AU2010227027B2

AU2010227027B2 - Apparatus and Method for Mounting Building Panels to the Framework Assembly of a Wall Structure

Info

Publication number: AU2010227027B2
Application number: AU2010227027A
Authority: AU
Inventors: Joseph Emmanuel Zarb
Original assignee: CSR Building Products Ltd
Current assignee: CSR Building Products Ltd
Priority date: 2009-10-07
Filing date: 2010-10-07
Publication date: 2016-12-01
Anticipated expiration: 2030-10-07
Also published as: AU2010227027A1; AU2017200718A1; AU2010101096A4

Abstract

Abstract An apparatus, and method of using the apparatus, for fastening a plurality of building panels to a frame assembly of a wall structure. The apparatus includes at least one base member, which is adapted to be secured to the frame assembly of the wall structure and one or more elongate members for mounting the building panels thereon. Each of the elongate mounting members are adjustably positionable with respect to the base member. In use, the position of each of the elongate mounting members is adjusted relative to both the frame assembly of the wall structure and the ground. When in a desired position, each of the elongate mounting members is securely fixed to the base member, such that one or more building panels can be mounted" to each of the one or more elongate members, thereby forming a substantially flush external wall surface.

Description

2010227027 13 Oct 2016 1

Apparatus and Method for Mounting Building Panels to the Framework Assembly of a Wall Structure

TECHNICAL FIELD 5 The present invention relates to an apparatus for supporting building panels from the framework assembly of a wall structure and a method of cladding at least a portion of a wall structure using the apparatus and a plurality of building panels.

10 BACKGROUND TO THE INVENTION

In Australia, there are two basic methods of building homes. The first and most common is the framed construction method, traditionally used for brick veneer over a timber frame. The second is the solid, or load 15 bearing construction method, generally used for double brick or block homes.

The present invention relates particularly to the framed construction method, though it may also be used to clad a load bearing wall. 20 With the framed construction method, a load bearing skeleton, typically of timber or steel, is assembled to provide the frame for the building. The frame is then provided with roofing and cladding to provide weather resistance. The cladding can be formed of a number of 25 materials including timber, fibreboard, sheet metal, stone, brick veneer, and concrete panels. Usually, several sheets or panels of cladding will be required to cover a single wall.

The construction of conventional walls, either by the 30 framed construction method or by the load bearing construction method is typically slow and labour-intensive 8247825J (GHMatters) P100954.AU 12/10/16 2010227027 13 Oct 2016 2 as well as requiring a high degree of skill and workmanship. Any failure in the workmanship may result in unevenness in the wall surface, and can lead to a wall surface that is not flush or smooth. 5 In the construction of conventional walls, any variation in the wall frame will need to be accounted for in order to avoid a wall surface that deviates from a substantially flush or smooth finish. Typically, this is achieved by tedious efforts at straightening the wall frame itself 10 and/or packing the space behind the building panels.

United States Patent No 5575124 discloses a wall system comprising an assembly of independent building panels.

Each of the building panels has a peripherally closed rectangular supporting frame forming one, or by means of 15 Intermediate frame elements fixed to this supporting frame, several open compartments. These open compartments are arranged in a wall framework for receiving and fixing the building panels. Thereby, the wall can be constructed by slotting each of the building panels including the 20 intermediate frame elements into the wall framework.

However, this method suffers the disadvantage of requiring a special supporting or intermediate frame for each building panel as well as a unique wall frame work, which is customised to receive the building panels including the 25 special supporting intermediate frame. This system therefore may have limited applications and relatively high associated construction costs. A concealed ceiling system is manufactured and sold under the trade name Slimceil™ by Studco Building Systems Pty 30 Ltd, which is the subject of Australian Innovation Patent No. 2009100758 entitled "Bracket and Mounting Arrangement".

This system includes a bracket for connecting a first 8247826_1 (GHMatters) P100954.AU 12/10/16 2010227027 13 Oct 2016 3 structure to a second structure. The bracket includes a first leg, a second leg and a web portion extending between the first and second legs. The bracket includes one or more elongate apertures that are located in each of 5 the legs.

The bracket is attached to a surface of the first structure through the web portion and connection of the bracket is made to the second structure through an intermediate portion via one or more of the elongate 10 apertures.

The relative position of the bracket to the intermediate portion is adjustable via the elongate apertures to account for variations in the surface of the first structure. 15 This system is designed for use in ceilings and it is not adapted for use in the construction of a wall structure, i.e. a vertical application rather than a horizontal application. Similarly, the previous Studco system is not designed or engineered to withstand the various wind load 20 classifications (N1, N2, N3 and Cl).

