hole (so as to drill the hole) through the cut out. A socket may then be used to tighten the bolt nut into place. The socket may be accessed via the cu- out to improve access in some embodiments.
Figure 12b is the same as Figure 12a, with only one difference. This is shown in zoomed in portion which shows a cover element 53. The cover element is positioned
over the cut-out 51 so that it is not visible. This may help with restoring the strength properties of the masonry support angle. Moreover, this may allow the cut-out compliance with UK construction regulations. It is noted that the cover is optional and the cut-out may be left uncovered.
It is noted that the cut-out may be used with any masonry support element in which an upstanding (for example forming part of a masonry support angle) is used. This cut-out is not tied to any masonry support angle shown in this application.
Figure 13 shows an embodiment of a masonry support angle in which the masonry support bracket comprises a slot into which the masonry support angle is housed. The masonry support element of Figure 13 comprises a masonry support angle 19 and a masonry support bracket 7 (of which only the arms 11 are shown). The arms 11 are shown as omitting a central void which may beneficial in this embodiment. However, it is possible to incorporate a central void into this embodiment if required.
A slot 55 is present in the arms 11 shown. The upstanding 21 of the masonry support angle 19 fits into the slot 55 of the arms 11. The masonry support angle is therefore mechanically joined to the masonry bracket 7 through the slot. This may reduce the need for welding in the construction process, and may decrease the mass of the masonry support element 1. It is noted this slot may be used with any masonry support element comprising a bracket and a masonry support angle comprising an upstanding.
Described herein is an attachment element configured to attach to a secondary element, the attachment element comprising a proximal arm, a distal arm, a channel between the proximal arm and the distal arm, the channel leading to a first recess positioned below the proximal arm and a second recess positioned below the distal arm, and a tooth positioned within the second recess.
Figure 14 shows a close up of an attachment element. On the left is shown a masonry support element as detailed in the embodiments described above. A masonry bracket 7 and a masonry support angle 19 are shown. A central void 57 is also shown in the first column 9 in the side flush to the internal building structure 3 during use. Attachment means such as bolts may protrude through the central void 57 and may attach the masonry support bracket to the internal building structure 3. For example, a primary attachment means may be positioned near the top of the first column 9 within the central void 57. Near the top may comprise within 45mm of the top of the first column 9. Optionally a secondary attachment means may be located further down
(for example within 75mm of the primary attachment means, and/or within 45mm of the bottom of the first column). The secondary attachment means may either be located within the central void, or within a second void in the first column 9 (the second void is not shown). This may provide a secure attachment between the internal building structure and the internal building structure 3.
The close-up view on the right shows the attachment element 29. This attachment element may be used in any technical field, and may be divorced from this particular masonry support element, or from masonry support elements more generally. However, this attachment element is particularly advantageous for use in connecting a masonry support bracket to a cavity tray. The attachment element 29 is described with reference to the remaining Figures.
It is noted that the attachment element (and therefore the arms of the attachment element) are angled with respect to the vertical of the masonry support element. This may make it simpler to fit a cavity tray to the attachment element 29 during assembly. In some embodiments therefore the proximal arm extends form a position above the distal arm.
Figure 15 shows a cavity tray 23 and fire barrier 25 configured to sit in a cavity between an internal building structure 3 and a fagade 5; wherein the cavity tray 23 is configured to collect moisture within the cavity, and to provide an alternative path for said water to take across the cavity tray 23; wherein the fire barrier 25 is configured to be positioned either: atop the cavity tray 23; or beneath the cavity tray 23.
The proximal end of the cavity tray 23 (the end of the cavity tray adjacent the internal building structure 3) attaches directly onto the internal building structure 3, whilst the distal end of the cavity tray 23 is adjacent the masonry fagade 5. The attachment between the cavity tray 23 and the internal building structure 3 is via nuts and bolts 59 in Figures 15 and 16, however other mechanical, adhesive and welded joins are entirely possible, as is a separate attachment element.
The cavity tray 23 may optionally attach onto a load carrying feature, connected to the internal building structure 3, in the same manner (not shown). The load carrying feature may be an attachment element specifically designed to connect the cavity tray 23 to the internal building structure 3. Alternatively, the load carrying feature may have other primary functionality and be adapted to accommodate the cavity tray
23. As such, the load carrying feature may be the masonry support bracket 11 as described thus far above and connect to the cavity tray 23 in this alternate manner.
The cavity tray 23 shown in Figures 15 and 16 spans the majority of the cavity between the internal building 3 and the masonry fagade 5. The function of the cavity tray 23 is to capture moisture in the cavity (e.g. condensing from the cavity onto the cavity tray 23, or passing down the internal building structure 3). The cavity tray 23 is angled to cause moisture collecting on the cavity tray 23 to pass towards the masonry fagade 5. This angle may be between 3 and 10 degrees and preferably is 5 degrees. This may prevent pooling, whilst reducing the amount of mass needed to form the cavity tray 23.
In this embodiment, the cavity tray 23 has a second angled section 27 located at its proximal end. This second angled section 27 is 90 degrees to the horizontal and is seen best in Figure 15. The orthogonality of this second angled section 27 may be beneficial in maintaining a preferred first section angle of 5 degrees to the horizontal and achieve flush abutment with the internal building structure 3 wall for attachment. The second angled section 27 may alternatively be any other angle greater than the first section angle and is not limited by this square requirement. For embodiments with an attachment element, such as that of a masonry support bracket 11, the second angled section 27 may be 50 degrees. Alternatively, other angles may be used for both the first and second angled sections 27.
The end of the cavity tray features a lip 31 (purely optional). In this case the lip 31 extends vertically down and is parallel the internal building structure 3, but other angles may be used, for example, a slight angle towards the masonry fagade 5. This lip 31 may guide the moisture so that the moisture falling from the cavity tray 23 takes a predictable path. The moisture will then fall on the masonry support angle 19 (for embodiments in which this element is present). This makes use of the masonry support angle 19 as a secondary cavity tray. The water will then pass along the masonry support angle 19 and out of the cavity. The masonry fagade 5 may contain weep holes 60 (shown best in Figure 16) positioned adjacent the masonry support angle 19 to enable the moisture to leave the cavity and the building entirely. The masonry support angle 19 is shown as being entirely flat in the horizontal, however it may have a slight angle to encourage water flow out of the cavity.
In addition to this distal lip 31, and although not shown in Figure 15 or 16, the cavity tray may comprise a lip at one, or both, of its sides. The side lip or lips may be raised from the cavity tray 23 to prevent water from passing to the side and off of the cavity
tray 23. The angle of the lip(s) relative to the horizontal may be in the range of 10 to 90 degrees. A lip angle of 90 degrees ensures that the lips protrude above the fire barrier strips 25 to effectively channel the water. A lower lip angle may be advantageous in some embodiments as it achieves effective water confinement whilst maintaining a more-slender side profile with limited vertical protrusion as compared to higher side lip angles.
The cavity tray 23 may comprise a metal sheet, and may have a thickness of up to 2mm, and preferably 0.5mm. Such construction may aid in keeping the mass of the cavity tray 23 low.
It is noted that the cavity tray 23 of Figures 15 and 16 is of largely similar construction to the cavity tray 23 described in embodiments forming part of a masonry support element 1. Slight adaptations are present in the current embodiment to better accommodate the attachment to the internal building structure 3 as opposed to a masonry support bracket 11. These adaptations are entirely optional features. Both the cavity tray 23 and the masonry support bracket 11 may be modified in a number of ways to form embodiments that either complement one another, or stay independent of one another, such that they can be used without the other present.
Figure 15 shows a first cavity tray 23 laying longitudinally adjacent a second cavity tray 23, wherein the longitudinal direction is perpendicular the distance between the internal building structure 3 and the fagade 5. The cavity trays 23 are arranged side- by-side and in flush contact along their entire side edges such that there is no passage for water in between cavity trays 23. Alternatively, the cavity trays 23 may be arranged such that a portion of one tray 23 overlies a portion of a second tray 23 (not shown). Lower side lip angles (given sufficient vertical protrusion above the fire barrier strips 25) in the range provided may aid in minimising the vertical displacement, and therefore slanting, of the top tray 23 in an overlying arrangement as compared to higher lip angles.
Both Figures 15 and 16 show a strip of fire barrier 25 positioned atop an upper surface of a cavity tray 23. The strip of fire barrier 25 covers a portion of the cavity tray's 23 upper surface and is located at its distal end. The majority of the upper surface is left uncovered by the fire barrier 25. The uncovered portion may be covered by a fire prevention structure such as mineral wool (not shown). Alternatively, it may be the case that a fire prevention structure already present in the cavity predefines a portion of the cavity tray 23 to be covered by a fire barrier strip 25. The fire barrier 25 may then be dimensioned accordingly.
The fire prevention structure may be a structure specifically implemented in the cavity to provide protection from fire. Alternatively, the fire prevention structure may be an insulation material implemented primarily for its thermal properties yet provides fire prevention as its secondary functionality. This may be due to the insulation material being incombustible. The insulation material may also comprise mineral wool.
In other embodiments, it is entirely possible to place the fire barrier 25 on the lower surface of the cavity tray 23. However, placing the fire barrier 25 on the upper surface is advantageous as the fire barrier 25 is kept in position on the cavity tray 23 by gravity in addition to the attachment means. This is particularly useful in case of a fire should the attachment means fail under extreme heat.
