Bespoke IG Masonry Support solutions achieve desired aesthetic without compromising on structural integrity

Overview

In the Greengate area of Salford and close to Manchester city centre, Colliers Yard is a stunning new development featuring new homes across three meticulously designed towers, each with detailed brick podiums ranging from four to five storeys high. Built by main contractor Renaker and specialist brickwork contractor PLF Ltd, and delivered by Denton Corker Marshall, the centrepiece is Cortland, a 50-storey tower comprising 559 luxury apartments, including a range of one, two and three-bedroom apartments and penthouses, and a broad mix of shared amenities.

Due to its long-standing relationship with the main contractor and brickwork contractor, IG Masonry Support was approached to design and manufacture bespoke masonry support and A1 fire-rated brick slip solutions for the project, addressing critical safety requirements in high rise construction. Being able to offer a comprehensive package of solutions for large scale projects, IG Masonry Support streamlined the construction process and helped ensure quality across all aspects of masonry work.

The Challenge

The project presented a series of unique challenges that demanded innovative solutions and technical expertise from IG Masonry Support. The design of the building featured an exceptionally wide 460mm cavity which could not accommodate standard fixing solutions. The corners of the building also presented structural challenges, necessitating bespoke solutions to ensure stability and aesthetic consistency. The perimeter brickwork needed to support substantial loads, specifically two floors of masonry at 14 kN. Additionally, the design had to account for and avoid concrete edges of piers running up the building, adding another layer of complexity to the support system design.

The Solution

To address the challenges, IG Masonry Support provided a full package of solutions including Welded Masonry Support, Brick Slip Lintels and brick cutting. The wide cavities required IG’s standard fixing solutions to be redesigned. IG Masonry Support incorporated bespoke dropper brackets and Top Hat systems which joined together to help accommodate the cavities at the corners of the building and support the B.O.S.S. A1 units.

Continuing from the bespoke solutions mentioned, these systems also had to account for supporting the perimeter of the brickwork's high-bearing loads. The Welded Masonry Support systems had to follow the profile of the columns of the corners of the building and support two floors of masonry at 14kN. The concrete edge that the fixings were attached back to required rigorous design testing. Careful consideration was taken to address the complex design of the corners, with several FEAs (Finite Element Analysis) carried out.

As the masonry support would not be flush with the slab that it would secure back to, and to avoid the concrete edge of the piers running up the building, IG Masonry Support designed bespoke Top Hats to accommodate the parts of the slab that projected outwards. Throughout the process, rigorous testing protocols were implemented to verify the structural integrity and performance of these bespoke solutions, ensuring they met both safety standards and project requirements.

Once the design for the initial floors of masonry support was approved, it could be replicated for the remaining floors, as each level was either similar or identical to the others. This repetition streamlined the construction process significantly. Throughout the project, IG Masonry Support's technical team provided full support, especially in complex areas of the building where the slab was not flush or where the masonry support had to navigate corners or piers.

Peter Tsang, Associate Architect at Denton Corker Marshall commented: "IG’s innovative approach to addressing our unique design challenges, particularly with the wide cavities and complex corner structures, was impressive. Their bespoke solutions, including the Dropper Bracket and Top Hat system, allowed us to achieve our desired aesthetic without compromising on structural integrity and the technical team's support throughout the project was invaluable."

All products were delivered to the site ready for immediate installation, with delivery schedules carefully coordinated to accommodate the client's build program. The B.O.S.S. A1 and Brick Slip Lintel units used in the project are fully A1 fire-rated and BBA approved, ensuring compliance with stringent building safety standards.

IG Masonry Support also provided extensive brick cutting services for the project, processing 12,442 bricks in total. This involved cutting standard stretcher and pistol bricks from Wickford Antique Brick stock to precisely fit the masonry support systems. This meticulous cutting ensured each piece integrated seamlessly with the support framework, maintaining the building's aesthetic and structural integrity.

Nico Smithson, Construction Manager at Renaker said: "IG Masonry Support's comprehensive package of solutions, including the Welded Masonry Support and B.O.S.S. A1 systems, streamlined our construction process significantly. The on-site adjustability of IG’s products allowed us to address unforeseen issues quickly while the pre-cut bricks and ready-to-install components kept the build on track. IG's technical team's constant support, especially in complex areas of the build, was instrumental in overcoming challenges and ensuring a smooth and cost-effective installation."

Colliers Yard was a complex build that presented a number of challenges but through close collaboration with the contractor Renaker and the design team, IG Masonry Support overcame any hurdles to keep the project on track. IG’s technical and design assistance, and a wide range of bespoke brickwork solutions played a vital role in creating the building’s high quality brick façade.