Furthermore, the previous Studco system is not adapted for external panel types such as relatively heavy autoclaved aerated concrete (AAC) masonry panels, fibre cement, polystyrene, vinyl and timber cladding to be secured to 25 the intermediate portion.

Thus, it would be advantageous to have apparatus for supporting building panels from a wall structure and a method of cladding at least a portion of a wall structure using the apparatus and building panels, which provide for 30 a relatively fast, simple and reduced cost construction of a wall structure, as well as providing a flush or smooth wall surface which has an aesthetically pleasing finished appearance. 8247825_1 (GHMatters) P100954.AU 12/10/16 2010227027 13 Oct 2016 4

The present invention overcomes at least some of the disadvantages of previously known approaches in this field, or at least would provide a useful alternative.

DISCLOSURE OF INVENTION 5 Throughout this specification and claims, the terms "wall structure" and "wall assembly" are used to include the structural portion of either a solid wall or the stud frame of a framed construction.

According to one form of the present invention there is 10 provided an apparatus for mounting a building panel to a frame assembly of a wall structure comprising a base member adapted to be secured to the frame assembly of the wall structure, the base member having a first length, 15 the base member having a first flat surface for secure connection to the frame assembly to locate the base member with respect to the frame assembly and at least one second flat surface extending outwardly from the first flat surface for connection to an elongate mounting member for 20 mounting the building panel for forming the wall structure , the elongate mounting member having a flat mounting surface and at least one flat side portion extending from the flat mounting surface, 25 the elongate mounting member having a second length, the second length being greater than the first length, the elongate mounting member being adjustably positionable with respect to the base member to adjust the position of the building panel with respect to the frame assembly to a 30 desired position, 8247825J (GHMatters) P100954.AU 12/10/16 2010227027 13 Oct 2016 5 such that when the elongate mounting member is in the desired position the flat side portion of the elongate mounting member is in contact with the second flat surface of the base member for adjusting the position of the 5 elongate mounting member relative to the frame assembly of the wall structure to enable the elongate mounting member to be securely fixed to the base member, wherein when the elongate mounting member is securely fixed to the base member in the desired position the 10 building panel can be mounted to the elongate mounting member to form a substantially flush external wall surface of the wall structure in which the building panel is received against the flat mounting surface and the flat side portion of the elongate mounting member to connect 15 the building panel to the frame assembly.

According to one form of the present invention there is provided a method of mounting a building panel to a frame assembly of a wall structure using a building panel mounting apparatus, the method comprising the steps of 20 securing at least a first flat surface of a base member to the frame assembly of the wall structure to secure the base member to the frame assembly, the base member having a second flat surface extending outwardly from the first flat surface for cooperative 25 engagement with an elongate mounting member having a flat mounting surface and at least one flat side portion extending outwardly from the flat mounting surface, the elongate mounting member for mounting the building panel thereon for forming the wall structure, the elongate 30 mounting member having a length greater than the length of the base member, locating the elongate mounting member with respect to the base member so that the flat side portion of the mounting member is in contact with the second flat surface of the 8247825J (GHMatters) P100954.AU 12/10/16 2010227027 13 Oct 2016 6 base member, adjusting the location of the elongate mounting member with respect to the base member to position the elongate mounting member with respect to the frame assembly in a 5 desired position to adjust the location of the elongate member with respect to the frame assembly, securely fixing the elongate mounting member to the base member when the elongate mounting member is in the desired position with the second flat surface of the base member 10 in contact with the at least one side portion of the elongate mounting member, mounting the building panel to the elongate mounting member to form a substantially flush external wall surface of the wall structure, 15 wherein the building panel is received against the flat mounting surface and the flat side portion of the elongate mounting member to connect the building panel to the frame assembly.

Preferably, the building panels are lightweight aerated 20 concrete (AAC) masonry panels.

Preferably, the elongate member includes a body portion having an external surface adapted to have one or more building panels mounted thereon and two opposed, spaced apart flange members adapted to be movably positioned with 25 respect to the base member and secured thereto when the elongate member is in a desired position.

Preferably, the elongate member has a substantially C-shaped cross section when viewed in end view.

Preferably, the elongate member is manufactured from a 30 rigid material selected from one or more of plastic, aluminium, steel, metal or wood. 8247826_1 (GHMatters) P100954.AU 12/10/16 7 2010227027 13 Oct 2016

In one embodiment of the present invention the base member is preferably a batten.