The fire barrier 25 described is intended to be an intumescent material as this is preferred. Nevertheless, other embodiments may utilise other types of fire barrier 25 construction.
In Figures 15 and 16, one fire barrier 25 is positioned at the very distal end of the cavity tray 23. This fire barrier 25 only covers a portion of the total width of the cavity tray 23 surface spanning from its distal end. Here, the width of the cavity tray 23 is defined as the distance between its proximal and distal ends. Since the fire barrier 25 is a strip of an intumescent material that can be easily dimensioned to a range of widths, the width of the cavity tray 23 covered from the distal end can be conveniently varied.
The amount of fire barrier 25 coverage required may be dictated by legislation or, as already mentioned, by the fire prevention structures or insulation material (not shown) already in place on the cavity tray 23. Alternatively, it is entirely possible to attach more than one strip of fire barrier 25 atop or beneath a cavity tray 23. Such fire barriers 25 may be positioned adjacent one another transversely (width wise) on the cavity tray 23. Here, the transverse direction is the direction between the internal building structure 3 and the masonry fagade 5 (the width wise direction).
In alternate embodiments, the fire barrier strips 25 may be positioned at any transverse location on the cavity tray 23 and are not limited to being positioned at the distal end alone. Positioning at the very distal end (the leading edge of the cavity tray 23 adjacent the masonry fagade 5) may be advantageous in terms of ensuring adequate fire safety since most fire prevention structures or insulation material are situated at the proximal end of the cavity tray 23. This would minimise the risk of the
fire barriers 25 being positioned underneath a fire prevention structure or insulation material, which may reduce the effectiveness of the intumescent material.
Figure 15 shows an arrangement wherein the fire barriers 25 are positioned such that one fire barrier strip 25 covers the entire length of a cavity tray 23. The length of the cavity tray 23 is defined by its longest dimension i.e. distance in the longitudinal direction described above. Alternatively, the fire barrier 25 may be arranged such that it only covers a majority of the length of cavity tray 23, and not its whole length. 'Majority' in this context referring to a sufficient length of the cavity tray 23 being covered by the fire barrier 25 such that the fire barrier 25, optionally an intumescent material strip, is effective in its function. This may be more than half the length of the cavity tray 23.
The cavity tray 23 surface may be covered in the longitudinal direction by either one strip of fire barrier 25, as seen in Figure 15, or a plurality of fire barriers 25 arranged adjacent one another in the longitudinal direction (not shown). For both arrangements, it may be advantageous to leave gaps (not shown) between adjacent fire barriers 25 to allow for water/moisture to pass through onto the distal edge of the cavity tray 23 from which it may drop off. These gaps may be in between fire barriers 25 placed on the same cavity tray 23 or adjacent trays.
Each strip of fire barrier 25 attaches onto the cavity tray 23 by at least two mechanical attachment means (not shown). The mechanical attachment means may be rivets, bolts, crimping or clips, as well as other means not named here. The mechanical attachments are placed such that they are longitudinally separated from one another on each strip of fire barrier 25. This ensures that the fire barrier is adequately constrained to the cavity tray 23 along its length. This attachment may be achieved preferably by rivets. Rivets ensure a tight friction attachment yet allow some clearance in between attachment points for the flow of water beneath the fire barrier 25 to aid the cavity tray in its function.
The at least two mechanical attachments may be positioned such that they are at the same transverse location on the cavity tray 23/fire barrier 25, preferably at the fire barrier's 25 midpoint. This may ensure a uniform attachment that is easy to replicate, therefore improving efficiency and consistency during the assembly process. Optionally, the mechanical attachments may be positioned at different transverse locations to one another, for example, on diagonally opposite strip 25 corners. Further optionally, they may be placed at any arbitrary transverse locations in relation to one another so long as the mechanical attachments are longitudinally separated.
Figures 17 and 18 show an embodiment of the cavity tray 23 and fire barrier 25 described in Figures 15 and 16 in which the fire barrier 25 covers the total area of the upper surface of the cavity tray 23. Optionally, the fire barrier 25 may cover the total area of the lower surface of the cavity tray 23. This complete coverage may be particularly useful in embodiments where the fire barrier 25 is the only fire safety measure present in the cavity. That being said, it may also have some benefits when fitting into cavities alongside fire prevention structures or insulation material too. As there is no requirement to dimension the fire barrier 25 strip in accordance with any space limitations (since all the surface is covered regardless), time is saved in the initial strip sizing step. The full coverage of the upper (or lower surface) may also provide better fire protection due to the additional volume of the intumescent material as well as having no gaps between the fire barrier strip 25 and the fire prevention structures or insulation material.
Figure 19 shows an embodiment of the cavity tray 23 and fire barrier 25 described in Figures 17 and 18 in which the fire barrier 25 covers the total area of the lower surface of the cavity tray 23. Positioning the fire barrier 25 beneath the cavity tray 23, as shown, may be advantages should the upper surface of the cavity tray 23 be utilised by other infrastructure. Additionally, the surface of the intumescent material that forms the fire barrier 25 may be ridged and not substantially flat. Therefore, placing the fire barrier 25 beneath the cavity tray 23 allows for an unobstructed flow of water on the upper surface of the cavity tray 23. This may allow for more effective moisture removal from within the cavity.
Figure 20 shows a circular embodiment of a fire barrier 25 wrapped around a cavity tray 23, seen from a side-on cross section view. The circular shape allows the fire barrier 25 to wrap-a-around the cavity tray 23 and therefore attach onto both the upper and lower surfaces. This fire barrier 25 shape may be beneficial in terms of additional fire safety as it covers both the tray 23 surfaces. It may also be more convenient to position a fire barrier 25 of this shape onto the cavity tray 23 for attachment as it may naturally sit and 'hug' the cavity tray 23 in the desired position without falling away from the tray 23. Therefore, posing less dexterity challenges for the assembler.
Figures 21 and 22 show an embodiment in which the fire barrier 25 is positioned onto the masonry fagade facing surface of the vertical upstanding 21. The vertical upstanding 21 may function as a cavity tray 23 by collecting the moisture in the cavity through condensation and allowing it to flow onto the masonry support angle 19.
Figure 23a shows a cavity tray comprising: a tray section configured to extend at least partially between an inner cavity wall and an outer cavity wall, a fire prevention structure, wherein the fire prevention structure is configured to be positioned below the tray section, and to comprise a front face, wherein the front face is configured to face the outer cavity wall during use, and an inner face, wherein the inner face is configured to face the inner cavity wall during use, wherein both the front face and rear face comprise a fire prevention material.
Figure 23a shows a cavity tray 23 in accordance with an embodiment. This is an embodiment that is particularly adept at mitigating the risk of the spread of fire. The cavity tray itself comprises a tray section 61 and an attachment surface 63. In Figure 23a these are shown at an angle to one another. The cavity tray may also comprise a divider emanating from the end of the tray section 61 downwards. This is an optional feature. In this embodiment the divider is situated within the fire prevention structure 69.
Atop a portion of the tray section 61 is a fire prevention material 65. At the end of a the fire prevention material 65 is a lip 67 also formed of fire prevention material (not necessarily the same material - but often these are integral with one another). The lip is optional.
Beneath the tray section 61 is the fire prevention structure 69. This comprises a front face 71 and a rear face 73. Optionally, as shown in this embodiment, there is an intermediate portion 75 sandwiched between the front face and rear face. The front face 71 and rear face 75 are formed of a fire prevention material. The portion 75 is formed of an alternative fire prevention material in some embodiments.
In the embodiment shown the fire prevention material 65 positioned atop the tray section 61 is formed of intumescent material, as is the lip 67, and front face 71 and rear face 73. This means that in response to heat and/or fire the intumescent material will rapidly expand so as to prevent oxygen from reaching flames, in order to curtail the progress of the fire.
The fire prevention material 65 (which may be referred to as a fire barrier) atop the tray section 61 may expand vertically upwards to fill the cavity above the tray section 61. This may reach, or go towards the tray on the floor above. This may therefore reduce the chance of the fire spreading between floors.
The front face 71 and rear face 73 may both expand. The front face may expand until it reaches the outer cavity wall, and the rear face may expand until it reaches the
inner cavity wall. Therefore the front and rear faces together may form a barrier to prevent the spread of fire. The intermediate portion 75 formed from alternative fire prevention material which may be mineral wool, or other equivalent fire resistant materials, and may prevent fire, or hot air, from moving between the gap between the front and rear face. In other embodiments the front and rear faces may be directly attached to the divider 31 and so the alternative fire prevention material 75 may be removed. In some embodiments the intermediate portion 75 may aid in ensuring that the rear face expands to reach the inner cavity wall, or insulation abutting the inner cavity wall, and does not fall short. The intermediate portion may position the rear face 73 closer to the inner cavity wall to ensure this occurs. Moreover the thickness of the rear face is therefore not increased. A thickness of the intermediate portion 75 of 35mm may be suitable for this purpose.
The masonry support bracket may be designed such that there are no obstructions between the rear face of the fire prevention structure and the inner cavity wall (save as for some insulation which may be placed on the inner cavity wall). This may ensure that a barrier to fire and hot gases is created.
In Figures 23a and 23b the elements that may be formed from intumescent material are shown with diagonal shading to identify them. These are left unshaded in Figure 24 and the other remaining Figures.
