Cladding System

Abstract

An architectural cladding kit; and a method of preparing architectural masonry slips for subsequent attachment to a substrate employs a plurality of joint brackets having a base and two free ends. The joint brackets engage with a plurality of substantially rectangular masonry slips, each slip including an outer face; an inner face; two oppositely directed edge faces; and a slot formed in each edge face. The joint bracket is attachable to a substrate such as a building structure. Each joint bracket free end is adapted for engagement within the slot formed in an edge face of two opposed masonry slips which are attached to the substrate by an adhesive. The joint brackets ensures that the masonry slips cannot fall even if the adhesive connection were to fail.

Claims

1. An architectural masonry cladding kit comprising: a panel substrate; at least one joint bracket having a base and two free ends; a plurality of resiliently expandable fasteners for fastening the at least one joint bracket to the panel substrate; and at least two substantially rectangular masonry slips of a material selected from the group comprising clay bricks, natural or cast stone, and concrete tiles; each slip including: (i) an outer face of a first width; (ii) an inner face of a second width which is less than the first width; (iii) two oppositely directed edge faces each having a length and depth dimension; and (iv) a slot formed in each edge face; wherein each slot divides its edge face into front and rear portions; wherein the front portion extends from the outer face to the slot; and the rear portion extends from the inner face to the slot; and wherein the joint bracket is substantially U-shaped and provided with no more than two oppositely directed flange extensions at its respective free ends; each flanged extension being adapted for engagement within an aforementioned slot to thereby indirectly attach the masonry slips to a building structure via the panel substrate.

2. An architectural cladding kit according to claim 1, wherein each slot extends width-wise along a notional axis extending parallel to both the inner and outer masonry slip faces.

3. An architectural cladding kit according to claim 1, wherein each slot extends lengthwise in a straight line along the full length of each edge face.

4.-5. (canceled)

6. An architectural cladding kit according to claim 1, wherein the depth of the front portion is greater than the depth of the rear portion.

7-8. (canceled)

9. An architectural cladding kit according to claim 1, wherein the joint bracket is substantially U-shaped and provided with oppositely directed flange extensions at its respective free ends, each for engagement within a said slot.

10. An architectural cladding kit according to claim 1, further comprising a C-shaped end bracket having a first flange extension at one of its respective free ends for engagement within a said slot; and a second flange extension at the other of its respective free ends for engagement with the building structure and/or an intermediate substrate.

11. An architectural cladding kit according to claim 9, wherein the depth of each slot within each edge face is greater than the length of each flange extension on the joint bracket.

12. An architectural cladding kit according to claim 1, wherein one or more surfaces of the joint bracket are roughened or textured.

13. An architectural cladding kit according to claim 12, wherein one or more apertures are formed through the said one or more surfaces of the joint bracket.

14. A method of preparing architectural masonry slips for subsequent attachment to an inverted surface, including the steps of: (i) providing a plurality of substantially rectangular masonry slips, each slip including an outer face; an inner face; and two oppositely directed edge faces each having a length and depth dimension and a slot formed therein; (ii) providing a panel substrate; (iii) providing a plurality of joint brackets each having a base and no more than two free ends for joining two adjacent slips; (iv) providing s supply of mortar and/or adhesive; (v) applying adhesive to surfaces of either, or both, of the panel substrate and a slip; (vi) adhering the slip to the panel substrate; (vii) repeating steps (iv) and (v) to produce a first single aligned course of slips on the panel substrate; (viii) engaging one free end of a joint bracket within the aligned slots in each non-perimeter edge face of said aligned course of slips; (ix) adhering a second single aligned course of slips on the panel substrate alongside the first course whilst engaging slots along the opposing edge faces of the second course with the other free end of the joint bracket; and (x) filling the space between opposing edge faces of said first and second courses, and down to the base of the joint brackets, with said mortar and/or adhesive; wherein, when attached to an inverted surface, the free ends of each joint bracket are each capable of supporting the weight of the respective inverted courses thus providing a fail-safe support for the inverted masonry slips in the event of a failure of the adhesive bond applied between each masonry slip and the panel substrate.

