Precision masonry solutions for Manchester challenge

In the heart of Manchester’s Piccadilly regeneration area, The Castings is a newly built residential development consisting of 352 apartments including a mix of studio, one-, two-, and three-bed apartments alongside roof gardens, retail, and amenity spaces. Designed with a focus on sustainability, the four-stepped building elements rise to a height of 24 storeys and offer a highly efficient building fabric.

This high-rise project demanded masonry support at each of its 24 levels along with specialised brick slip solutions at various heights. A1 fire-rated brick slip solutions were required due to the building exceeding 11m. The building’s design incorporates movement joints at window edges, necessitating custom lintels to accommodate these features. IG Masonry Support was chosen for its longstanding relationship with subcontractor Midgard and its ability to supply a full package of masonry support, brick slip systems and brick cutting.

The Challenge

The Castings’ project presented a few challenges that required innovative solutions in terms of masonry support. Firstly, movement joints were positioned at window sill edges, requiring careful consideration in support design. The building's structure added further complexity, with slab edges varying in different areas after pouring. The brickwork pattern deviated from traditional methods, featuring a distinctive design where every third course stepped out by 10mm. This unconventional brick layout demanded precise planning and execution to ensure proper alignment and support throughout the façade.

The Solution

IG Masonry Support produced a variety of highly-bespoke solutions to address some unusual design challenges and avoid any clashes with other building elements, ensuring the build remained on schedule. IG was tasked with managing thermal movement in brickwork where lintels crossed movement joints. With traditional methods using DPC no longer viable due to new regulations, IG designed a bespoke Slip Plane Lintel with a separate bearing and a connection detail. This allowed movement along the lintel’s length while resisting vertical and rotational forces. Initial prototypes were tested for traditional loads, then adapted to simulate thermal movement. The final design was universal for left or right-hand movement joints.

The IG Masonry Support team adapted its systems to accommodate varying slab edges and cavity widths, requiring close collaboration to ensure each support system met specific area requirements. In some instances, bracket sizes were reduced or shims provided to allow fine adjustment for increased cavity widths.

The B.O.S.S. A1 (Brick On Soffit System) units were designed to follow the unusual brickwork course including the 10mm protrusion at every third course, particularly prominent at the first level. Additionally Folded Angle masonry support and cleats were supplied to support the sill and manage abseiler loads.

This comprehensive approach, which included standard lintels from IG Lintels, was facilitated by a single point of contact for both sister brands, streamlining communication and project management.

Ben Douglas, Regional Construction Director at Kinlan said: “Working with IG Masonry Support on The Castings was exceptional. The company’s bespoke designs, especially for the unique brick pattern and B.O.S.S. A1 units, demonstrated their technical expertise. The fact the team was so responsive significantly eased our installation process on what was a challenging project.”

Through close collaboration with Midgard Ltd, brickwork contractor Kinlan, and the design team, IG Masonry Support provided technical and design assistance, and a comprehensive range of brickwork solutions. All masonry support products were delivered to the site ready for immediate installation, with delivery schedules tailored to the client's build program.

Bespoke lintels were designed to meet specific client requirements, particularly addressing the thermal movement challenge. The collaboration between IG Masonry Support and IG Lintels, coordinated through a single point of contact, enhanced project efficiency.

With this landmark residential project now complete, IG Masonry Support’s ability to deliver customised, high-quality solutions whilst maintaining project timelines and meeting stringent safety and performance standards, ensured the client’s objectives were achieved.