In some embodiments the lip may not be formed from intumescent material. Instead the lip may be formed from an alternative fire prevention material. This may be a flexible material that holds it shape, and that optionally has a density lower than that of intumescent material. The lip may be attached to the fire barrier 65 atop the tray portion 61, or may be directly attached to the tray portion 61. The lip may be hinged about this connection. The lip may be configured in normal circumstances without fire to hang down at an angle, for example approximately 45 degrees. In the event of fire below the tray section 61 there will likely be a heat gradient within the cavity. Associated with the heat below the cavity there is also likely to be an increased pressure (due to any combustion - and due to the gases heating up and expanding). This increase in pressure can drive the lip to move about the hinge. Therefore, in the event of fire the lip may move to seal the gap between the end of the tray section 61 and the outer cavity wall. This may limit, or prevent, hot gases from passing from below the tray section to above the tray section. Sealing the gap may occur when the lip is parallel with the extent of the tray section 61. This may be the furthest that the hinge allows the lip to rotate in response to the increased pressure. The lip may be formed from a foil, or from glass fibres or the like. The lip may extend by 40-50mm,
preferably 45mm so that the majority/all of the distance to the outer cavity wall is filled by the lip once the lip has rotated - this reduces any gap between the end of the tray portion and the outer wall of the cavity.
Alternatively in some embodiments the lip could be formed from intumescent material. In such embodiments, the lip 67 may expand towards the outer cavity wall, and up, effectively expanding into the space between that filled by the front surface and the fire prevention material 65 on the tray section 61. The lip 67 may form a barrier in the gap between the cavity tray 23 and the outer cavity wall. The lip may be optional. In some embodiments the fire prevention material atop the tray section 61 may similarly be removed.
In some embodiment in normal use as water passes over the tray section 61 it may then pass over the lip and be directed to a tray below.
The use of these elements together is especially advantageous for reducing the risk of fire as the spread is drastically curtailed.
In Figure 23a the end of the fire prevention structure 69 is shown as being approximately flush with the end of the tray section 61. This may be the case in some embodiments. In others, a section adjacent the edge (either right most of left most) may be removed such that there is a gap. This may facilitate the overlapping of the cavity trays, and reduce the amount of work involved at site in the installation process. By leaving a small gap, such as 50mm at the edge of the fire prevention structure this may allow the cavity tray to be overlapped with an adjacent cavity tray. In some embodiments in which a gap is left the side face of the fire prevention structure 69 directly adjacent the gap may be covered by a fire prevention material, such as an intumescent material. This may then expand into the gap in the event of fire - such that the gap does not increase the risk of the spread of fire in any way.
Figure 23b shows the embodiment of Figure 23a in side view. This shows the cavity tray 23 formed of the tray section 61, and the attachment surface 63 (and optionally the divider 31 not shown).
Also shown are the fire prevention material 65 atop the tray portion 61, the lip 67, and the fire prevention structure formed of a front face 71, a rear face 73, and optionally the intermediate portion 75.
This side view may best aid in visualising how the intumescent material may expand to fill the cavity around the cavity tray in the event of a fire.
Figure 24a shows a masonry support element comprising a masonry support bracket, a masonry support angle, a cavity tray as shown in figure 23a -c, wherein the masonry support angle is configured to extend into the outer cavity wall, and to take the load of the outer cavity wall and transfer this load to the masonry support bracket, wherein the masonry support bracket is configured to be attached to the inner cavity wall, and is configured to transfer the load from the masonry support angle to the inner cavity wall, wherein the cavity tray is configured to sit above the masonry support angle such that water passing across the cavity tray drops down onto the masonry support angle.
The masonry support bracket and angle may be similar in structure to those shown in Figures 1-21, and the features disclosed in those Figures may be used in combination with those disclosed herein (with the exception only of those that are contradictory).
Figure 24a shows a cavity tray 23 attached to a masonry support element comprising a masonry support bracket 7 and a masonry support angle 19. The cavity tray i s attached to the masonry support element by attachment element 29. Attachment element 29 may be any suitable attachment element - such as that shown in Figure 14. In other embodiments the cavity tray may attach directly to the inner wall of the cavity.
As per Figure 23 the cavity tray 23 comprises a tray section 61, an attachment surface 63, a fire prevention material 65 situated atop the tray section 61, a lip 67 formed of fire prevention material, and a fire prevention structure with a front face 71 and a rear face 73. An intermediate portion 75 between the front face 71 and the rear face 73 is also shown - although this is entirely optional.
In Figure 23a element 7 is the masonry support bracket. Whilst some of the structure of this element is visible a lot is not and is it is not annotated in any detail. This is shown in more detail in figure 24b. It is noted however that in some embodiments a pair of first arms and/or second arms extends from a single first column.
The masonry support angle 19 is shown. This is configured to extend into the outer wall of the cavity. This provides support to the outer cavity wall such that the weight of the outer cavity wall is supported by the masonry support angle 19. This transfers this weight through the masonry support bracket to the inner cavity wall, or the internal building structure.
Additionally the masonry support angle is configured to be positioned below the cavity tray 23 and for water passing over the cavity tray 23 to pass on to the masonry support angle 19 below. This may then exit the outer cavity wall through weep holes or the like.
In this embodiment the cavity tray is principally designed to cause the water to pass to the masonry support angle 19. Additionally the lip 67 may further aid in this direction of water passing across the cavity tray.
Wall ties are also shown - and these are optional. The wall ties may provide a further fixation point between the masonry support bracket 7 and the outer cavity wall. This may prevent movement of the masonry support bracket relative to the outer cavity wall, and may aid in the transfer of weight to the masonry support bracket.
Figure 24b shows a side on view of the masonry support of Figure 24a. The cavity tray 23 is shown comprising the tray section 61 and attachment surface 63. The attachment surface 63 is attached to the masonry support bracket 7 by the attachment element 29. The fire prevention structure below the tray portion 61 is also shown. This is formed from the front surface 71, the rear face 73 and the intermediate portion 75 (optional).
Shown in more detail is the masonry support bracket 7. The masonry support bracket comprises an arm 11, a first column 9, a second column 15, a first arm 11, a second arm 13, and a central void 17. It is noted that in some embodiments the second arm may not be present. In others the void may not be present and may be infilled. A portion of the first column may extend across - perpendicular to the portion shown in Figure 24b.
The central void may be advantageous for saving weight so that it is simpler to install the masonry support bracket 7, as well as being cheaper to produce.
The arm 11 forming two portions that are angled to one another allows the tray portion 61 to be separated from the top edge of the arm. This in turn enables the fire prevention structure to be positioned between the tray portion 61 and the arm 11. In the event of a fire this provides additional protection to prevent the spread as discussed above in relation to Figure 23.
The first portion and second portion of the arm are joined at an elbow such that they are angled relative to one another. This angle is the same (or similar) to the angle between the tray portion 61 and the attachment surface 63 of the cavity tray.
The fire prevention structure is positioned above the second column 15 of the masonry support bracket 7, and optionally above a portion of the masonry support angle 19.
Figure 24c shows the front view of the masonry support. This shows the attachment surface 63, the fire prevention material 65, the lip 67, the fire prevention structure 68, and the masonry support angle 19. The masonry support bracket 7 is also shown. This shows the additional portion of the first column 9. The portion of the first column 15 visible in Figure 24c is perpendicular to the portion of the first column 15 visible in Figure 24b.
Figure 25a shows an additional alternative embodiment of the masonry support element 7. In this embodiment the cavity tray is unchanged as compared to that shown in Figure 24.
The first arm is once again formed of two portions. However, the first arm comprises a shoulder portion configured for a portion of the tray portion 61 of the cavity tray 23 to sit on. This may secure the position of the cavity tray, and prevent and oscillations of the tray if there is a large force associated with the movement of air within the cavity.
Figure 25b shows a further additional alternative embodiment of the masonry support element. The cavity tray 23 is once again unchanged with respect to Figure 24.
The first arm in this embodiment is not formed of two portions, but instead of a single portion. This extends from the point at which the cavity tray 23 attaches to the masonry support bracket 7, to the end of the arm, where a second column is positioned in this embodiment. The end of the arm sits below the fire prevention structure.
It is noted that in some embodiment either the arm or the second column comprises a flat surface that the base of the fire prevention structure sits on. Indeed in some such embodiments the fire prevention structure is attached directly to the masonry support bracket 7 at this point. Any suitable attachment may be used such as the rivets discussed above. Moreover, a divider may extend from the arm or second column up and within the fire prevention structure. The fire prevention structure may then be secured to the divider. In some embodiments the fire prevention structure may be secured both to the cavity tray 23 and to the masonry support bracket 7, although in others it may be secured to only one of these two elements.
Figure 26 shows the structure of the masonry support and the cavity tray without the fire prevention structure or fire prevention material present. The masonry support element, or the masonry support bracket alone, may be sold without the fire prevention structure, or the fire prevention material, or intumescent material in some circumstances. This may then be retrofitted on if the owner desires. The fire prevention structure may therefore also form a self-contained product in its own right. Therefore, the divider 31 is visible. This extends down from the tray portion 61. It is noted that in this embodiment it extends form the end of the tray portion 61, but it may extend below the tray portion 61 at a position that is not at the very end of the tray portion 61.