15. A method according to claim 14 comprising the further steps of adhering further courses of slips to the substrate alongside each preceding course; and engaging slots along the opposing edge faces of adjacent courses within the flange extensions of an interposed joint bracket.

16. A method according to claim 14 comprising the further step of engaging the aligned slots in each edge face of the first single aligned course of slips with a free end of a C-shaped end-bracket.

17. A method according to claim 16 comprising the further step of attaching the C-shaped end-bracket to a perimeter edge of the panel substrate.

18. A method according to claim 14 comprising the further step of mechanically fastening the joint brackets to the panel substrate.

19. A method according to claim 18 wherein the joint brackets are fastened to the panel substrate by means of a resiliently expandable fastener.

20. A method according to claim 14 comprising the further steps of adhering further courses of slips to the substrate alongside each preceding course; and engaging slots along the opposing edge faces of adjacent courses within the flange extensions of an interposed joint bracket; and comprising the further step of engaging the aligned slots in each edge face of the first single aligned course of slips with a free end of a C-shaped end-bracket.

21. A method according to claim 20 comprising the further step of mechanically fastening the joint brackets to the panel substrate.

22. A method according to claim 21 wherein the joint brackets are fastened to the panel substrate by means of a resiliently expandable fastener.

Description

BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS

[0047] Embodiments of the present invention will now be described, by way of example only, with reference to the following diagrams, in which:

[0048] FIG. 1 is sectional view showing the component parts of a cladding kit in which masonry slips are attached to a ceiling panel substrate;

[0049] FIG. 2 is a sectional view corresponding to that of FIG. 1 whereby the ceiling panel substrate and masonry slips are of increased thickness;

[0050] FIG. 3 is a sectional view corresponding to that of FIG. 1, showing a terminal end bracket and a manner in which panel substrates may be adjoined;

[0051] FIG. 4 is a sectional view corresponding to that of FIG. 2, showing a terminal end bracket and the manner in which panel substrates are adjoined;

[0052] FIG. 5a is a sectional view of the joint bracket shown in FIGS. 1 to 4;

[0053] FIG. 5b is a sectional view of the end bracket shown in FIGS. 3 and 4;

[0054] FIGS. 6a and 6b are sectional views of alternative joint and end brackets;

[0055] FIG. 7 shows end, plan and elevation views of a masonry slip;

[0056] FIG. 8a is a side view of a fastener for use in the present invention;

[0057] FIG. 8b is a sectional view the fastener of FIG. 8a rotated to illustrate its expanded state;

[0058] FIG. 9 shows the side and sectional views of the fasteners of FIGS. 8a and 8b in-situ fastening a joint bracket to a ceiling panel substrate;

[0059] FIG. 10 shows a joint bracket of the present invention in combination with a fastener insulator collar; and

[0060] FIG. 11 shows end and plan views of a typical masonry clad panel substrate.

DETAILED DESCRIPTION OF THE INVENTION

[0061] FIGS. 1 and 2 each show a ceiling structure of a building including a cement particle board substrate 10 having a thickness of 8 mm or 12 mm respectively, and a density of 1300 kg/m.sup.3. A number of spaced apart joint brackets 12 (shown in more detail in FIGS. 5a and 6a) are attached to the substrate 10. Each joint bracket 12 is integrally formed from a single piece of sheet stainless steelhaving a thickness of 0.5 mmwhich has been cold rolled into a square omega shaped sectional profile. Alternative materials for the joint brackets 12 may include nylon and/or plastics or any other materials having the appropriate strength characteristics. Each joint bracket 12 is provided with a planar base 12a having a width of 10 mm; two planar walls 12b, 12c extending perpendicularly from either side of the base 12a, each having a height of 10 mm; and a flange extension 12d, 12e extending perpendicularly from the ends of the planar walls 12b, 12c which are remote from the base 12a, each having a length of between 5 mm (FIGS. 5a) and 10 mm (FIG. 6a) to account for differing tolerances in the slot lengths between different brick materials. The surface planes of the flange extensions 12d, 12e are each orientated so as to be parallel to the surface plane of the base 12a.