In a second embodiment of the present invention the base member is preferably a length of angle having a 5 substantially C-shaped cross section when viewed in end view.

Preferably, the base member is manufactured from one or more of plastic, fibre cement, aluminium, steel, wood or compressed foam. 10 Preferably, the base member defines a channel for receiving a portion of one of the elongate mounting members therein.

Preferably, the portion of the elongate mounting members that is received in the channel of the base member is the 15 spaced apart flange members.

Preferably, the elongate members are securely fixed to the base member by one or more mechanical fixing means selected from the group consisting of a nail, a screw or a rivet. 20 Preferably, the length of each elongate member is longer than the vertical height of each of the building panels.

In this specification, unless the context clearly indicates otherwise, the term "comprising" has the nonexclusive meaning of the word, in the sense of "including 25 at least" rather than the exclusive meaning in the sense of "consisting only of". The same applies with corresponding grammatical changes to other forms of the word such as "comprise", "comprises" and so on.

BRIEF DESCRIPTION OF THE DRAWINGS 30 Preferred embodiments of the invention will now be described, by way of example only, with reference to the 8247825_1 (GHMatters) P100954.AU 12/10/16 2010227027 13 Oct 2016 8 accompanying drawings in which: FIG 1 shows a perspective view of a framework assembly for a wall structure of a building adapted for use with the present invention; 5 FIG 2 shows a perspective view of a building panel adapted for use with the present invention; FIG 3 shows a perspective view of a base member in accordance with a first embodiment of the present invention; 10 FIG 4 shows a perspective view of an elongate mounting member of the present invention; FIG 5 shows a perspective view of a base member in accordance with a second embodiment of the present invention; 15 FIG 6 shows a front perspective view of the base member of FIG 3 installed on a frame assembly as shown in FIG 1; FIG 7 shows a perspective view of the elongate mounting member of FIG 4 being installed onto a wall assembly 1 as shown in FIG 1 by engaging with a plurality of base 20 members; FIG 8 shows a perspective view of a frame assembly of a wall structure as shown In FIG 1 fitted with a plurality of the elongate mounting members of FIG 4 secured to a plurality of base members; 25 FIG 9 shows a perspective view of the adjustment of one of the elongate mounting members of FIG 4 with respect to the frame assembly of the wall structure as shown in FIG 1 and the ground; FIG 10 shows a perspective view of the adjustment of a 30 plurality of the elongate mounting members of FIG 4 with 8247825_1 (GHMatters) P100954.AU 12/10/16 2010227027 13 Oct 2016 9 respect with respect to the frame assembly of the wall structure as shown in FIG 1; FIG 11 shows a perspective view of a partially completed wall structure including a frame assembly as shown in FIG 5 1 fitted with a plurality of the elongate mounting members of FIG 4 secured to a plurality of base members; FIG 12 shows a front perspective view of a plurality of building panels secured to the partially completed wall structure of FIG 11 with an optional horizontal stud 10 member; FIG 13 shows a front perspective view of a completed wall assembly constructed according to the method of the present invention; FIG 14 shows a top view of the plurality of building 15 panels secured to the partially completed wall structure of FIG 11 with an optional horizontal stud member, FIG 15 shows a side perspective view of the building panels secured to the partially completed wall structure of FIG 11 with an optional horizontal stud member; 20 FIG 16 shows a side plan view of a completed wall assembly constructed according to the method of the present invention; FIG 17 shows a perspective view of a base member in accordance with a third embodiment of the present 25 invention being installed on a frame assembly as shown in FIG 1; FIG 18 shows a front perspective view of the base member of FIG 19 installed on a frame assembly as shown in FIG 1; FIG 19 shows a sectional view of a completed wall assembly 30 constructed according to the method of the present invention, including a control joint; 8247825J (GHMatters) P100954.AU 12/10/18 2010227027 13 Oct 2016 10 FIG 20 shows an enlarged sectional view of the control joint of FIG 19; FIG 21 shows a front perspective view of a completed wall assembly including a window frame, constructed according 5 to a first embodiment of the method of the present invention; FIG 22 shows a front perspective view of a completed wall assembly, including a window frame, constructed according to a second embodiment of the method of the present 10 invention; FIG 23 shows a front perspective view of a completed wall assembly, including a window frame, constructed according to a third embodiment of the method of the present invention; 15 FIG 24 shows a top plan view of a completed internal wall assembly constructed according to the method of the present invention, including a combination of the base members shown in FIG 3 and FIG 5; and FIG 25 shows an enlarged top plan view of a corner portion 20 of the completed internal wall assembly shown in FIG 24.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The present Invention generally relates to an apparatus for mounting building panels on a supporting structural frame, such as those constructed of steel or timber. 25 Specifically, the building panels are lightweight autoclaved aerated concrete (AAC) masonry panels. One such suitable type of building panels are manufactured and sold under the Hebei® trade mark by CSR Building Products Limited. 30 Similarly, the present invention also relates to a method of cladding at least a section of a wall structure using 8247826_1 (GHMatters) P100954.AU 12/10/16 2010227027 13 Oct 2016 11 the apparatus of the invention and a plurality of building panels. The apparatus and method of the present invention are described below in combination with the drawings shown in FIGS 1 to 25. 5 FIG 1 shows a sample stud frame assembly 20 for a wall structure of a typical building construction. Typically, the stud frame assembly 20 is at least 1000 mm high and 1000 mm wide, having a plurality of 600mm centre studs 22 spaced along the length of the stud frame. 10 The apparatus of the present invention includes at least one base member 30 for attaching to the centre studs 22 of the wall frame assembly 20 and one or more elongate mounting members 40 for mounting a plurality of building panels 10 thereon. 15 In one preferred embodiment, the base member 30 is in the form of a C-section bracket 36, as is best shown in FIG 3. The C-section bracket 36 is made of a pliable but rigid material, such as rigid plastic, aluminium, timber, steel or the like. 20 This configuration is particularly suitable for use in the construction of a wall to be erected in a moderate to high wind load application. In a moderate wind load application, the C-section bracket 36 can be securely fixed to the stud 22 of the frame wall with the use of a 25 nail gun. In a high wind load application, the C-section bracket 36 can be securely fixed to the stud 22 of the frame assembly of the wall structure 20 with the use of a mechanical fastener such as a screw 34. This is best shown in FIG 6. 30 In another embodiment of the present invention, the base member 30 is in the form of a block 32, as is best shown In FIG 19. The block 32 is made of rigid material, such as timber, fibre cement, aluminium, steel, plastic, 8247825_1 (GHMatters) P100954.AU 12/10/18 2010227027 13 Oct 2016 12 compressed foam or the like.