The divider may be used to attach the fire prevention structure 69 to the cavity tray 23. For example, the front face 71 may directly attach to the divider 31. In some embodiments the rear face 73 may also directly attach to the divider 31. In other embodiments an intermediate portion may be positioned between the divider and one of these faces, such as the rear face 73.
The divider may attach to the fire prevention surface by any suitable jointing means. For example, rivets may be used so that no hot air can pass through the jointing means in the case of fire. Rivets may be positioned through the front face 71 and through the divider 31, and/or through the rear face 73 and through the divider 31. In cases where an intermediate portion 75 is also used rivets would pass through the intermediate portion 75 as well.
In some embodiments the divider may be castellated. The divider may form a non- continuous structure, such that form above/below it appears as a dashed line. This may reduce the weight associated with the divider, and therefore the weight of the cavity tray.
Alternatively, the divider may be removed. In such embodiments the fire prevention structure 69 may be attached to the cavity tray 23 by rivets that attach through the tray portion 61. These rivets may also pass through the fire prevention material 65 in some embodiments. The rivets may pass into the intermediate portion 75. Washers may be used to secure the rivets in the intermediate portion 75 if needed. For example if mineral wool is used in intermediate portion 75 then this may keep the fire prevention structure 69 in a secure position.
In embodiments the cavity tray or masonry support may be installed in a building, such as a high rise building comprising more than 18 stories or floors. In particular a
cavity tray may be installed on one floor (for example the ninth floor), and a second cavity tray may be installed at the floor above (in this case the tenth floor). This may be particularly advantageous if the second tray is above the first so that in the event of fire the fire prevention material 65 atop the tray section 71 on the first tray on the ninth floor expands towards the second cavity tray on the tenth floor. This then reduces the air between the two trays - making it difficult for the fire to spread between the floors, and therefore slowing the fires progress.
Figure 27 shows the steps of a method for preparing the cavity tray (or masonry support) as shown in Figures 23-25 for installation. In these embodiments the fire prevention structure extends so that it is approximately flush with the rightmost and/or leftmost portions of the tray portion 61. In installation of cavity trays it is common for there to be a short distance of overlap between the trays. This can be used to prevent water passage becoming uncontrolled, and to prevent the passing of hot air/flames in the event of fire. This overlapping distance is typically around 50mm. For cavity trays without a fire prevention structure the tray portion 61 typically has enough flexibility to enable such overlap without modifying the tray in any way. However, the fire prevention structure 69 is thicker than the tray portion 61 and therefore modification is needed to enable overlap in some cases.
The first step therefore comprises providing a first cavity tray 81. At least one end of the fire prevention structure 69 is then trimmed by cutting the rightmost and/or leftmost end of the fire prevention structure 83. This removes a pre-set length of the fire prevention structure (for example 50mm).
A second tray is then provided 85. This is then overlapped with the first tray by the pre-set length 87. Alternatively the fire prevention structure on both trays may be trimmed by a portion such that the total timed is equal to the pre-set length.
Figure 28 shows the attachment element in cross section. The attachment element comprises a proximal arm 89, a distal arm 91. Below the proximal arm is a first recess 93. Below the distal arm 91 is a second recess 95. Within the second recess 95 is a tooth 97. The tooth 97 divides the second passage 95 into a first passage and a second passage 99. The first passage is adjacent the anterior side 115 of the tooth, and the second passage is adjacent the posterior 113 side of the tooth.
Also shown in Figure 28 are the top surface of the proximal arm 107, and the underside of the proximal arm 105. Similarly, the top side of the distal arm 111 and
the underside of the distal arm 109 are also shown. The anterior side of the tooth 115 and the posterior side of the tooth 113 are also shown.
It is noted that "below" means adjacent the underside 105, 109 of the proximal 89 or distal 91 arms. Therefore, the second recess 95 being below the distal arm 91 comprises the second recess 95 being adjacent the underside 109 of the distal arm 91.
The first recess 93 and the second recess 95 are shown as being joined together to form a single void. The first recess 93 and second recess 95 share a base 103.
The tooth 97 is positioned within the second recess 95. It is noted that in other embodiments the tooth 97 rests directly on top of the base 103. However, in the embodiment shown in Figure 28 the tooth 97 is elevated above the base 103 such that second passage 99 is formed. The second passage is positioned between the posterior side of the tooth 113 and the base 103.
A channel is also shown in Figure 1. This is the space between the proximal arm 89 and the distal arm 91. The channel connects the first recess 93 and second recess 91 with the outside environment.
The anterior side of the tooth 115 is angled relative to the underside of the distal arm 109. Similarly, the underside of the proximal arm 105 is angled relative to the base 103. In both of these cases the angle may be between 5 and 20 degrees (relative to one another). This angle may preferably be between 14 and 18 degrees, and most optimally may be 16 degrees. This angular range may make the secondary element simple to fit to the attachment element 29. The two angles may be the same to enable the secondary element to slide form the anterior side of the tooth 115 to the underside of the proximal arm 105 easily during installation.
The posterior side of the tooth 113 is parallel with the base 103 such that the passage 99 is approximately cuboidal.
In Figure 28 the underside of the distal arm 109 is further from the base than the underside of the proximal arm 105. Indeed, the underside of the distal arm 109 is further from the base 103 than the top side of the proximal arm 107.
The distal arm forms an elongate bar as the top side 111 and underside 109 are parallel. These surfaces are parallel to both the top side of the proximal arm and the base 103, and the posterior side of the tooth 113.
As shown in the Figures below a secondary element may co-operate with the attachment element to couple together. An element may slide along the top surface of the proximal arm 107, and then onto the underside of the distal arm 109 (passing across the channel 101 whilst doing so). Once inside the second recess 95 the secondary device may be pivoted onto the anterior surface of the tooth 115, and then slid onto the underside of the proximal arm 105 in the first recess 93. The secondary element may then be further pivoted to be flush with the base 103. Optionally the secondary element may then be slid into the passage 99.
Figure 29 shows a cavity tray with means for attachment to the attachment element. The cavity tray may be used in the masonry support element 1 as described in the above figures. The cavity tray 23 comprises a bar 117. The bar may act as the secondary element to co-operate with the attachment element 29. Either side of the bar 117 are voids 119, 121. The first void 119 extends from the bar 117 to the first edge of the cavity tray. The bar 117 therefore makes up a portion of the perimeter of the cavity tray 23. The second void 121 extends from the bar towards the interior of the cavity tray 23. The second void 121 is therefore surrounded by material of the cavity tray 23. The voids 119, 121 may be used to provide space for manoeuvring the bar through the attachment element 29. In advantageous embodiments the voids may be 8-12mm in length (that is the dimension perpendicularly away from the bar). A distance of 10mm may be particularly advantageous.
It is noted that there are two sets of bar 117, first void 119, and second void 121 close together to form a pair. This may be useful in creating a secure attachment between a masonry support element and the cavity tray. For example, an attachment element may be situated above two arms of a masonry support element, either side of the first column 9.
The bar 117 has a width of between 3mm and 7mm, and preferably 5mm. This may fit particularly well with the attachment element 29.
It is also noted that in Figure 29 there are two pairs of bars 117. This may provide a particularly secure attachment between a cavity tray 23 and a masonry support element 1, particularly a masonry support element 1 containing two brackets 7.
Figure 30 shows a close up of the attachment means of the cavity tray. This shows the bar 117, first void 119 and second void 121 in more detail. The bar is approximately flat with a thickness significantly smaller than tis length or width. The bar may have a thickness or depth of approximately 0.5mm.
In Figure 30 the first void 119 is shown as being longer than the second void 121. This may allow the bar to be offset from the top of the cavity tray such that it is simpler to manoeuvre the cavity tray during installation. The first void 119 may be 12mm long, and the second void 121 may be 8mm long in this embodiment.
Figure 31a is a close up of the attachment means of the cavity tray from above. This shows the bar 117, first void 119 and second void 121 in more detail.
Figure 31b is a view of the cavity tray from above. This shows that the bar 117, first void 119, and second void 121 may all be positioned on a raised secondary angled section 27 of the cavity tray.
It is noted that the length of the first and second voids may be 1mm longer than the length of the top side of the distal arm in some embodiments, and may be 1mm longer than the distance between the rear of the distal arm and the tooth.
Figure 32 shows the attachment means of the cavity tray attached to the attachment element. This shows the cavity tray 23 within the attachment means 29. This is in the final position once the two are attached. The bar 117 is shown as being held within the second passage 99, below the tooth 97.
It is noted that the second passage may have a depth approximately equal to the depth of the bar - however the second passage may comprise an additional tolerance to ensure the bar fits within the second passage. This tolerance may be 0.1mm for example.
Similarly, (as explained above) the distance between the base 103 and the top of the proximal arm 107 is less than the distance between the base 103 and the underside of the distal arm 109, and wherein the difference between these distances is equal to the depth of the bar. This distance may also include an additional tolerance, for example of 0.1mm.
The width of the bar 117 may be wider than the channel 101, such that the bar 117 may only enter the channel at a specific angle.
Figure 33 shows one step in the process of attaching the cavity tray to the attachment element. This is shown from above (Figure 33A), cross section (Figure 33B), and perspective view (Figure 33C). It is noted that a first step may include sliding the bar 117 along the top surface of the proximal arm 107. However, this first step is not essential in all configurations and so is omitted from the drawings herein.
This stage shows the bar 117 being positioned under the underside of the distal arm 109. The bar is shown within the second recess 95. To get to this position the bar 117 may have passed through the channel 101.