[0062] Each joint bracket 12 is connected to the substrate 10 by a suitable fixing means. In one embodiment (e.g. as shown in FIGS. 1 to 4 and 8) the fixing means comprises a hex bolt 14, the head of which is received within the U-shaped space defined by the base and wall surfaces 12a, b, c of the joint bracket. The a hex bolt 14 extends through the substrate 10 and a washer and Nyloc nut are tightened against its upper side surface to thus securely fasten the joint bracket 12 to the lower side surface of the substrate 10.

[0063] In an alternative embodiment (see FIGS. 8a and 8b), a one-piece plastics expandable fastener 114 having a split shaft is employed to connect the joint bracket 12 to the substrate 10. The split shaft (best shown in the sectional view of FIG. 8b) comprises two shaft members 116, 118 which are resiliently hinged together proximate the head 120 of the expandable fastener 114. The distal ends of the shaft members 116, 118 are in the form of bulbous ends 122, 124. The shaft members 116,118 can be pivoted and/or twisted relative to one another about their connecting hinge so as to overlap one another. In the particular example illustrated, the shaft members 116, 118 and their bulbous ends 122, 124 are capable of overlapping one another in a manner similar to scissor blades. In doing so, the combined diameter of the bulbous ends 122, 124 in at least one plane is reduced to be less than the diameters of the apertures within the substrate 10 and the base 12a of the joint bracket 12.

[0064] It will be appreciated that this structural relationship, together with the inherent resilience of the plastics material, allows the two shaft members 116, 118 and their bulbous ends 122, 124 to be squeeze through the aforementioned aperture. Once the bulbous ends 122, 124 pass through the aperture they resiliently expand. In doing so, their combined diameter in the at least one plane mentioned above is greater than the diameters of the apertures within the substrate 10 and the base 12a of the joint bracket 12 (i.e. as shown on the right in FIG. 9). The expandable fastener 114 is thereby effectively locked in an engaged position and cannot easily be removed from the aforementioned apertures. Advantageously, no secondary item such as a nut is required to secure the fastener 114 in its locked condition. The fastener 114 may be used in addition to alternative types of fasteners. For example, the aforementioned hex bolt 14 may be used in strategic positions corresponding to the presence of structural members such as battens, posts, beams and steel framing, whereas the expandable fasteners may be used in other positions intermediate those structural members.

[0065] The head 120 of the expandable fastener 114 is configured to receive a driving instrument to assist in inserting it through the aforementioned apertures. When fully inserted, the head 120 may be countersunk within a correspondingly shaped recess formed in the surface of the substrate 10.

[0066] As shown in FIGS. 8a and 8b, the fastener 114 has the following measurements:

Overall length: 22 mm
Length of head 120: 5 mm
Length of bulbous end 122, 124: 8 mm
Length of shaft members 116, 118 (minus bulbous end): 9 mm
Maximum width of head 120: 10 mm
Maximum combined width of shaft members 116, 118: 4.8 mm
Minimum combined width of bulbous end 122, 124: 4.8 mm
Maximum (expanded) width of bulbous end 122, 124: >10 mm

[0067] Other conventional metallic fasteners such as self-tapping Tek screws, rivets, woodscrews, cartridge nails, and nuts/bolts etc. may also be used to secure the joint bracket 12 to the substrate 10. However, since the joint bracket 12 will usually be formed from stainless steel, galvanic or bimetallic corrosion can occur over time and compromise the strength and reliability of the connection between the fastener and the joint bracket 12. In a worst case scenario, the connection may fail. To avoid this potentially dangerous scenario, a tubular insulation collar 150 is positioned within the U-shaped space bounded by the base 12a and side walls 12b, 12c of the joint bracket 12. As shown in FIG. 10, the insulation collar has a length 10 mm; an outer diameter of 8.5 mm and an inner diameter of 5.5 mm. The insulation collar 150 serves to isolate the shaft of any fasteners from the majority of the surface area of the joint bracket 12.

