The present invention relates to apparatus for building a wall and more specifically to a support profile for adjustably supporting a conventional line block secured to the end of a brick line used to build a wall.

Conventional bricklaying techniques to build a wall typically involve building opposed corner leads on a level foundation and building up the brick courses between the corner leads to complete the wall. To ensure each brick course is level, a brick line is used as a reference to work to. A first brick pin is pushed into soft mortar or hammered into set mortar of a lower course of bricks of the first corner lead and one end of the brick line is secured to the first brick pin. A second brick pin is pushed into soft mortar or hammered into set mortar of the corresponding lower course of bricks of the opposed second corner lead and the other end of the brick line is secured to the second brick pin to provide a substantially horizontal reference to build the lower course of bricks between the corner leads. Alternatively, a line block may replace the second brick pin. A line block is a substantially L-shaped member having a body portion and a flange portion oriented at 90 degrees to each other for engaging the corner of a corner lead. The body portion is configured to allow the brick line to be pulled taut and secured thereto to provide a well-defined and level reference to build to. The same process is involved for building a new wall extending from an existing wall. The first brick pin with the first end of a brick line wrapped therearound is hammered into the set mortar of a lower course of the existing wall and a second brick pin or line block attached to the second end of the brick line is used to support the brick line in a taut and level state with respect to a corner lead of the new wall to be built.

However, at least one brick pin is always needed which compromises the integrity of the mortar, particularly in an existing wall when the brick pin must be hammered into the mortar. The brick pin must be removed and pushed or hammered into the next mortar course each time a new course of bricks is to be laid and the resulting holes in the mortar must be repaired with new mortar. A conventional two-storey extension typically comprises around 75-80 courses meaning the brick pin must be hammered into the mortar 75-80 times and the resulting holes filled. The whole process is therefore particularly time consuming, wastes materials and energy, and can compromise the mortar and the integrity of the existing wall itself. Furthermore, the brick pin can easily fall or be knocked out of the mortar by a person walking by. In an attempt to increase security of the brick pin in the mortar, the brick pin is typically hammered into a vertical mortar join between adjacent bricks proximal to the corner of the existing building to thereby be oriented vertically to better resist the tension in the brick line in use. However, the vertical joins in adjacent courses of bricks are staggered so the brick line must be rolled and unrolled around the brick pin before it is hammered into the next vertical join of the course above, whilst trying to keep the brick line taut to prevent the line block on the other end of the brick line slipping down the corner lead. This is time consuming, fiddly and particularly frustrating for the bricklayer. Additionally, the brick pin must be hammered into each vertical mortar join at a specific location each time such that the brick line extends horizontally from the brick pin to align with the corresponding horizontal mortar course to which the new course is to be laid. This requires particular skill and accuracy and is particularly difficult to achieve when hammering into hard mortar which often results in an inaccurate datum to work to.

It is an aim of certain embodiments of the present invention to provide apparatus for supporting a conventional line block at a desired height to which a first course of bricks is to be laid, and efficiently adjusting the height of a brick line secured to the line block to which a second course of bricks is to be laid.

It is an aim of certain embodiments of the present invention to provide apparatus for efficiently raising the height of a brick line without the need for a brick pin.

According to a first aspect of the present invention there is provided apparatus for selectively adjusting the height of a brick line secured to a line block, comprising: an elongate body having a substantially L-shaped cross section defining a first flange portion and a second flange portion, wherein the first flange portion comprises a first inner surface, a first outer surface and a first end surface extending therebetween, and the second flange portion comprises a second inner surface, a second outer surface and a second end surface extending therebetween, and wherein the second inner surface is oriented substantially perpendicularly to the second end surface; a slot extending along the first flange portion and located proximal to the second inner surface of the second flange portion; and a recessed region extending along the first outer surface of the first flange portion and laterally from the slot to the second outer surface of the second flange portion.

Optionally, the first outer surface is substantially flat for engagement with a substantially flat wall surface of an existing wall.

Optionally, the second inner surface and the second end surface of the second flange portion are substantially flat for corresponding engagement with substantially flat inner surfaces of a line block.