This embodiment shows that the length of the distal arm is optionally 0.5mm (or more) greater than the width of the bar 117. This may provide space to make it simple to pivot the bar 117 (the next step shown in Figure 34).
This embodiment may also show that the distance between the end of the proximal arm and the tooth is at least half of the width of the bar. This is entirely optional, and may simply make the pivoting of the bar simpler. However, if this is not the case whilst the pivoting may be less ergonomic for the user, it can still be done to fit the bar to the attachment element.
Figure 34 shows a further step of the method of Figure 33. The same perspectives as used in Figure 33 are used for Figure 34. Figure 34 (as compared to Figure 33) shows the bar 117 being pivoted within the second recess 95. The bar then sits on the anterior surface of the tooth 115.
Figure 35 shows a further step of the method of Figures 33 and 34. The same perspectives as used in Figures 33 and 34 are used in Figure 35. Figure 35 (as compared with figure 34) shows the bar 117 slid into the first recess 93 to the underside of the proximal arm 105.
In this embodiment the length of the base to the entrance of the second passage 99 is at least 0.5mm greater than the width of the bar. This may make it simple to pivot the bar during installation (in particular the second pivoting action described below) - however shorter measurements may also be used.
Figure 36 shows a further step of the method shown in Figures 33 to 35. The same perspectives as used in Figures 33-35 are used in figure 36. Figure 36 (as compared to Figure 35) shows the bar 117 having been pivoted to be flush with the base 103. An optional step is also shown in which the bar 117 is slid into the second passage 99 between the base 103 and the posterior of the tooth 113. This final entry into the second passage 99 is optional, but may advantageously secure the bar 117 in place such that without human intervention it is extremely unlikely to move.
In this embodiment the length of the second passage 99 is at least half of the width of the bar. This means that half of the bar is contained within the second passage 99 in order to secure the bar 117. As stated above the second passage is entirely
optional, and some embodiments may have a shorter passage for manufacturing purposes (although this may make the bar 117 less secure in use).
A method of making the above described devices may include welding, forming, casting or any other suitable equivalent process.
The above embodiments are to be understood as illustrative examples. Further embodiments are also envisaged. It is to be understood that any feature described in relation to any one embodiment may be used alone, or in combination with other features described and may also be used in combination with one or more features of any other of the embodiments, or any combination of any other of the embodiments.
Furthermore, equivalents and modifications not described above may also be employed without departing from the scope of the invention, which is defined in the accompanying claims.
In some examples, one or more memory elements can store data and/or program instructions used to implement manufacture of devices described herein. Embodiments of the disclosure provide tangible, non -transitory storage media comprising program instructions operable to program a processor to said manufacture method and/or claimed herein.
The processor of such manufacturing apparatus (and any of the methods, activities or instructions outlined herein) may be implemented with fixed logic such as assemblies of logic gates or programmable logic such as software and/or computer program instructions executed by a processor. Other kinds of programmable logic include programmable processors, programmable digital logic (e.g. a field programmable gate array (FPGA), an erasable programmable read only memory (EPROM), an electrically erasable programmable read only memory (EEPROM), an application specific integrated circuit (ASIC) or any other kind of digital logic, software, code, electronic instructions, flash memory, optical disks, CD-ROMs, DVD ROMs, magnetic or optical cards, other types of machine-readable mediums suitable for storing electronic instructions, or any suitable combination thereof. Such data storage media may also provide the data storage of the manufacturing device.
Claims
1. A masonry support element configured to sit in a cavity between an internal building structure and a fagade, and to transfer the load of the fagade to the internal building structure, the masonry support element comprising: a masonry support bracket; a masonry support angle; a cavity tray; wherein the masonry support angle is configured to extend into the fagade, and to take the load of the fagade and transfer this load to the masonry support bracket; wherein the masonry support bracket is configured to be attached to the internal building structure, and is configured to transfer the load from the masonry support angle to the internal building structure; wherein the masonry support bracket comprises a first column configured to lie parallel with the internal building structure, and at least one arm extending perpendicular to the column away from the internal building structure and towards the fagade, wherein the masonry support angle is attached to the masonry support bracket; wherein the cavity tray is configured to overlie the at least one arm of the masonry support bracket; wherein the cavity tray is configured to collect moisture within the cavity, and to provide an alternative path for said water to take across the cavity tray; wherein the cavity tray sits above the masonry support angle such that water passing across the cavity tray drops down onto the masonry support angle.
2. The masonry support element of claim 1 or the masonry support bracket of claim 29, further comprising a second column attached to the other end of the at least one arm, wherein the second column is perpendicular to at least a portion of the first column and is angled relative to the at least one arm, optionally wherein angled to comprises the arm extending from the first column towards the fagade, and the second column extending from the first arm downwards, approximately parallel to the fagade.
3. The masonry support element of claim 2, wherein the arm is a sheet, and is in a two dimensional plane, and wherein the second column is in the same two- dimensional plane.
4. The masonry support element of any preceding claim, wherein the masonry support angle being attached to the masonry support bracket comprises the masonry support angle being attached to the second column of the masonry support bracket.
5. The masonry support element of any preceding claim or the masonry support bracket of claim 29, wherein the at least one arm comprises two arms extending from the first column, such that the proximal end of the arms are attached to the first column, optionally when dependent on claim 2, wherein the distal ends of both the first arm and the second arm are attached to the second column.
6. The masonry support element of claim 5, wherein there is a void between the first and second arms.
7. The masonry support element of any of claims 5-6, wherein the first arm emanates from the top of the first column, and the second arm emanates from the bottom of the first column.
8. The masonry support element of any of claims 5-7, wherein the masonry support bracket comprises a second pair of arms, the third arm and fourth arm, that extend from the first column, optionally wherein the third arm and fourth arm are parallel to the first arm and second arm, optionally wherein the third arm and fourth arm are both joined to a third column, optionally when dependent on claim 2, wherein the third column is perpendicular to at least a portion of the first column, and is parallel to the second column, optionally wherein the third column is angled relative to the third arm and the fourth arm, wherein the third and fourth arm extend from the first column towards the fagade, and wherein the third column is approximately parallel the fagade, optionally wherein the arm is a sheet, and is in a two dimensional plane, and wherein the third column is in the same two-dimensional plane.
9. The masonry support element of claim 8, wherein there is a void between the third arm and the fourth arm.
10. The masonry support element of any preceding claim or the masonry support bracket of claim 29, wherein the first column comprises a sheet of material,
preferably metal, preferably stainless steel; and/or wherein the at least one arm comprises a sheet of material, preferably metal, preferably stainless steel.
11. The masonry support element of any preceding claim or the masonry support bracket of claim 29, wherein the top surface of the at least one arm comprises an indent, optionally wherein a fire barrier or fire prevention material sits within the indent, such that the fire barrier is positioned between the at least one arm and the cavity tray, optionally wherein the fire barrier is an intumescent material.
12. The masonry support element of any preceding claim, wherein a fire barrier is positioned between the cavity tray and the at least one arm, optionally wherein the fire barrier is an intumescent material.
13. The masonry support element of any preceding claim, wherein a fire barrier is positioned atop the cavity tray, optionally wherein the fire barrier is an intumescent material.
14. The masonry support element of any preceding claim, wherein a fire prevention structure is positioned atop the cavity tray, optionally wherein the fire prevention structure comprises mineral wool.
15. The masonry support element of any preceding claim, further comprising a wall tie attached to the masonry support bracket, optionally attached to the second column of the masonry support bracket, optionally wherein the wall tie is attached to a slot within the masonry support bracket, allowing the height of the wall tie to be adjusted.
16. The masonry support element of any preceding claim or the cavity tray and fire barrier of claim 53, wherein the cavity tray comprises a metal sheet, preferably of a thickness of up to 2mm, preferably wherein the thickness is 0.5mm.
17. The masonry support element of any preceding claim, wherein the cavity tray is angled relative to the horizontal, preferably wherein the angle is between 3 and 10 degrees, and preferably wherein the angle is 5 degrees, optionally wherein the cavity tray further comprises a second angled section at a greater angle to the horizontal than the rest of the cavity tray, wherein the second angled section is positioned adjacent the first column, optionally wherein the greater angle is 50 degrees from horizontal, optionally wherein the second angled portion comprises the attachment point to attach the cavity tray to the masonry support bracket.
18. The masonry support element of any preceding claim, wherein the cavity tray extends to overlie at least a portion of the first column of the masonry support bracket, optionally wherein the cavity tray overhangs the end of the at least one arm, and the second column, optionally wherein at the end of the overhang of the cavity tray the cavity tray comprises a lip, optionally wherein the lip extends downwards, optionally vertically down parallel to the internal building structure.
19. The masonry support element of any preceding claim, wherein the cavity tray is attached to the masonry support bracket by one of a mechanical join, an adhesive join or a welded join, optionally wherein the cavity tray is attached to the masonry support bracket by an attachment element.
20. The masonry support element of any preceding claim, wherein the masonry support angle comprises an upstanding element such that the upstanding is attached to the at least one arm and/or second column of the masonry support bracket, optionally wherein the upstanding element extends at least 50mm from the horizontal plane of the portion of the masonry support angle that extends into the fagade, further optionally wherein this extension is at least 100mm, optionally wherein the upstanding element is perpendicular to the portion of the masonry support angle configured to extend into the fagade, optionally wherein the upstanding comprises a cut-out at the top edge of the upstanding, wherein the cutout is positioned in line with the central void of the first column, optionally further comprising a cover to cover the cut-out of the upstanding when installed.