[0068] A series of cladding masonry slips 16 (shown in more detail in FIG. 7)i.e. clay brick slips, natural or cast stone, ceramic tiles, or concrete tilesare adhered to the substrate 10 in a conventional manner (e.g. by means of a two part epoxy adhesive having a density of 1650 kg/m.sup.3). However, the masonry slips 16 are additionally connected to the flange extensions 12d, 12e of each joint bracket 12 to provide a fail-safe connection to the substrate 10.

[0069] Each masonry slip 16 comprises an inner face 18, an outer face 20; and two oppositely directed edge faces 22, 24 each having a length dimension (i.e. perpendicular to the plane of the paper) and a depth dimension (i.e. between the inner and outer faces 18, 20). A slot 30 is formed in each edge face 22, 24. Each slot 30 has a breadth along a notional width-wise axis which extends perpendicularly with respect to both edge faces 22, 24; and has a length which extends in a straight line along the full lengthwise extent of each edge face 22, 24.

[0070] Each slot 30 divides its edge face 22, 24 into front and rear portions 22f, 22r and 24f, 24r. The front portions 22f, 24f are bounded by the edge of the outer face 20 and the slot 30; and the rear portions 22r, 24r are bounded by the edge of the inner face 18 and the slot 30. As can be seen by comparing FIGS. 1 and 2 (or FIGS. 3 and 4), the depths of the respective front and rear portions 22f, 24f and 22r, 24r may be equal or non-equal. For example, the depths of both the front and rear portions in FIG. 1 are 9 mm whereas in FIG. 2 the depth of the front portions 22f, 22r is increased to 14 mm. Indeed the overall depth of the masonry slip 16 of FIG. 2 is 5 mm greater than that of FIG. 1, and its associated substrate 10 is also 4 mm thicker. In each case, the slot 30 has a height in the depth direction of 2 mm.

[0071] As shown in FIGS. 1 to 4, the width of the inner face 18 is marginally less than that of the outer face 20. Accordingly, the lowermost surface 301 of the slot 30 projects slightly beyond its corresponding uppermost surface 30u. As is clear from FIGS. 1 to 4, the breadth of each slot 30 as measured along its lowermost surface 301 is greater than the length of each flange extension 12d, 12e of the joint bracket 12. The combination of an oversized slot 30 and a reduced width inner face 18 permits a degree of lateral movement or play which is necessary to facilitate adjustment, insertion and removal of masonry slips 16 from each flange extension 12d, 12e. It also accommodates variation in slot depth/breadth due to manufacturing tolerances.

[0072] As shown in FIGS. 3 and 4, an end bracket 40 is used as a terminal support for engaging with slots 30 located at the peripheral edge of an area of cladding. As best shown in FIGS. 5b and 6b, each end bracket 40 is integrally formed from a single piece of sheet stainless steelhaving a thickness of 0.5 mmwhich has been bent or cold rolled into an asymmetrical, square-cornered C-shaped sectional profile. Each end bracket 40 is provided with a planar base 40a having a height of 24 mm; and two planar flange extensions 40b, 40c extending perpendicularly from either side of the base 40a. The lower flange extension 40b measures between 5 mm and 10 mm in length and is locatable within a slot 30 of a masonry slip 16. The upper flange extension 40c measures between 20 mm (FIG. 6b) and 25 mm (FIG. 5b) in length and is locatable against the upper surface of substrate 10.

[0073] The process for manufacturing and installing architectural cladding according to the present invention is as follows. Firstly, masonry slips 16 are manufactured in a workshop at, or off-site from, the construction site. Here, an experienced brick-cutting operator would cut suitably dimensioned masonry slips 16 using a masonry saw with appropriate dust extraction or water based dust suppression in place. When cut to a correct thickness the slips 16 are passed through a purpose made spindle slot cutting process to form the elongate slots 30 along their end faces 22, 24. The prepared slips 16 are then dried and blown clean with compressed air to remove all dust and loose granular material.

