Abstract:
The present invention provides for a novel balcony, a kit and a method of attaching a balcony to a building or existing construction. One aspect of the invention provides a balcony for attachment to an existing construction, the existing construction have a plurality of stubs fitted thereto, each stub having a first engagement portion, the balcony having a plurality of second engagement portions on one side of the balcony wherein the first and second engagement portions are arranged to engage with each other so as to cause the weight of the balcony to be supported by the existing construction and the balcony to be securely attached to the construction.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates to a balcony and to a method of fitting a balcony to a building or other structure. 
       BACKGROUND OF THE INVENTION 
       [0002]    Metal balconies are often specified in the plans drawn up by architects for new or existing buildings. These balconies may be decorative, but in many cases must be structurally secure and capable of supporting the load of several people as well as the furniture (balustrades, panels, handrails, etc.) needed to make the balcony safe. 
         [0003]    In existing building approaches, a metalworker will generally attend the site to bolt ‘stubs’ onto/into the concrete frame while the basic structure of the building is being constructed. At a later stage, often after the main structure of the building, including brickwork and windows is complete, a frame for the balcony is manufactured off site from mild steel, galvanised and transported to site. The balcony frame is then lifted by crane and hold aloft adjacent to the stubs whilst the frame is firstly aligned with the stubs and then bolted onto them by workers working underneath or adjacent the loose balcony. 
         [0004]    Whilst this method has been followed for many years and produces acceptable results, there are a number of problems with this process. 
         [0005]    Firstly, there is a safety risk for the workers who are aligning the balcony and bolting it in place. These workers normally have to either work from either an elevated platform (a “cherry picker”), or on a scaffold tower from the ground level or the floor below. There is inevitably a risk of falling associated with such work at height. Furthermore there are risks associated with the manual handling of trying to push the balcony into position, and a risk of trapping hands and fingers when trying to get the balcony into position and bolted on. These risks are increased because of the length of time it takes to fix a balcony using this method (see below). 
         [0006]    Secondly, it takes a substantial amount of time to install each balcony using this method. The crane has to stay in position supporting the balcony in mid-air while the workers align and bolt the balcony firmly in place. The workers then have to move all their access equipment and tools up to the next floor or balcony location before they can start the next one. As a result, the delivery driver also has to stay on site whilst each of the balconies is lifted into position one at a time through the day. 
         [0007]    Thirdly, the resulting balconies are far from ideal in terms of their appearance, or alternatively require additional work on site to improve their appearance. Due to the need for the workers installing the balcony to have access to both the bolts and the nuts in order to secure the balcony to the building, the plates through which the bolts pass to secure the balcony to the building have to project out from the building line so they can be accessed from both sides. This means the plates and bolts are usually visible from beneath the finished balcony which does not look very good. In order to address this problem, balconies can have a soffit fitted underneath them, such as timber or metal cladding. However since access is required during the installation process to the bolts and nuts which will be hidden by such a soffit, the soffit has to be retrofitted to the balcony once all the bolts are tightened, which takes up more on site time. 
         [0008]    The present invention aims to address one or more of the above problems with existing balcony construction and fitting processes. 
       SUMMARY OF THE INVENTION 
       [0009]    Accordingly, at their broadest, aspects of the present invention provide a method of attaching a balcony to a building or other construction by dropping or sliding the balcony onto pre-fitted stubs, a balcony which is configured to be attached by dropping or sliding onto pre-fitted stubs and a kit comprising such a balcony and corresponding stubs. 
         [0010]    A first aspect of the present invention preferably provides a balcony for attachment to an existing construction, the existing construction have a plurality of stubs fitted thereto, each stub having a first engagement portion, the balcony having a plurality of second engagement portions on one side of the balcony wherein the first and second engagement portions are arranged to engage with each other so as to cause the weight of the balcony to be supported by the existing construction and the balcony to be securely attached to the construction. 
         [0011]    Preferably when the second engagement portions engage with the first engagement portions, no further connections are necessary in order to secure the balcony to the building or construction and so the process can be simple and quick. 
         [0012]    In one embodiment, the second engagement portions are generally hook-shaped and the first engagement portions are configured to receive the second engagement portions such that the balcony can be lowered onto the stubs and securely attached to the construction. 