21. The masonry support element of any preceding claim or the masonry support bracket of claim 29, wherein the first column comprises a central void.
22. The masonry support element of any preceding claim or the masonry support bracket of claim 29, wherein a primary attachment between the masonry support bracket, and optionally the internal building structure is positioned at the top of the first column, optionally within 45mm of the top of the first column.
23. The masonry support element of claim 22, when dependent on claim 21, wherein the primary attachment is through the central void of the first column.
24. The masonry support element of any of claims 22-23, further comprising a secondary attachment between the masonry support bracket and the internal building structure, optionally wherein the secondary attachment is positioned at the bottom of the first column, and optionally within 75mm of the primary attachment, optionally wherein the secondary attachment is through the central void, or wherein
the secondary attachment is through a secondary void in the first column, optionally wherein one or both of the primary and secondary attachments are in the form of a bolt into the internal building structure.
25. The masonry support element of any preceding claim, wherein a side of the cavity tray, parallel to the at least one arm, comprises a lip, optionally wherein both sides parallel to the at least one arm comprise a lip, optionally wherein the lip rises from the cavity tray to prevent water from passing to the side and off of the cavity tray.
26. The masonry support element of any preceding claim, wherein the at least one arm, or the second column, comprises a slot into which the upstanding of the masonry support angle is positioned.
27. The masonry support element of any preceding claim or the masonry support bracket of claim 29, wherein the first column comprises a notch, such that there is an offset from a first portion of the column to a second portion.
28. The masonry support element of any preceding claim or the masonry support bracket of claim 29, wherein each masonry support bracket comprises a pair of brackets attached to a single masonry support angle, optionally wherein each of the masonry support brackets are positioned angled to one another, optionally perpendicular to one another, optionally wherein the masonry support angle comprises a first section and a second section are angled to one another, optionally perpendicular to one another, optionally wherein the cavity tray comprises a first and second section angled to one another, optionally perpendicular to one another, optionally wherein the masonry support element is configured to attach as a single unit around an external/internal corner of the internal building structure.
29. A masonry support bracket for transferring the load of a building fagade to the internal building structure, wherein the masonry support bracket comprises: a first column, and at least one arm extending perpendicular to the first column away from the internal building structure and towards the fagade; wherein the first column is configured to lie parallel with the internal building structure; wherein the first column is configured to attach to the internal building structure.
30. The masonry support bracket of claim 29, wherein the masonry support bracket attaches onto a masonry support angle; wherein the masonry support bracket is configured to transfer the load from the masonry support angle to the internal building structure; wherein the masonry support angle is configured to extend into the fagade, and to take the load of the fagade and transfer this load to the masonry support bracket.
31. A cavity tray comprising: a tray section configured to extend at least partially between an inner cavity wall and an outer cavity wall; a fire prevention structure, wherein the fire prevention structure is configured to be positioned below the tray section, and to comprise a front face, wherein the front face is configured to face the outer cavity wall during use, and an inner face, wherein the inner face is configured to face the inner cavity wall during use; wherein both the front face and rear face comprise a fire prevention material.
32. The cavity tray of claims 31, further comprising fire prevention material covering at least a portion of the tray section, preferably wherein the fire prevention material covers the portion of the tray section configured to be positioned closest to the outer cavity wall during use.
33. The cavity tray of claims 31 or 32, further comprising a lip formed of fire prevention material extending from the edge of the tray section that is configured to be closest to the outer cavity wall during use, preferably wherein the lip extends at an angle to the tray section, further preferably wherein the lip is angled further downwards as compared to the tray section, optionally wherein the lip is hinged with the end of the tray section, or the fire prevention material covering the tray section, further optionally wherein the lip is configured such that when heat and an associated increase in pressure occurs below the tray section, the lip moves about the hinge so as to block at least a portion of any gap between the end of the tray section and the outer cavity wall, optionally wherein the lip extends between 40- 50mm beyond the edge of the tray section, preferably wherein this distance is 45mm, optionally wherein the lip is configured to aid in the direction of water off of the tray section, such that water passing off of the tray section is directed onto a further tray below, optionally wherein the lip is formed of non-expansive fire prevention material.
34. The cavity tray of any of claims 31 to 33, wherein the fire prevention structure comprises an intermediate portion situated between the front face and the rear face.
35. The cavity tray of any of claims 31 to 34, wherein the fire prevention material is an intumescent material.
36. The cavity tray of claim 35 when dependent on claim 34, wherein the fire prevention structure comprises a first outer layer of intumescent material forming the front face, and a second outer layer of intumescent material forming the rear face, with a layer of alternative fire prevention material situated there between forming the intermediate portion, preferably wherein the alternative fire prevention material is mineral wool.
37. The cavity tray of any of claims 31 to 36, wherein the tray section comprises a divider configured to extend downwards in the cavity, and wherein the front and rear surfaces are separated by the divider, optionally wherein the alternative fire prevention material is situated adjacent the divider and the rear face, optionally wherein the divider is castellated.
38. The cavity tray of any of claims 31 to 37, wherein a jointing structure attaches the fire prevention structure to the cavity tray, optionally wherein the jointing structure comprises rivets, optionally wherein rivets are configured to protrude through the divider and at least one of the front face and/or rear face, and optionally wherein the rivets protrude through both the front face and rear face, or optionally wherein the rivets are configured to protrude through the tray section and into the alternative fire prevention material, further optionally wherein washers are used to hold rivets within the alternative fire prevention material, optionally wherein the divider is absent when the tray section is used as the point of connection between the fire prevention structure and the cavity tray.
39. The cavity tray of any of claims 31 to 38, wherein the rightmost and/or leftmost portion of the fire prevention structure terminates prior to the rightmost and/or leftmost portion of the tray section such that a gap is left at the rightmost and/or leftmost end of the fire prevention structure, optionally wherein said gap is to enable adjacent cavity trays to be fitted with an overlapping section, optionally wherein said gap is 50mm, optionally wherein the rightmost and/or leftmost portion of the fire prevention structure comprises a fire prevention material situated at the end face, optionally wherein the fire prevention material is intumescent material.
40. The cavity tray of any of claims 31 to 39, comprising an attachment surface, attached to the tray section, and configured to attach the tray section to an external component during use, optionally wherein the external component is a masonry support element or the inner cavity wall.
41. A masonry support element comprising: a masonry support bracket; a masonry support angle; a cavity tray as set out in any of claims 31-40; wherein the masonry support angle is configured to extend into the outer cavity wall, and to take the load of the outer cavity wall and transfer this load to the masonry support bracket; wherein the masonry support bracket is configured to be attached to the inner cavity wall, and is configured to transfer the load from the masonry support angle to the inner cavity wall; wherein the cavity tray is configured to sit above the masonry support angle such that water passing across the cavity tray drops down onto the masonry support angle.
42. A masonry support element comprising: a masonry support bracket; a masonry support angle; a fire prevention structure; wherein the masonry support angle is configured to extend into the outer cavity wall, and to take the load of the outer cavity wall and transfer this load to the masonry support bracket; wherein the masonry support bracket is configured to be attached to the inner cavity wall, and is configured to transfer the load from the masonry support angle to the inner cavity wall; wherein the fire prevention structure comprises a front face, wherein the front face is configured to face the outer cavity wall during use, and an inner face, wherein the inner face is configured to face the inner cavity wall during use; wherein both the front face and rear face comprise a fire prevention material.
43. The masonry support element of claims 41 or 42, wherein the fire prevention material is an intumescent material.
44. The masonry support element of claims 42 or 43, further comprising a cavity tray, wherein the cavity tray is configured to sit above the masonry support angle such that water passing across the cavity tray drops down onto the masonry support angle, preferably wherein the cavity tray is the cavity tray of any of claims 31-40.
45. The masonry support element of any of claims 41 to 44, wherein the fire prevention structure is configured to sit above or on a portion of the masonry support bracket, optionally: wherein the masonry support bracket is formed from an arm extending from the inner cavity wall to the outer cavity wall, and wherein the fire prevention structure is configured to sit on or above the arm; and/or wherein the masonry support bracket is formed from a first column parallel to the inner cavity wall, an arm extending from the inner cavity wall to the outer cavity wall, and a second column at the end of the arm, wherein the fire prevention structure is configured to sit on or above the second column.
46. The masonry support element of claims 41 to 45, wherein the volume between the inner cavity wall and the rear face of the fire prevention structure is kept clear of any obstructions, preferably wherein a layer of insulation is positioned on the surface of the inner cavity wall, optionally wherein no portion of the masonry support bracket is configured to be situated between the rear face of the fire prevention structure and the inner cavity wall.
47. The masonry support element of any of claims 41 to 46, wherein the masonry support bracket comprises a first column configured to lie parallel with the internal cavity wall, and at least one arm extending away from the internal building structure and towards the outer cavity wall.
48. The masonry support element of claims 45 to 47, wherein the arm is formed from a first portion and a second portion that are angled to one another, optionally wherein the first portion emanates from the attachment surface of the cavity tray, and the second portion extends towards the masonry support angle, optionally wherein the angle between the first portion and the second portion of the arm is the same as the angle between the attachment surface and the tray portion.