[0074] A suitable panel of substrate material 10 is cut to the required dimensions and laid on a bench or surface in readiness for fabrication. The surface of the panel substrate 10 is abraided with grit paper and is also blown clean with compressed air. The panel surface is then coated with well mixed fresh two part epoxy adhesive (British Board of Agrment (BBA) approved or UKAS approved), and combed to a thin layer ready for laying slips 16 thereon. The inner surface 18 of each slip 16 is coated with the same adhesive and the thin layer wiped off to leave a smear of adhesive over its whole inner surface 18. The prepared slip is then pressed into the thin layer of adhesive on the panel substrate 10 and this is repeated until a single course length is complete.

[0075] The above process is started at a peripheral edge of the substrate panel 10 and a flange 40b of a C-shaped end cap/bracket 40 is then fitted into the aligned slots 30 along the edge face 24 of the first course of slips 16. Individual slips 16 may be adjusted in position before the adhesive cures to provide an even joint width and a straight alignment as required by the design. The straight steel length of the C-shaped end cap/bracket 40 assists in this process. A first flange extension 12d of the elongate omega shaped joint bracket 12 is inserted into the slots 30 running along the opposite edge face 22 of the first course of slips 16 with any necessary positional adjustments being made.

[0076] A second course of slips is then pushed into position with individual slots 30 in each slip being engaged with the opposing flange extension 12e. The straight edges of the omega shaped joint bracket 12 therefore ensures that the second course of slips extends parallel to the first course. The process steps of coating the panel substrate 10 with adhesive; sliding joint brackets 12 into slots 30 in the previous course; and pressing adhesive-smeared slips 16 into position is repeated until the panel substrate 10 is completely covered (see FIG. 8).

[0077] Each joint bracket 12 may be secured to the substrate panel 10 along its length (for example, by a series of fasteners of the type described above) after one course of slips is positioned, and before the next course is positioned alongside. Alternatively, the process of securing all joint brackets 12 to the substrate panel 10 may be performed after all masonry slips 16 are correctly positioned, either before or after the adhesive has cured.

[0078] Where two panel substrates 10 are to be joined (see FIGS. 3 and 4), the final course on the first panel substrate 10 is completed by fixing a base 12a of a joint bracket 12 along its intermediate perimeter edge 10p. In doing so, the outer flange extension 12e extends beyond the intermediate perimeter edge 10p to enable its engagement within slots 30 in the first course of slips of the adjoining panel substrate 10. A further C-shaped end cap/bracket 40 is fitted to the terminal perimeter edge 10t of a panel 10.

[0079] Once the adhesive is fully cured, individual panel substrates 10 may have other holes drilled and other fixings and/or sub-frames attached in readiness for their direct or indirect mechanical attachment to a building structure by a cladding contractor. A series of panel substrates 10 may be seamlessly connected together as indicated in FIGS. 3 and 4 with gaps pointed in-situ. Alternatively, pointing may be performed prior to lifting individual panel substrates 10 into position, this being advisable in the case of, e.g., hanging soffits where slips 16 are fully inverted.

[0080] The fixing of clad sections must meet engineers' requirements for the support of load and structural strength, e.g. using test data (provided by the United Kingdom Accreditation Service (UKAS) or other accredited laboratories prescribed for such activities). The mechanical fixing methods and arrangements used to secure the substrate panels 10 to the building structuree.g. by hex bolts 14are prescribed and recommended by organisations such as the NHBC and other warranty bodies. A scissor jack may be the most appropriate device to assist installation on site. Substrate panels 10 can be bolted together in situ to create a solid independent hanging surface with soft joints allowing movement around the perimeter margins to prevent stress cracking or fractures.

[0081] Although particular embodiments of the invention have been disclosed herein in detail, this has been done by way of example and for the purposes of illustration only. The aforementioned embodiments are not intended to be limiting with respect to the scope of the appended claims. It is contemplated by the inventor that various substitutions, alterations, and modifications may be made to the invention without departing from the scope of the invention as defined by the claims. In particular, the precise dimensions of the various surfaces in each of the joint bracket, end bracket and masonry slips can each be adjusted to suit particular requirements. Also, the order of performing each of the individual method steps of the second embodiment can be varied.