Optionally, a width of the second inner surface and the second end surface is at least equal to a length of the corresponding inner surface of the line block.

Optionally, the slot and recessed region are configured to receive and accommodate a brick line extending from the line block when supported on the second flange portion in use.

Optionally, at least one longitudinal edge of the slot is substantially convex in cross section.

Optionally, the longitudinal edge is proximal to the second inner surface.

Optionally, the second inner surface is oriented between 90 and 45 degrees with respect to the first outer surface.

Optionally, the second inner surface is oriented by 75 degrees with respect to the first outer surface. Optionally, the first outer surface is oriented substantially perpendicularly to the second outer surface.

Optionally, the first flange portion comprises a first wall region extending substantially perpendicularly from the first inner surface and extending longitudinally between opposed end regions of the apparatus to define a channel between the second flange portion and the first wall region.

Optionally, the apparatus comprises a second wall region longitudinally extending along the first inner surface of the first flange portion and between the second inner surface and the first wall region to divide the channel into a first channel region and a second channel region, wherein the second channel region communicates with the slot.

Optionally, the second wall region comprises an inner wall surface facing the second inner surface of the second flange portion and an outer wall surface facing the first wall region of the first flange portion, wherein the outer wall surface is substantially perpendicular to the first inner surface of the first flange portion and the inner wall surface is sloped with respect to the first inner surface of the first flange portion.

Optionally, the inner wall surface of the second wall region is angled by 60 degrees with respect to the first inner surface of the first flange portion.

Optionally, second wall region terminates before each end region of the profile to provide a gap therebetween.

Optionally, each end region provides a stop surface for limiting a range of slidable movement of a line block along the second flange portion in use.

Optionally, the apparatus comprises at least one aperture extending through the first flange portion for receiving a fixing to secure the apparatus to a wall.

Optionally, the at least one aperture comprises three longitudinally spaced apart slots. Optionally, outer ones of the slots are longer than an inner one of the slots.

According to a second aspect of the present invention there is provided a system for building a wall, comprising at least one apparatus according to the first aspect of the present invention, at least one line block, and a brick line.

Description of the Drawings

Certain embodiments of the present invention will now be described with reference to the accompanying drawings in which:

Figure 1 illustrates an isometric view of a support profile according to certain embodiments of the present invention;

Figure 2 illustrates a cross sectional view through the profile of Figure 1 and approximately midway along its length;

Figure 3 illustrates a conventional line block for use with the profile;

Figure 4 illustrates a cross sectional view of the line block mounted on the profile in use; and

Figure 5 illustrates the profile in use to build a new wall extending from an existing wall to which the profile is attached.

Detailed Description

As illustrated in Figures 1 and 2, a builders’ profile 100 according to certain embodiments of the present invention is elongate and has a substantially L-shaped cross section defining a first flange portion 102 oriented with respect to a second flange portion 104. The first flange portion 102 provides a substantially flat first outer surface 106 oriented substantially perpendicularly to a substantially flat second outer surface 108 provided by the second flange portion 104. A first inner surface 110 of the first flange portion 102 is substantially parallel with the first outer surface 106. A second inner surface 112 of the second flange portion 104 is angled with respect to the first inner surface 110 by around 75 degrees. An end surface 109 of the second flange portion 104 extending between second inner surface 112 and the second outer surface 108 thereof is substantially perpendicular with respect to the second inner surface 112.

The first flange portion 102 includes a first wall region 114 extending substantially perpendicularly from the first inner surface 110 and extending longitudinally between opposed end regions 116,118 of the profile 100. An inner wall surface 120 of the first wall region 114 and the second inner surface 112 of the second flange portion 104 define opposed sides of a channel 122 and the first inner surface 110 of the first flange portion 102 defines a base of the channel 122. The first wall region 114 defines an outer wall surface 121 which is substantially perpendicular with respect to the first outer surface 106 of the first flange portion 102. The outer wall surface 121 and the first outer surface 106 define a first longitudinal corner edge 105 of the profile 100, and the first and second outer surfaces 106,108 define a second longitudinal corner edge 107 of the profile. The first wall region 114 is optional and adds strength and bending stiffness to the profile.

