Animated Structural Arch Construction

Segmental Lintel   Flat Lintel   Circular Lintel
   
     
Arch Construction Animation

Fully bonded structural arch with hidden stainless steel lintels

Reinforced Brick Cladding

SAFESECURE®  Secure retention of facing bricks in all situations.

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Bekynton Field is the largest new development at Eton College since it was founded.

The £19 million development includes 40 new classrooms for modern languages, economics and politics, as well as a lecture theatre and exhibition space.

It features conservation-grade brickwork as well as stonework features and more than 80 brick arches.

Designed by architect Michael Simpson of John Simpson Architects & Partners Ltd in the neoclassical style, it is one of the few areas of the College that required renewal rather than conservation and was designed to blend in with the historic environment. The main contractor was Feltham Construction with the bricklaying undertaken by Lee Marley. Brick Cutters was commissioned by Feltham's Technical Consultant Ian Gilmore who had not been able to get satisfactory responses from any of the tendering brick suppliers or brick cutters.

Feltham Construction commissioned Brick Cutters to produce 28 of the more complicated arches in a total of 88 arches for three buildings.  The brief was to replicate a ‘thick wall’ appearance while working in a thin wall building with a cavity and structural frame behind.

Every masonry component was mechanically secured as well as epoxy resin bonded in position. Brick Cutters commissioned Exescodo Design Ltd to develop the detailed drawings required for approval and manufacture.

For all these arches, individual brick voussoirs were machine cut to a tight tolerance, bonded into fabricated laser cut and welded stainless steel trays and pointed and delivered for onsite assembly into the completed arches. The stainless steel lintels and backing trays were fabricated by Harvey Steel lintels. Polystyrene formers were supplied for the on site installation by Cordek Ltd.

The arches shown above and to the left form a vaulted walk-through between two of the new buildings at the college. Lower left is shown a link arch in red brick. This is to the left of the entrance to the walk-through shown above.

This double arch was the first to be commissioned.  It comprises an inner segmental concave arch, with an outer flat segmental arch incorporating a concave soffit.  Each pre-fabricated voussoir unit was formed from bespoke bricks of large dimension and accurate curved faces (1), cut to a very high tolerance to match the curves in two directions. The voussoir units were bonded into stainless steel backing trays and pre-pointed in lime mortar. The steel trays were then back filled with concrete before delivery to site for installation on the purpose made laser profiled formers.

Special brick shapes by WH Collier Ltd, Marks Tey, Essex

Structural Arch Projects

Jafar Hall, Eton College

This award winning project features conservation grade brickwork as well as stonework features and more than 80 brick arches for which Brick Cutters produced 28 of the more complicated arches.

Granary Wharf Chelsea

This prestigious development in Lots Road, Chelsea features structural segmental brick arch lintels supplied with calculations to meet building control regulations.

St Pancras Station

brick archesWest Elevation arches were set out & hand cut at Brick Cutters' workshops. The project won 4 titles and high praise from Judges at the 2006 Brick Awards. The Renaissance Hotel was completed in 2010 in similar style and quality.

Kew Gardens Library and Herbarium

structural steel brick lintelsThe Library is an impressive timber and brick clad facade around a precast concrete frame. Brick Cutters was asked to design and supply the massive 12m hidden steel lintels to the large glass entrance and windows.

St Pancras Renaissance Hotel

After a  decade-long transformation the Midland Grand hotel, the Victorian palace attached to St Pancras station, was returned it to its original luxury in 2011.

Bekynton Field, Eton College

Bekynton Field is the largest new development at Eton College since it was founded.

The £19 million development includes 40 new classrooms for modern languages, economics and politics, as well as a lecture theatre and exhibition space.

It features conservation-grade brickwork as well as stonework features and more than 80 brick arches.

Kings Cross Station

The 1852 Grade 1 listed station has been completely refurbished and massively expanded whilst the station remained open for business. Brick Cutters designed & supplied large span brick arch lintels with hidden structural support that could be man handled into position without crane access.