         [0013]    In this manner the balcony can be lowered from above the stubs so as to “hook on” to the stubs and connect the balcony securely to the building. A lowering operation from a crane or similar structure is a very simple operation and the human input required in the operation may be limited to the operation of the crane and the guiding of the engagement portions together to secure the balcony. This can result in a very quick operation to attach the balcony to the building. 
         [0014]    The balcony of this embodiment preferably has a framework structure and the second engagement portions comprise a projecting hook attached to that framework. For example, the projecting hook may be welded to the framework. 
         [0015]    The projecting hook may include a first member which is attached to the framework and a second member which forms the hook. More preferably the first and second members may be arranged substantially at right angles to each other. For example, the projecting hook may be substantially L shaped in profile when viewed from the side of the balcony. 
         [0016]    In certain configurations, the hook can be formed of two or more projecting portions with a recessed portion between them. 
         [0017]    In another embodiment the first engagement portions comprise one or more projections from the stubs and the second engagement portions comprise one or more apertures or cavities in the structure of the balcony which are configured so as to receive the projections such that the balcony can be slid substantially horizontally onto the stubs by sliding the apertures or cavities onto the projections. 
         [0018]    In this manner the balcony can be suspended level with the desired level of installation and the stubs and then “slid on” to the stubs. This type of balcony may be preferred for larger or heavier balconies where a greater rotational moment of the balcony is required to be supported by the stubs. 
         [0019]    In a particularly advantageous configuration of this embodiment, the balcony may have a framework structure and the apertures or cavities are formed as part of the framework structure. This may allow the balcony to be constructed with a hollow frame which then provides for the cavities as part of that frame. Alternatively, apertures can be provided in the frame which can be slid over the projections. In one configuration, apertures can be provided in a plurality of parts of the frame which each run substantially perpendicular to the projections such that the turning moment of the balcony can be supported. 
         [0020]    A second aspect of the present invention provides a kit including a balcony according to the above first aspect (including some, all or none of the optional or preferred features of that aspect) and the plurality of stubs. 
         [0021]    The kit of the second aspect preferably provides a complete kit for the assembly of a balcony on the exterior of an existing construction or a building under construction. 
         [0022]    At its broadest, a third aspect of the present invention provides a method of attaching a balcony to a building other construction wherein the balcony can be “dropped on”, “slid on” or otherwise engaged with components secured to the construction, preferably without the need for detailed or complex attachment processes. 
         [0023]    Preferably the third aspect provides a method of attaching a balcony to a building or other existing construction, the method comprising the steps of: fitting a plurality of stubs to the existing construction, each stub having at least one first engagement portion; attaching a balcony having a plurality of second engagement portions on one side of the balcony to the building by causing said second engagement portions to engage with the first engagement portions such that the weight of the balcony is supported by the stubs and the balcony is securely attached to the construction. 
         [0024]    By fitting the plurality of stubs to the building in advance of attaching the balcony, only minor work is required for the attachment of the stubs to the construction and once the stubs have been fitted, the balcony can be simply, quickly and easily attached to the stubs to form a secure attachment. This may allow for short installation times when the balcony itself is delivered to site and preferably also avoid the need for lengthy, difficult and/or complex connection processes when attaching the balcony to the building. 
         [0025]    In one embodiment, the second engagement portions are generally hook-shaped, the first engagement portions are configured to receive the second engagement portions and the step of attaching includes lowering the balcony from a position and vertically above the stubs so that the hook-shaped engagement portions engage with the first engagement portions of the stubs. 
         [0026]    In this embodiment, the balcony can be lowered from a crane or similar arrangement to immediately engage by “hooking on” to the stubs. Preferably when the second engagement portions engage with the first engagement portions, no further connections are necessary in order to secure the balcony to the building or construction and so the process can be simple and quick. 
         [0027]    In another embodiment, the first engagement portions comprise one or more projections from the stubs and the second engagement portions comprise one or more apertures or cavities in the structure of the balcony which are arranged to receive the projections and the step of attaching includes suspending the balcony such that it is substantially vertically aligned with the stubs and sliding the apertures or cavities over the projections. 
         [0028]    In this embodiment, the balcony can be suspended from a crane or similar arrangement and then “slid on” to the stubs in a substantially horizontal motion. Preferably when the second engagement portions engage with the first engagement portions, no further connections are necessary in order to secure the balcony to the building or construction and so the process can be simple and quick. 