This configuration is particularly suitable for use in the construction of a wall to be erected in a low to moderate wind load application. In a low wind load application, the 5 block 32 can be securely fixed to the stud 22 of the frame wall 20 with the use of a nail gun. In a moderate wind load application, the block 32 can be securely fixed to the stud 22 of the frame wall 20 with the use of a mechanical fastener such as a screw 34. 10 In either embodiment, each of the base members 30 has a height that is substantially shorter than that of the studs 20. Also, each of the base members 30 has a similar width as the studs 20 and have a depth, which is sufficient for engaging with the elongate mounting members 15 40. This is best shown in FIG 7.

Each of the elongate mounting members 40 of the present invention is adapted to engage with one or more base members 30. To facilitate this, each elongate mounting member 40 is a C-section frame, having two flanges 46 20 extending from a body portion, which has a substantially flat external mounting surface 44 that is adapted to have a building panel 10 affixed thereto.

Each of the flanges 46 is adapted to engage with a base member 30 in one of two ways. Firstly, the flanges 46 may 25 fit within the side surfaces of the base members 30. This is the preferred engagement combination where the base member 30 is in the form of a C-section bracket 36.

Alternatively, the flanges 46 may fit over, and substantially surround, the side surfaces of the base 30 member 30. This is the preferred engagement arrangement where the base member 30 is in the form of a block 32.

In either embodiment, when the elongate mounting member 40 has been adjusted to be located in a desirable position, 8247825_1 (GHMatters) P100954.AU 12/10/16 13 2010227027 13 Oct 2016 the flanges 46 are then secured to the base members 30 using a mechanical fastener, an adhesive or combination of the two.

In order to achieve a substantially flush external wall 5 surface, it is necessary for a builder to account for any deviation or irregularities that may be present in the frame work assembly 20 of the wall structure. This is achieved through the interaction of the base members 30 and the elongate mounting members 40. Specifically, this 10 is achieved by adjusting the position of each of the elongate mounting members 40 with respect to its respective base member 30, the frame assembly of the wall structure 20 and the ground.

As best shown In FIGS 9 and 10, when all of the necessary 15 base members 30 have been installed on the studs 22 of the frame assembly of the wall structure 20, a builder will position a plurality of elongate mounting members 40 along the frame work assembly corresponding with the location of the base members. The builder will then ensure that the 20 elongate mounting members 40 are square both with respect to the ground (FIG 9) and each other (FIG 10). This will ensure that the building panels 10 will form a substantially flush external wall surface when the panels are affixed to the flat mounting surface of the elongate 25 mounting members 40.