A second wall region 124 in the form of a rib axially extends along the base of the channel and between respective inner surfaces of the opposed end regions 116,118 of the profile 100. The second wall region 124 includes an inner wall surface 126 facing, and substantially parallel with, the inner wall surface 120 of the first wall region 114, and a second wall surface 128 facing the second inner surface 112 of the second flange portion 104. The second wall surface 128 is angled by around 60 degrees with respect to the first inner surface 110. The second wall region 124 adds strength and bending stiffness to the profile and divides the channel 122 into a first channel region 123 and a second channel region 125. The angle of the second inner surface 112 of the second flange portion 104 and the angle of the second wall surface 128 of the second wall region 124 defines the wedge-shaped second channel region 125 which corresponds in cross-sectional profile to a conventional line block as illustrated in Figure 4 and as described further below. As such, the second wall region 124 helps to support a line block in a desired position on the profile in use and prevents the line block being unintentionally knocked laterally off the second flange portion 104 in use, as described further below. However, the second wall region 124 is also optional and may be present with or without the first wall region 114 being present. Furthermore, the ends of the second wall region 124 may terminate before the inner surfaces of each end region 116,118 of the profile to provide a gap therebetween as opposed to joining the end regions. The end regions of the profile are also optional and may not be present.

As illustrated in Figure 1 , three longitudinally spaced apart first slots 130 are provided through the base of the first channel region 123. The first slots are equally spaced apart from each other. The two outer slots are around 240mm long and the central slot is around 200mm long. Alternatively, all three slots may be substantially equal in length. Each slot is around 10mm wide to receive a suitable fixing, such as a screw, to secure the profile 100 to a wall, as described further below. The first slots provide an amount of tolerance and adjustability in use and desirably ensures each slot will always overlap a mortar course of an existing wall into which each fixing screw can be driven to secure the profile to the wall. Aptly, the slots are sized and arranged such that at least the two outer slots always overlap a mortar course based on conventional metric bricks being 65mm high, imperial bricks being 73mm or 75mm high, and blocks being 215mm high. More or less than three through slots may be provided in the base of the first channel region depending on the desired length of the profile. Alternatively, particularly for relatively lightweight applications, the first slots 130 may be optional and the profile 100 may be secured to the wall using non-invasive attachment means such as ‘hook and loop’ elements, e.g.

Velcro™ pads adhered to the first outer surface 106 of the profile 100 and the wall, or the like.

As illustrated in Figure 2, a second slot 132 is provided through the base of the second channel region 125 and along the intersection of the first inner surface 110 and the second inner surface 112. The second slot 132 extends between the end regions 116,118 of the profile 100. The longitudinal surfaces of the second slot 132 are aptly curved or tapered to eliminate any sharp edges along its length. The second slot 132 extends into a longitudinally extending recessed region 134 provided in the first outer surface 106 of the profile 100 and which terminates at the second outer surface 108 of the profile 100. The recessed region 134 provides a gap between the profile and a wall to which the profile is secured in use to thereby define a passageway extending from the channel region 122 and out through the second outer surface 108 of the profile. The recessed region 134 has a depth of around 2-3mm to accommodate a brick line and allow the same to slide along the profile without becoming trapped between the profile and a wall to which the profile is attached in use.

The opposed end regions 116,118 of the profile are substantially closed to add strength and stiffness to the end regions and may be hollow or solid. The second flange portion 104 is also substantially closed and may also be hollow or solid. The opposed end regions may provide opposed stop surfaces for limiting the range of slidable movement of a line block along the second flange portion in use.

Aptly, as an example, the profile 100 is around 1800mm long, the first outer surface 106 is around 63mm wide and the second outer surface 108 is around 67mm wide. Alternatively, the first and second outer surfaces may be equal in length. The end surface 109 of the second flange portion 104 is around 28mm wide and the outer wall surface 121 of the first wall region 114 is also around 28mm wide. The channel 122 is around 45mm wide and the recessed region 134 in the first outer surface 106 is around 12mm wide. The profile may be a plastics material and may be additively manufactured, moulded or the like. The end regions 116,118 of the profile provide strength and stiffness to the profile but may be omitted such that the profile has the same cross section along its entire length to allow it to be formed in a plastics or metal material by extrusion. Alternatively, the profile may be a formed from metal, such as aluminium, by punching/reaming and folding or the like.