         [0029]    The method of the present aspect may include any combination of some, all or none of the above described preferred and optional features. 
         [0030]    The method of the present aspect is preferably implemented with a balcony according to the first aspect of this invention, as described above, or a kit according to the second aspect of this invention, as described above, but need not be. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0031]    Embodiments of the invention will now be described by way of example with reference to the accompanying drawings in which: 
           [0032]      FIGS. 1 a -1 c    show perspective views of part of a balcony according to an embodiment of the present invention; 
           [0033]      FIGS. 2  shows a perspective view of a stub which forms part of an embodiment of the present invention; 
           [0034]      FIGS. 3 a  and 3 b    show, respectively, a plan view and a side view of the installation of a balcony according to an embodiment of the present invention; and 
           [0035]      FIG. 4  shows a perspective view of a balcony according to an embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0036]      FIGS. 1 a -1 c    show perspective views of part of the framework of a balcony according to an embodiment of the present invention and the formation of a hook-shaped engagement portion on that part of the framework. 
         [0037]      FIG. 1 a    shows a steel arm  11  which forms part of the main structure of the balcony. The arm  11  is made from 152×89 UB section (an I-shaped beam). As usual, it has a back plate  12 , typically sized 100 mm wide×150 mm high×12 mm thick, welded to the end of it. 
         [0038]    A hook-shaped engagement portion  13 , shown in  FIG. 1 b   , which is a piece of 150×50×12 mm steel angle cut 100 mm long is then welded to the arm  11  and the back plate  12  around  3  sides, to form a hook. 
         [0039]    The hook-shaped portion  13  has a first part  13   a  which is configured to provide a connection to the arm  11  and a second part  13   b  which is substantially at right angles to the first part. In the centre of this second part  13   b , a tapered notch  13   c  is cut (for example using a plasma cutter). This notch helps to guide the balcony into position on the stubs and also acts to stop it from moving sideways when attached. 
         [0040]      FIG. 2  shows a stub  20  itself will be made from steel plates welded together to form an H-shaped construct. A first plate  21  of the stub is provided with mounting holes through which bolts can pass to secure the stub  20  to a building. The stub  20  of  FIG. 2  is shown with four mounting holes, but it will be appreciated that more or fewer mounting holes may be provided depending on the size of the stub and the size of balcony to be supported. 
         [0041]    The stub  20  has a fin  22  which projects from the building. In this embodiment the fin  22  is 150 mm high×30 mm thick. To the end of the fin  22  is welded a plate  23  which is typically the same size as the back plate  12  on the end of the balcony arm  11 . 
         [0042]      FIGS. 3 a  and 3 b    show the typical layout of the balcony  10  and stubs  20  in plan view and side view respectively. In  FIG. 3 a    a typical balcony  10  with area dimensions of 3 m×1.2 m is shown which has a generally lattice structure of three arms  11  (which are configured as set out in  FIG. 1  above) and three cross beams  15 . These arms  11  and cross beams  15  support a floor structure (not shown) and may also be encased on the underside e.g. for aesthetic reasons. 
         [0043]    As shown in  FIG. 3 a   , the stubs  20  are attached to the wall of the building  30 , for example using bolts  33 , and each stub is located so as to engage with the hook  13  of one of the arms of the balcony. The balcony shown in  FIG. 3  has three arms, three hooks and therefore three stubs are affixed to the building. However, it will be appreciated that any number and configuration of hooks, arms and stubs can be chosen depending on the specific installation, for example depending on the configuration and construction of the balcony, the weight and moment of the balcony to be supported and the dimensions of the stubs and hooks. 
         [0044]    As shown in  FIG. 3 b   , the balcony  10  is attached to the building  30  by simply lowering the balcony from a position above the stubs  20  so that the hooks  13  engage with the fin  22  and outer plate  23  of the stubs, thereby securing the balcony to the building by supporting both its weight and its turning moment. This process is, compared to the prior art processes described above, simple in terms of labour in that, apart from the operation of the crane to lower the balcony, human input is only required to guide the hooks  13  onto the stubs  20  and no further fixing operations are required. 
         [0045]    As shown in  FIG. 3 b   , the stub  20  can be connected to the concrete frame  31  of the building whilst the exterior brickwork (or other cladding material) can be built around the stub, thereby potentially hiding or disguising the connection of the stubs to the building. 