When each of the elongate mounting members 40 are in the correct and desired position, the builder will then securely fasten in turn each of the elongate mounting members to its respective one or more base members 30, 30 typically using a mechanical fastener such as a screw, nail or rivet, or alternatively using adhesive, or a combination of both.

The builder will then securely fasten the building panels 10 to the flat mounting surface 44 of the elongate 8247825J (GHMatters) P100954.AU 12/10/16 2010227027 13 Oct 2016 14 mounting members 40. As each of the elongate mounting members 40 is substantially longer than the each of the building panels 10, a plurality of building panels can be installed on each of the elongate mounting members in an 5 adjacently stacked arrangement.

Typically, the adjacently stacked arrangement of the building panels is a stretcher bond pattern. In this way, the building panels 10 can be laid in a similar fashion to conventional bricks . 10 As is shown in FIGS 12 to 15, optional horizontal stud members 50 may be connected to a building panel 10 that has been installed and affixed to an elongate mounting member 40 before adjacent building panels are installed. The optional horizontal stud members 50 act as a blocking 15 member to secure two adjacent building panels together, independently of the stud wall frame assembly 20 or the elongate mounting members 40.

The optional horizontal stud members 50 are particularly used where the length of the unsupported building panel 10 20 from the last fixing point, i.e. one of the elongate mounting members 40, is greater than half of the mid-span of one of the building panels 10.

Used in this way, the optional horizontal stud members 50 assist in aligning, stiffening and supporting the building 25 panels 10 at the vertical joints. The horizontal stud members 50 may also be used vertically between a horizontal panel joint if so desired.

Additional components may be utilised within the apparatus and method of using the apparatus of the present invention 30 to create wall structures having particular features.

These will now be discussed below.

During the life cycle of a building, the building and the materials that it is constructed from will move. These 8247825_1 (GHMatters) P100954.AU 12/10/18 15 2010227027 13 Oct 2016 movements are due to many factors working together or individually, such as support structure movement (lateral sway or vertical deflection), thermal expansion and contraction and differential movements between materials. 5 This movement, unless relieved or accommodated for, will induce stress in the materials, which may be relieved in the form of cracking.

To accommodate these movements and relieve any induced stresses, which could potentially crack the wall, movement 10 joints may need to be installed. These movement or control joints are provided to relieve the induced stresses resulting from thermal expansion or contraction of the building panels 10, or differential movement between the building panels and another material or structure, such as 15 abutting walls or columns of concrete or brickwork.

Control joints can delineate coating shrinkage breaks.

Vertical control joints should coincide with control joints in the supporting structure (i.e. the wall frame assembly 20) and anywhere that significant structural 20 movement is expected, where the wall abuts a vertical s structure, such as an existing building, or adjacent to large openings. The use of a vertical control joint Is best shown in FIG 19.

Typically, the vertical control joint is nominally 5mm to 25 10mm wide and filled with an appropriate backing rod 60, a solid packer 80 and flexible polyurethane sealant 70. This is best shown in FIG 20.

Another issue that may be considered is condensation. Condensation is a complex problem, and can occur under a 30 variety of conditions, not just cold conditions. Where condensation is likely to be an issue, the appropriate use of a wall wrap as a vapour barrier or as thermal insulation, or both, can be effective in controlling 8247825_1 (GHMatters) P100954.AU 12/10/18 2010227027 13 Oct 2016 16 condensation.

When constructing a wall structure with a window frame, there are a number of different ways to arrange the building panels 10. Three alternative options are shown in 5 FIGS 21 to 23.

In FIG 21, the wall structure includes a vertical control joint 50 adjacently located to the window frame 55.

In FIG 22, the wall structure includes a building panel 10a that has a length that is longer than that of the 10 window frame 55 installed above the frame. In this way the building panel 10a acts as a lintel above the window frame 55. In this arrangement, although the installation of the panel 10a above the window frame 55 is relatively simple, the panels on either side of the window frame that support 15 the lintel panel need to be installed in line with the top of the window frame. This requires some preplanning and relatively more skill by the installer.

In FIG 23, a building panel 10c is again installed above the window frame to act as a lintel. However, unlike the 20 arrangement shown in FIG 22, the building panels on either side of the window frame 55 do not need to be installed in line with the top of the frame. Instead, the building panels 10 either side of the window frame 55 can be notched out to accept the lintel panel 10c. This 25 arrangement and method is typically easier to install.