A conventional line block 200 is illustrated in Figure 3. The line block 200 includes a first flange portion 202 oriented perpendicularly to a second flange portion 204. The flange portions respectively define a first inner surface 206 and a second inner surface 208. The first flange portion 202 incudes a channel 210 extending continuously around its periphery for accommodating a brick line wrapped therearound to secure an end of the brick line to the line block 200 in use. The first flange portion 202 further includes a slot 212 disposed on a central axis of the line block and extending through the first flange portion such that is meets the second inner surface 208 of the second flange portion 204. A groove 214 is disposed on the central axis of the line block and extends along the second inner surface 208 the second flange portion 204 from a free end thereof to communicate with the slot 212. This arrangement allows one end of the brick line to be wrapped around the first flange portion 202 in the channel 210 thereof and fed through the slot 212 and along groove 214. The other end of the brick line can then be secured to a brick pin in accordance with conventional brick laying methods or to a second line block in accordance with certain embodiments of the present invention as described further below.

In use, and in accordance with certain embodiments of the present invention, a first end of a brick line 450 is secured to a first conventional line block 200 as described above by wrapping the first end of the brick line around the channel 210 of the first line block in a conventional manner. The first line block is mounted on a prebuilt corner lead distal to the existing wall between which the new wall is to be built. Alternatively, the first line block may be located on a post, such as a length of timber or metal, fixed to the prebuilt corner lead.

The second end of the brick line is then fed through the second slot 132 of the profile 100 from the first outer surface 106 side of the profile and into the second channel region 125. The second slot 132 may include a notch substantially midway along its length and extending into the first flange portion 102 to provide a slightly larger opening for ease of feeding the second end of the brick line through the profile via the second slot 132. The second end of the brick line can now be pulled sufficiently through the profile. The first outer surface 106 of the profile 100 is then located on an outside wall of a building from which a new wall is to be built, as shown in Figure 5. The profile 100 may be located on the same wall surface from which the new wall is to be built or on a side wall surface of a corner of the building wherein the new wall is to be built from the other wall surface of the corner. The profile 100 is oriented substantially vertically and a spirit level may be used to confirm the profile is oriented vertically and substantially parallel with the corner edge of the building. Alternatively, the profile may comprise a spirit level mounted thereon or moulded therein. As described above, each of the first slots 130 (not visible in Figure 5) will overlap a mortar course 502 of the existing wall 500 and suitable fixings, such as masonry screws, are used to secure the profile to the wall. At least the outer two slots may be used to secure the profile to the wall.

The second end of the brick line 450 is then secured to a second conventional line block (as illustrated in Figure 3) by wrapping the second of the brick line around the channel 210 of the second line block in a conventional manner. With sufficient tension in the brick line, the second line block is then located on the second flange portion 104 of the profile 100, as illustrated in Figure 4. As shown, the first inner surface 206 of the line block 200 engages with the end surface 109 of the second flange portion 104 of the profile 100 and the second inner surface 208 of the line block 200 engages with the second inner surface 112 of the second flange portion 104 of the profile 100.

The brick line 450 extends from the second line block 200 and out of the profile via the second slot 132 and recessed region 134 thereof. If the profile 100 is attached to the same wall surface from which the new wall is to be built, the brick line extends from the second line block, through the second slot 132 and recessed region 134, and over the second outer surface 108 of the second flange portion 104 towards the first line block located on the distal prebuilt corner lead. If the profile is attached to a side wall surface of a corner of the building wherein the new wall is to be built from the other wall surface of the corner, the brick line extends from the second block, through the second slot 132 and recessed region 134, and out towards the first line block located on the distal prebuilt corner lead.