49. The masonry support element of any of claims 41 to 48, further comprising a wall tie attached to the masonry support bracket.
50. A masonry support bracket comprising: a first column configured to lie parallel to the inner cavity wall; a first arm extending from the first column towards the outer cavity wall; wherein the first arm comprises a first portion and a second portion that are angled relative to one another.
51. The masonry support bracket of claim 50, further comprising a second column, wherein the second portion of the arm terminates at the second column, wherein the second column is configured to be attached to a masonry support angle.
52. The masonry support bracket of claims 50 or 51, wherein the first portion of the arm is configured to be attached to a cavity tray, such that in use the cavity tray is positioned above the second portion of the arm.
53. The masonry support bracket of claims 50 to 52, further comprising a fire prevention structure configured to be attached on to or above the second portion of the arm or the second column.
54. A cavity tray and fire barrier configured to sit in a cavity between an internal building structure and a fagade; wherein the cavity tray is configured to collect moisture within the cavity, and to provide an alternative path for said water to take across the cavity tray; wherein the fire barrier is configured to be positioned either: atop the cavity tray; or beneath the cavity tray.
55. The cavity tray and fire barrier of claim 54, wherein the fire barrier is configured to be positioned atop the cavity tray through a mechanical attachment.
56. The cavity tray and fire barrier of claim 55, wherein the mechanical attachment is one of: rivets, bolts, crimping or clips.
57. The cavity tray and fire barrier of any preceding claim, wherein the fire barrier is a strip.
58. The cavity tray and fire barrier of claim 57, wherein the strip of fire barrier is dimensioned to cover either a portion or all of the cavity tray surface to which it is attached.
59. The cavity tray and fire barrier of claim 57, when dependant on claim 55, wherein each strip of fire barrier is configured to be attached to the cavity tray by at least two mechanical attachments.
60. The cavity tray and fire barrier of claim 59, wherein the mechanical attachments are positioned longitudinally separated from one another on each strip of fire barrier such that the fire barrier is constrained to the cavity tray along its length.
61. The cavity tray and fire barrier of any of claims 54 to 60, wherein the fire barrier is configured to cover a portion of the total area of a cavity tray surface onto which it is attached, optionally wherein the cavity tray surface is the top surface.
62. The cavity tray and fire barrier of claim 61, wherein the fire barrier is configured to cover a portion of the total width of the cavity tray surface spanning from its distal end towards the proximal end, wherein the distal end is the end of the cavity tray configured to be adjacent the fagade and wherein the proximal end is configured to be adjacent the internal building structure, optionally wherein the fire barrier is configured to cover the very distal end of the cavity tray surface to which it is attached.
63. The cavity tray and fire barrier of claim 62, when dependant on claim 57, wherein the cavity tray surface is covered in the transverse direction by either one strip of fire barrier or a plurality of strips of fire barriers arranged adjacent one another.
64. The cavity tray and fire barrier of claim 61, wherein the fire barrier is configured to cover the majority of the length of the cavity tray surface, wherein length is defined in the longitudinal direction of the cavity tray.
65. The cavity tray and fire barrier of claim 64, when dependant on claim 57, wherein the cavity tray surface is covered in the longitudinal direction by either one strip of fire barrier or a plurality of strips of fire barriers arranged adjacent one another in the longitudinal direction, optionally wherein a gap is left between longitudinally adjacent fire barriers.
66. The cavity tray and fire barrier of any of claims 54 to 65, wherein a fire prevention structure is configured to be positioned atop the cavity tray, optionally wherein the upper surface of the cavity tray uncovered by the fire prevention structure is configured to be covered by the fire barrier, optionally wherein a portion of the upper surface of the cavity tray is left exposed, further optionally wherein the fire prevention structure comprises mineral wool.
67. The cavity tray and fire barrier of any of claims 54 to 66, wherein a side of the cavity tray comprises a lip, optionally wherein both sides of the cavity tray comprise a lip, further optionally wherein the lip rises from the cavity tray to prevent water from passing to the side and off of the cavity tray.
68. The cavity tray and fire barrier of claim 67, wherein the angle of the lip relative to the horizontal is between 10° to 90°, preferably wherein the angle is 90°.
69. The cavity tray and fire barrier of any of claims 54 to 68, wherein a first cavity tray is configured to lay longitudinally adjacent a second cavity tray, optionally wherein a portion of one tray overlies a portion of a second tray such that there is no passage for water in between cavity trays.
70. The cavity tray and fire barrier of any of claims 54 to 69, wherein the cavity tray is configured to be attached to the internal building structure, optionally wherein the cavity tray is configured to be attached to a load carrying feature in connection with the internal building structure, further optionally wherein the cavity tray is configured to attach to the internal building structure by one of: a mechanical join, an adhesive join, a welded join or an attachment element.
71. The cavity tray and fire barrier of claim 70, wherein the load carrying feature is a masonry support bracket, optionally wherein the cavity tray is attached to the masonry support bracket by one of a mechanical join, an adhesive join or a welded join, further optionally wherein the cavity tray is attached to the masonry support bracket by an attachment element.
72. The cavity tray and fire barrier of any of claims 54 to 71, wherein the cavity tray is configured to be angled relative to the horizontal, optionally wherein the angle is
between 3 and 10 degrees, and preferably wherein the angle is 5 degrees, wherein the cavity tray further comprises a second angled section at a greater angle to the horizontal than the rest of the cavity tray, wherein the second angled section is configured to be positioned adjacent the internal building structure, optionally wherein the second angle is 50 degrees from the horizontal, optionally wherein the second angled portion comprises an attachment means, optionally wherein the cavity tray comprises a lip at its distal end, optionally wherein the lip extends downwards, optionally vertically down and parallel to the internal building structure.
73. The cavity tray and fire barrier of any of claims 54 to 72, wherein the fire barrier is an intumescent material.
74. An attachment element configured to attach to a secondary element, the attachment element comprising: a proximal arm; a distal arm; a channel between the proximal arm and the distal arm; the channel leading to a first recess positioned below the proximal arm and a second recess positioned below the distal arm; and a tooth positioned within the second recess.
75. The attachment element of claim 74, wherein the attachment element is positioned on a masonry support element, optionally wherein the masonry support element is a masonry support bracket, and is configured to attach to a building structure.
76. The attachment element of claim 75, wherein the proximal arm is located on the masonry support element, and/or wherein the distal arm is located on the masonry support element.
77. The attachment element of any of claims 74 to 76, wherein the second recess is divided by the tooth into a first passage adjacent the channel and the anterior of the tooth, and a second passage adjacent the posterior of the tooth, optionally wherein the anterior side of the tooth is angled relative to the underside of the distal arm, optionally wherein the angle between the anterior side of the tooth and the distal arm is between 5 and 20 degrees, optionally wherein the angle is between 14 to 18 degrees, and further optionally wherein the angle is 16 degrees.
78. The attachment element of any of claims 74 to 77, wherein the arms of the attachment element are angled with respect to the vertical of the masonry support element, optionally wherein the proximal arm extends from a position above the distal arm.
79. The attachment element of any of claims 74 to 78, wherein the top side of the distal arm and the top side of the proximal arm are parallel.
80. The attachment element of any of claims 74 to 79, wherein the top side of the distal arm is parallel to the bottom side of the distal arm.
81. The attachment element of any of claims 74 to 80, wherein the bottom side of the proximal arm is angled with respect to the top side of the proximal arm, optionally wherein the angle between the top side of the proximal arm and the bottom side of the proximal arm is between 5 and 20 degrees, optionally wherein the angle is between 14 to 18 degrees, and further optionally wherein the angle is 16 degrees.
82. The attachment element of claims 81, wherein the angle between the top side of the proximal arm and the bottom side of the proximal arm is the same as the angle between the anterior side of the tooth and the distal arm.
83. The attachment element of any of claims 74 to 82, wherein the first recess and the second recess are joined to form a single cavity, optionally wherein the first recess and second recess share a base, optionally wherein the base is parallel with the posterior side of the tooth, optionally wherein the base is parallel with the top of the distal arm.
84. The attachment element of claim 83, wherein the base is parallel with the top of the proximal arm.
85. The attachment element of any of claims 83 or 84, wherein the distance between the base and the underside of the proximal arm is less than the distance between the base and the underside of the distal arm.
86. The attachment element of any of claims 83 to 85, wherein the distance between the base and the top of the proximal arm is less than the distance between the base and the underside of the distal arm.
87. The attachment element of any of claims 74 to 86, wherein the distal arm is shaped as an elongate bar in cross section.
88. The attachment element of any of claims 74 to 87, wherein the secondary element comprises an attachment bar.
89. The attachment element of claim 88, wherein the attachment bar forms part of a cavity tray; and/or wherein the bar is flat, such that the length and width of the bar are greater than the depth of the bar, optionally wherein the depth of the bar is 0.5mm; and/or wherein either side of the bar is a void, and wherein the voids are at least a distance x in length, optionally where x is 8mm to 12mm; and/or wherein the distance between the base and the top of the proximal arm is less than the distance between the base and the underside of the distal arm, and wherein the difference between these distances is equal to the depth of the bar optionally wherein equal includes an additional tolerance, for example of 0.1mm; and/or wherein the second passage has a depth equal to the depth of the bar, optionally wherein equal includes an additional tolerance, for example of 0.1mm; and/or wherein the width of the bar is greater than the width of the channel; and/or wherein the length of the distal arm is 0.5mm greater than the width of the bar; and/or wherein the length of the second passage is at least half the width of the bar; and/or wherein the length of the base to the entrance of the second passage is at least 0.5mm greater than the width of the bar; and/or wherein the distance between the end of the proximal arm and the tooth is at least half of the width of the bar, optionally wherein the length of the top side of the distal arm is at least 1mm smaller than x; and/or wherein the length of tooth to the rear of the distal arm is at least 1mm smaller than x.