Where the wall structure that is constructed using the apparatus and method of the present Invention is an internal wall structure including a corner, a length of angle 31 as is best shown in FIG 5, will be used in the 30 corner junction.

The length of angle 31 is secured to the frame assembly 20 of the wall structure by using a mechanical fastener (such as a screw) to pass through the length of angle, through a 8247825_1 (GHMatters) P100954.AU 12/10/16 2010227027 13 Oct 2016 17 building panel 10 and into an elongated mounting member 40 that is located behind the panel. The mechanical fasteners penetrate the face 44 of the elongate mounting member 40. However, the length of angle 31 provides a surface for an 5 end section of the building panels 10 to abut against to form a flush internal finish. The arrangement of the corner assembly is best shown in FIG 24.

In order to allow for some movement of the building panels 10 and to prevent moisture egress into the internal wall 10 structure, an appropriate backing rod 60 and flexible polyurethane sealant 70 will typically be positioned between the length of angle 31 and the adjacently abutting building panels 10. This arrangement is best shown in FIG 25. 15 According to the method of the present invention, a plurality of the base members 30 are attached along each of the vertical stud risers 22 of the frame assembly 20 of the wall structure. This is best shown in FIG 16. A first elongate mounting member 40 is then positioned 20 over the base members 30 of a first vertical stud riser 22, such that the elongate mounting member can be movably positioned with respect to the base members that secured to the first vertical stud riser. This is best shown in FIG 7. 25 The elongate mounting member 40 is then adjusted with respect to the frame assembly 20 of the wall structure and the ground until it is positioned as desired. The main adjustment of each of the elongate members 40 is with respect to the distance of the flat mounting surface 44 of 30 the elongate members from the frame assembly 20 of the wall structure .

In other words, the flanges 46 of the elongate mounting members 40 can be adjusted with respect to the depth of 8247825J (GHMatters) P100954.AU 12/10/16 2010227027 13 Oct 2016 18 the base member 30, such that the flat mounting surface 44 reaches a desired position with respect to the frame assembly 20 of the wall structure and base member 30. In this way, the flat mounting surface 44 of each successive 5 elongate mounting member 40 that is affixed to the frame assembly 20 of the wall structure can be adjusted to be made substantially flush with the flat mounting surface of each other elongate mounting member that is affixed to the frame assembly of the wall structure. This is best shown 10 in FIGS 9 and 10.

Furthermore, when an elongate mounting member 40 is secured to a plurality of base members 30 that are located along the same vertical stud member 22, the angle of the elongate mounting member with respect to the ground can be 15 adjusted to ensure that the finished wall surface will have a desired angle. The angle of the elongate mounting members 40 relative to the ground is referred to as the inclination.

Once the first elongate mounting member 40 is adjusted to 20 the desirable inclination, it is then securely fixed to the base members 30 on the first stud member 22 with suitable fixing means. For example, when a low wind load application is required, the typical fixing means will be a nail gun, whilst when a high wind load application is 25 required, the typical fixing means will be a screw. A second elongate mounting member 40 is then positioned with respect to one or more base members 30 fixed to a second vertical stud riser 22, such that the second elongate mounting member can be movably positioned with 30 respect to the base members secured to the second vertical stud riser.

The second elongate mounting member 40 is then adjusted with respect to the frame assembly 20 for the wall structure, the ground and particularly to match both the 8247826_1 (GHMatters) P100954.AU 12/10/18 2010227027 13 Oct 2016 19 angle and the distance from the frame assembly 20 of the first elongate member on the first stud riser 22.

Once the second elongate mounting member 40 is adjusted to the desirable inclination and distance from the frame 5 assembly 20, it is then securely fixed to the base members 30 on the second stud member 22 with suitable fixing means. For example, when a low wind load application is required, the typical fixing means will be a nail gun, whilst when a high wind load application is required, the 10 typical fixing means will be a screw.

Further elongate mounting members 40 are then affixed to further stud risers 22 in a similar process and this process is repeated as necessary until the wall structure reaches a desired length. 15 A plurality of building panels 10 are then secured to the flat mounting surfaces 44 of the elongate mounting members 40 in an adjacently stacked arrangement. Typically, this adjacently stacked arrangement of the building panels is a stretcher bond pattern. In this way, the building panels 20 10 can be laid in a similar fashion to conventional bricks.