Alternatively, the second end of the brick line may first be attached to the second line block in a conventional manner and the first end of the brick line then passed through the second slot 132 and out of the profile via the recessed region 134. The profile can then be attached to the existing wall (front or side face as described above) and the second line block located on the second flange portion of the profile. The first end of the brick line can then be taken to the distal corner lead and the first line block attached thereto in a conventional manner to apply a sufficient tension in the brick line before the first line block is located on the corner lead or post attached thereto. The first and second ends of the brick line are wrapped around the first and second line blocks respectively a sufficient number of times to apply a sufficient tension in the brick line and to ensure the same remains taut in use to provide an accurate horizontal datum to work to. A sufficient tension in the brick line also ensures either line block does not slip down the profile or corner lead or post respectively in use. If tension in the brick line 450 is lost and the second line block 200 slips down the profile, the second line block will be caught by the lower end region of the profile and the brick line will remain in the second slot. The tension can be restored and the second line block repositioned.

Desirably, in use, the second line block 200 is pulled into the second channel region 125 by the tension in the brick line and on to the second flange portion 104 which increases friction between the line block and the profile and helps to secure the line block in the desired location on the profile whilst each new course is laid. Additionally, the 75-degree orientation of the second inner surface 112 (and the end surface 109 for abutting the correspondingly angled inner surfaces of the line block) with respect to the substantially flat first outer surface 106 of the first flange portion 102 which engages with the existing wall surface also urges the line block against the second flange portion of the profile to improve grip and support of the line block on the profile in use. Alternatively, the second inner surface 112 may be oriented substantially perpendicularly to the first outer surface 106 or at any angle from around 45 to 90 degrees. The second inner surface 112 and/or the end surface 109 of the second flange portion 104 of the profile 100 may include a plurality of protrusions, such as ridges or bumps, to provide additional grip between the profile and the line block.

In use, the first line block is moved to a desired height on the distal corner lead or post secured thereto such that the brick line is aligned with a mortar course of the corner lead up to which a new course of bricks is to be built. The second line block 200 is then slidably moved along the profile to a corresponding height so that the brick line 450 is substantially horizontal and at the desired height to which the new course of bricks is to be laid. A spirit level may be used to confirm the brick line is horizontal. The first new course of bricks is then laid using the brick line as an accurate reference. The first line block is then moved up a course with respect to the corner lead and the second line block is slidably moved up the profile by a corresponding distance. A spirit level may be used to confirm the brick line is horizontal. The second new course of bricks is then laid on the first course of bricks using the brick line as an accurate reference. This process is repeated until the new wall is complete.

If the new wall being built is higher than the length of the profile, the upper fixing hole in the existing wall can be used as the lower fixing hole when the profile is secured higher up the wall as the new wall is being built. The ends of the profile may be open and each end slot 130 may continue into the respective open end to thereby allow the fixings to be loosened and at least the upper fixing to remain in the wall. The profile can be slidably moved down to release it from the upper fixing and up to release it from the lower fixing. The profile can then be slidably located on to the upper fixing via the lower slot and a new upper fixing can be located in the upper slot and engaged in a new upper fixing hole in the wall. The upper and lower fixings can then be tightened to secure the profile to the existing wall to continue building the upper courses of the new wall. This process can be continued until the new wall is complete.

When the new wall is complete, the profile is removed from the existing wall and the few fixing holes used to secure the profile to the existing wall are filled with new mortar. In view of the substantially uniform cross section of the profile along its length, the profile can be simply inverted to be used on the opposite side of the existing wall for building a new wall there off in the same way as described above.

Certain embodiments of the present invention therefore provide apparatus for selectively and efficiently adjusting the height of a brick line with respect to the ground or a lower course of bricks of a wall being built without need for using a brick pin which is often particularly strenuous, difficult, frustrating and time consuming to hammer into existing mortar and can undesirably compromise the integrity of the mortar and an existing wall itself. Furthermore, the many holes left in the vertical joints of each course of mortar by the brick pin according to conventional methods must be filled which also adds cost in terms of time and materials. The apparatus according to certain embodiments of the present invention desirably does not require the use of a brick pin and saves on time, materials and in turn cost, and also ensures less mortar is used which is environmentally friendly. The apparatus according to certain embodiments of the present invention also allows the end of a brick line to be efficiently and consistently supported proximal to an existing wall from which a new wall is to be built and at a desired level without the need for a brick pin whilst at least reducing, if not eliminating, the risk of the brick line unintentionally slipping in use.