90. A cavity tray comprising a first sheet comprising a plurality of edges; at a first edge there is a first void extending from the edge towards the interior of the sheet; at the end of the first void is a bar of material such that a first side of the bar is adjacent the first void; adjacent the second side of the bar is a second void, wherein the second void is entirely surrounded by material of the sheet.
91. The cavity tray of claim 90, wherein the bar has a width of between 3mm and 7mm, preferably 5mm.
92. The cavity tray of any of claims 90 or 91, wherein the void extends between 8mm and 12mm into the interior of the cavity.
93. The cavity tray of any of claims 90 to 92, wherein the second void extends away from the bar for a distance of at least 8mm to 12mm.
94. The cavity tray of any of claims 90-93, wherein the cavity tray further comprises: at the first edge, or an edge adjacent the first edge, a third void extending from the edge towards the interior of the sheet; at the end of the third void a second bar of material such that a first side of the second bar is adjacent the third void; adjacent the second side of the second bar a fourth void, wherein the fourth void is entirely surrounded by material of the sheet.
95. An assembly comprising the attachment element of claims 74-89 incorporated into a masonry support bracket, and a cavity tray of any of claims 90-94.
96. A masonry support element comprising the attachment means of any of claims 74-89, optionally wherein the masonry support element is a masonry support bracket.
97. A building comprising: an internal building structure; a masonry fagade; a masonry support element as claimed in claims 1-28; wherein the masonry support element is connected between the masonry fagade and the internal building structure.
98. The building of claim 97, further comprising weep vents positioned at the end of the masonry support angle such that water is expelled from the building via the weep vents.
99. A high rise building comprising a plurality of floors, and an inner cavity wall and an outer cavity wall with a cavity therebetween; and a cavity tray of any of claims 31-40, wherein the cavity tray is situated at a
first floor of the high rise building, and within the cavity between the inner cavity wall and the outer cavity wall.
100. The high rise building of claim 99, further comprising a second cavity tray situated one floor above the first cavity tray, optionally wherein the fire prevention material covering at least a portion of the tray section is configured to expand towards the second cavity tray in the event of fire.
101. A method of installing the masonry support element of claims 1-28, the method comprising the steps of: positioning a first masonry support bracket and angle at an intended position adjacent the internal building structure; positioning a second masonry support bracket and angle adjacent the position of the first masonry support element, and adjacent the internal building structure; attaching both the first masonry support bracket and angle and the second masonry support bracket and angle to the internal building structure; positioning a first cavity tray over the at least one arm of the first masonry support bracket; attaching the first cavity tray to the first masonry support bracket.
102. The method of claim 101, further comprising: positioning a first infill cavity tray over a portion of the first masonry support angle and a portion of the second masonry support angle; attaching the first infill cavity tray to the first masonry support angle and the second masonry support angle.
103. The method of claim 101 or 102, wherein the first cavity tray extends over at least a portion of the second masonry support bracket.
104. The method of any of claims 101 to 103, further comprising positioning a second cavity tray extending over at least a portion of the second masonry support bracket, optionally further comprising attaching the second cavity tray to the second masonry support bracket.
105. The method of any of claims 101-104, wherein positioning the first masonry support bracket and angle comprises positioning the first masonry support bracket
and angle one side of an external/internal corner of the building structure; wherein positioning the second masonry support bracket and angle comprises positioning the second masonry support bracket and angle the other side of the external/internal corner of the building structure to the first masonry support bracket and angle, optionally wherein positioning the first cavity tray over the at least one arm of the masonry support bracket comprises the cavity tray extending around the external/internal corner of the internal building structure, optionally wherein positioning a first infill cavity tray comprises positioning the infill cavity tray over the external/internal corner of the internal building structure.
106. The method of any of claims 101-105, wherein attaching the first masonry support bracket to the internal building structure comprises securing a first bolt through a central void in the first column of the masonry support bracket, and said bolt attaching to the internal building structure, optionally wherein the first bolt is positioned at the top of the first column, optionally wherein securing further comprises securing a second bolt through the first column of the masonry support bracket, and said second bolt attaching to the internal building structure, optionally wherein the cut-out is aligned with the central void, or a secondary void, of the first column of the masonry support bracket, optionally comprising drilling a hole in the internal building structure aligned with the cut-out, and further optionally utilising a socket to tighten the bolt nut into place, optionally further comprising attaching a cover to cover the cut-out after the second bolt is attached.
107. A method of installing a cavity tray of any of claims 31-40 comprising the steps of: providing a first cavity tray in accordance with any of claims 31-40; cutting the rightmost and/or leftmost end of the fire prevention structure to remove a pre-set length of the fire prevention structure; providing a second cavity tray in accordance any of claims 31-40; overlapping the first cavity tray and the second tray by the pre-set length.
108. A method for manufacturing the cavity tray and fire barrier of claims 54-73, wherein the method comprises attaching the fire barrier to the cavity tray.
109. The method of claim 108, wherein attaching the fire barrier to the cavity tray comprises:
positioning the fire barrier on the cavity tray at a predetermined location; placing a first mechanical attachment at a first longitudinal and transverse location on the fire barrier; optionally wherein the mechanical attachment extends through the fire barrier and cavity tray arrangement; optionally wherein the first transverse location is preferably the midpoint of the width of the fire barrier strip.
110. The method of claim 108 or claim 109, wherein attaching the fire barrier to the cavity tray further comprises: placing a second mechanical attachment on the fire barrier, optionally wherein the second mechanical attachment extends through the fire barrier and cavity tray arrangement; wherein the second longitudinal location is separated from the first longitudinal location so as to constrain the fire barrier to the cavity tray along its length; optionally wherein the second mechanical attachment is positioned at the first transverse location and a second longitudinal location; optionally wherein the second mechanical attachment is a rivet.
111. A method for installing the cavity tray and fire barrier of claims 54-73, wherein the method comprises attaching the cavity tray to the internal building structure.
112. The method of any of claims 108 to 111, wherein the fire barrier is attached to the cavity tray prior to attaching the cavity tray to the internal building structure.
113. A method of attaching the attachment element of any of claims 74-89, with a secondary element comprising an elongate flat bar, the method comprising: positioning the bar on the top of the proximal arm; sliding the bar into the first passage below and parallel the distal arm; pivoting the bar such that the bar is parallel with the anterior side of the tooth; sliding the bar into the first recess below and parallel the proximal arm; pivoting the bar to be parallel with the base.
114. The method of claim 113, further comprising the step of sliding the bar into the second passage.
115. The method of any of claims 113 or 114, wherein the secondary element comprises a cavity tray, the attachment element is attached to a masonry support element, and the method is a method of attaching a cavity tray to a masonry support element, optionally wherein the cavity tray is the cavity tray of any of claims 90-94.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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GBGB2316912.1A GB202316912D0 (en) | 2023-04-21 | 2023-11-03 | A masonry support system attachment means |
Applications Claiming Priority (6)
Application Number | Priority Date | Filing Date | Title |
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GB2206949.6 | 2022-05-12 | ||
GB2206949.6A GB2618597B (en) | 2022-05-12 | 2022-05-12 | Masonry support element and/or attachment mechanism |
GB2219667.9 | 2022-12-23 | ||
GB2219667.9A GB2618640A (en) | 2022-05-12 | 2022-12-23 | A cavity tray and fire barrier |
GB2305909.0 | 2023-04-21 | ||
GB2305909.0A GB2620474A (en) | 2022-05-12 | 2023-04-21 | A cavity tray and masonry support element |
Publications (1)
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WO2023217968A1 true WO2023217968A1 (en) | 2023-11-16 |
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PCT/EP2023/062612 WO2023217968A1 (en) | 2022-05-12 | 2023-05-11 | A cavity tray and masonry support element |
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WO (1) | WO2023217968A1 (en) |
Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20170370097A1 (en) * | 2014-12-17 | 2017-12-28 | Hilti Aktiengesellschaft | Facade assembly, building structure and method for mounting the facade assembly |
WO2021084047A1 (en) * | 2019-10-30 | 2021-05-06 | Acs Stainless Steel Fixings Limited | Cavity tray system with jointing structures |
GB2598811A (en) * | 2020-08-17 | 2022-03-16 | Acs Stainless Steel Fixings Ltd | Building tray and method of construction |
-
2023
- 2023-05-11 WO PCT/EP2023/062612 patent/WO2023217968A1/en unknown
Patent Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20170370097A1 (en) * | 2014-12-17 | 2017-12-28 | Hilti Aktiengesellschaft | Facade assembly, building structure and method for mounting the facade assembly |
WO2021084047A1 (en) * | 2019-10-30 | 2021-05-06 | Acs Stainless Steel Fixings Limited | Cavity tray system with jointing structures |
GB2598811A (en) * | 2020-08-17 | 2022-03-16 | Acs Stainless Steel Fixings Ltd | Building tray and method of construction |
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