As discussed above, optional horizontal stud members 50 may also be connected to the previously installed building panels 10 before the adjacent building panels are erected. 25 The optional horizontal stud members 50 assist in aligning, stiffening and supporting the building panels 10 at the vertical joints. The horizontal stud members 50 may also be used vertically between a horizontal panel joint if so desired. 30 In this way, due to the positioning of each of the elongate mounting members 40, the building panels 10 are installed uniformly at the desired inclination and distance from the frame assembly 20. This overcomes any 8247825_1 (GHMatters) P100954.AU 12/10/16 2010227027 13 Oct 2016 20 inconsistencies or deviations in the frame assembly, 20 and allows for the construction of a wall structure having a substantially flush or smooth external wall surface. In most cases, it will be desired that the wall surface be 5 substantially vertical with respect to the ground, although in some cases a wall assembly having a different angle may be desired.

The method provided by the present invention, when compared to traditional construction methods of wall 10 assemblies, allows a builder to achieve a wall structure having a substantially uniform and flat wall surface quickly, simply and cheaply regardless of how straight or flat the stud wall frame assembly 20 is to begin with.

This is achieved by securing one or more base members 30 15 to the upright studs 22 of the frame assembly 20, engaging one or more elongate mounting member 40 with the base members on each stud riser, adjusting each of the elongate mounting members in one straight line, and fixing off to the base members. In this way, no tedious packing of the 20 wall assembly is required and there is no need to individually adjust each building panel 10 before securing it to the elongate mounting members 40 of the wall structure.

As this system and method allow the builder to build a 25 substantially flat wall with a plurality of building panels 10, it reduces the cost of texture coat finishes. This is because if the wall surface of the finished wall is not smooth, then thicker texture coatings are usually required to mask the uneven building panel installation. 30 As a result of the present invention, cost savings may be achieved through the use of thinner texture coat systems as a result of flatter building panel installation in the wall structure.

It is envisaged that other fixing means, such as adhesive, 8247825_1 (GHMatters) P100954.AU 12/10/18 21 2010227027 13 Oct 2016 may be used for attaching the base members 30 to the stud risers 22 of the frame assembly 20 of the wall structure. Adhesive may also be used to affix the building panels 10 to either the elongate mounting members 40 and/or the 5 optional horizontal stud members 50. Indeed, it is also envisaged that a combination of adhesive and mechanical fasteners can be used to provide a more secure join between these elements.

It will be apparent that obvious variations or 10 modifications may be made which are in accordance with the spirit of the invention and which are intended to be part of the invention, and any such obvious variations or modifications are therefore within the scope of the invention. 15 Although the invention is described above with reference to specific embodiments, it will be appreciated by those skilled in the art that it is not limited to those embodiments, but may be embodied in many other forms.

INDUSTRIAL APPLICABILITY 20 The invention can be utilised in building clad walls. Particularly, the present invention can be used to facilitate the fastening of sections of cladding to the wall structure in the construction of clad walls having a lower cost through reduced time to adjust the building 25 panels, and improved ability to adjust the relative position of adjacent cladding panels.

The present invention also facilitates a method of installing cladding onto a wall structure.

In the claims which follow and in the preceding 30 description of the invention, except where the context requires otherwise due to express language or necessary implication, the word "comprise" or variations such as "comprises" or "comprising" is used in an inclusive sense, 8247826_1 (GHMatters) P100954.AU 12/10/16 22 2010227027 13 Oct 2016 i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention.

It is to be understood that, if any prior art publication 5 is referred to herein, such reference does not constitute an admission that the publication forms a part of the common general knowledge in the art, in Australia or any other country. 8247825_1 (GHMatters) P100954.AU 12/10/16

Claims

THE CLAIMS DEFINING THE INVENTION ARE AS FOLLOWS:

1. An apparatus for mounting a building panel to a frame assembly of a wall structure comprising a base member adapted to be secured to the frame assembly of the wall structure, the base member having a first length, the base member having a first flat surface for secure connection to the frame assembly to locate the base member with respect to the frame assembly and at least one second flat surface extending outwardly from the first flat surface for connection to an elongate mounting member for mounting the building panel for forming the wall structure , the elongate mounting member having a flat mounting surface and at least one flat side portion extending from the flat mounting surface, the elongate mounting member having a second length, the second length being greater than the first length, the elongate mounting member being adjustably positionable with respect to the base member to adjust the position of the building panel with respect to the frame assembly to a desired position, such that when the elongate mounting member is in the desired position the flat side portion of the elongate mounting member is in contact with the second flat surface of the base member for adjusting the position of the elongate mounting member relative to the frame assembly of the wall structure to enable the elongate mounting member to be securely fixed to the base member, wherein when the elongate mounting member is securely fixed to the base member in the desired position the building panel can be mounted to the elongate mounting member to form a substantially flush external wall surface of the wall structure in which the building panel is received against the flat mounting surface and the flat side portion of the elongate mounting member to connect the building panel to the frame assembly.
2. An apparatus according to claim 1 wherein the building panel is a lightweight autoclaved aerated concrete (AAC) masonry panel.
3. An apparatus of claim 1 or 2 wherein the mounting surface of the elongate mounting member is a body portion having an external surface adapted to have one or more building panels mounted thereon and the at least one flat side portion of the elongate mounting member includes two opposed, spaced apart flange members adapted to be movably positioned with respect to the base member and secured thereto when the elongate mounting member is in a desired position.
4. An apparatus according to any one of claims 1 to 3 wherein the elongate mounting member has a substantially C-shaped cross section when viewed in end view.
5. An apparatus according to any one of claims 1 to 5 wherein the elongate mounting member is manufactured from a rigid material selected from one or more of plastic, aluminium, steel, metal or wood.
6. An apparatus according to any one of claims 1 to 5 wherein the base member is a batten.
7. An apparatus according to any one of claims 1 to 6 wherein the base member is a length of angle having a substantially C-shaped cross section when viewed in end view.
8. An apparatus according to any one of claims 1 to 7 wherein the base member is manufactured from one or more of plastic, fibre cement, aluminium, steel, wood or compressed foam.
9. An apparatus according to any one of claims 2 to 8 wherein the base member is a channel for receiving a portion of one of the elongate mounting members therein.
10. An apparatus according to claim 9 wherein the portion of the elongate mounting member that is received in the channel of the base member is the spaced apart flange members of claim 3.
11. An apparatus according to any one of the preceding claims, wherein the elongate mounting member is securely fixed to the base member by one or more mechanical fixing means selected from a nail, a screw or a rivet.
12. An apparatus according to any one of the preceding claims, in which the building panel is in the form of a substantially rectangular prism having a longitudinal length wherein the length of the elongate mounting member is longer than the longitudinal length of the building panel.
13. An apparatus according to any one of the preceding claims in which the building panel is arranged to extend substantially vertically or to extend substantially horizontally.
14. An apparatus according to any one of the preceding claims in which the base member is in the form of a block.
15. An apparatus according to any one of the preceding claims in which the length of the base member is less than the length of the frame assembly.
16. An apparatus according to any one of the preceding claims in which the frame assembly includes a stud wherein the width of the base member is similar to the width of the stud.
17. An apparatus according to any one of claims 3 to 16 in which the flanges of the elongate mounting member fit within the side surface or side surfaces of the base member.
18. An apparatus according to any one of claims 3 to 16 in which the flanges of the elongate mounting member fit over and substantially surround the side surface or side surfaces of the base member.
19. An apparatus according to any one of the preceding claims in which the building panel is fastened to the flat mounting surface of the elongate mounting member.
20. An apparatus according to any one of the preceding claims in which there is a plurality of building panels, a plurality of base members and a plurality of elongate mounting members arranged such that each one of the plurality of elongate mounting members is adjustably positioned with respect to the base members for mounting the building panels in the desired positions to form the substantially flush external wall surface of the wall structure.
21. A method of mounting a building panel to a frame assembly of a wall structure using a building panel mounting apparatus, the method comprising the steps of securing at least a first flat surface of a base member to the frame assembly of the wall structure to secure the base member to the frame assembly, the base member having a second flat surface extending outwardly from the first flat surface for cooperative engagement with an elongate mounting member having a flat mounting surface and at least one flat side portion extending outwardly from the flat mounting surface, the elongate mounting member for mounting the building panel thereon for forming the wall structure, the elongate mounting member having a length greater than the length of the base member, locating the elongate mounting member with respect to the base member so that the flat side portion of the mounting member is in contact with the second flat surface of the base member, adjusting the location of the elongate mounting member with respect to the base member to position the elongate mounting member with respect to the frame assembly in a desired position to adjust the location of the elongate member with respect to the frame assembly, securely fixing the elongate mounting member to the base member when the elongate mounting member is in the desired position with the second flat surface of the base member in contact with the at least one side portion of the elongate mounting member, and mounting the building panel to the elongate mounting member to form a substantially flush external wall surface of the wall structure, wherein in the desired position the building panel is located intermediate the flat mounting surface and the flat side portion of the elongate mounting member to connect the building panel to the frame assembly.
22. A method according to claim 21 using the apparatus for mounting the building panel according to any one of claims 1 to 20.