         [0046]      FIG. 4  shows a perspective view of a balcony  10 ′ according to a second embodiment of the present invention in position for mounting on a building  30 ′. Only the frame of the balcony  10 ′ is shown in  FIG. 4 , as the deck that would normally form the upper surface of the balcony has been omitted to show the internal structure of the balcony. Similarly, the balcony would usually have a lower surface such that the internal structure of the balcony frame that is shown in  FIG. 4  would not normally be visible from below. 
         [0047]    As with the first embodiment described above, stubs  20 ′ are attached to the wall of the building  30 ′, for example using bolts (which are not shown in  FIG. 4  as they are covered by cladding  31 ′). In the embodiment shown there are four stubs  20 ′. Again, it will be appreciated that any number and configuration of hooks, arms and stubs can be chosen depending on the specific installation, for example depending on the configuration and construction of the balcony, the weight and moment of the balcony to be supported and the dimensions of the stubs and hooks. 
         [0048]    In the embodiment shown in  FIG. 4 , the stubs  20 ′ are identically constructed from 152×89 mm I-beam steel  22 ′ to which an end plate  23 ′ has been welded. 
         [0049]    The frame of the balcony  10 ′ shown in  FIG. 4  is of an open lattice type structure, in this case manufactured from 200×90 mm parallel flange channel (PFC) steel. The balcony has two arms  11 ′ forming the left and right sides of the frame when viewed facing the building which are connected by three cross beams  15   a ,  15   b  and  15   c.    
         [0050]    A first of these cross beams  15   a  forms the front edge of the frame when viewed facing the building and is a simple metal beam. 
         [0051]    A second of these cross beams  15   c  forms the rear edge of the frame when viewed facing the building and has four apertures  16  which are sized and positioned so as to permit each of the stubs  20 ′ to pass through the apertures with a small clearance. The degree of clearance is generally chosen as a trade-off between a) providing for easier installation by requiring less precision in the installation process and a degree of tolerance for the attachment of the stubs  20 ′ to the building  30 ′ and b) providing a snug fit for the balcony  10 ′ in its fitted position. 
         [0052]    The third cross beam  15   b  is positioned parallel to and intermediate the other two cross beams  15   a ,  15   c . This cross beam  15   b  also has four apertures  17  corresponding to those in the second cross beam  15   c  and likewise sized and positioned so as to permit each of the stubs  20 ′ to pass through with a small clearance. 
         [0053]    The position of the third cross beam  15   b  relative to the other cross beams  15   a ,  15   c  is chosen depending on the weight and turning moment of the balcony (and its anticipated load) so as to provide a secure and stable support for the balcony through the engagement between the second and third cross beams and the stubs  20 ′. It will therefore be appreciated that for lighter balconies, the stubs  20 ′ can be made shorter and the second cross beam  15   b  positioned closer to the third cross beam  15   c , and for heavier balconies it may be preferred that the stubs  20 ′ are of similar dimensions to the arms  11 ′, and in some variants, the first cross beam  15   a  could also have apertures formed in it, such that the stubs engage with this cross beam as well. In such configurations, the second cross beam  15   b  could be provided midway between the other cross beams, or could be omitted entirely. 
         [0054]    For installation, the balcony  10 ′ is suspended from a crane in a position such that the apertures  16  are level with the stubs  20 ′ and adjacent thereto (i.e. in the position shown in  FIG. 4 ). The balcony  10 ′ is then attached to the building  30 ′ by moving the balcony horizontally so that the stubs  20 ′ pass through the apertures  16  and  17  thereby securing the balcony to the building by supporting both its weight and its turning moment. This process is, compared to the prior art processes described above, simple in terms of labour in that, apart from the operation of the crane to lower the balcony, human input is only required to guide the stubs  20 ′ into the apertures  16  as the balcony is moved towards the building and no further fixing operations are required. 
         [0055]    In a further embodiment of the present invention, which is not illustrated in the Figures, but which is similar to the second embodiment described above, the arms of the balcony structure provide the “apertures” by having a cross-section (as viewed from the building) which substantially matches that of the stubs, such that the balcony can be installed by sliding the arms over the stubs. 
         [0056]    Although the embodiments of the invention described above have been set out with precise dimensions it will be apparent to the skilled person that these dimensions are purely illustrative of specific embodiments of the present invention and that the dimensions can be varied depending on the configuration of the balcony desired without departing from the scope of the present invention.