GB2363404A

GB2363404A - Wall cladding: thermal insulation

Info

Publication number: GB2363404A
Application number: GB0014769A
Authority: GB
Inventors: Ozdemir Keskin
Original assignee: Individual
Current assignee: Individual
Priority date: 2000-06-17
Filing date: 2000-06-17
Publication date: 2001-12-19
Also published as: EP1164231A2; EP1164231A3; GB0014769D0

Abstract

A thermal insulation panel of extruded polystyrene has a grooved face 5 to bond with concrete, and a face 3 covered with polypropylene mesh embedded in high strength fibre concrete 4, and profiled for the receipt of brick slips 8. The panels are located with face 4 adjacent outer aluminium shuttering, and with face 5 spaced from inner shuttering, and concrete is cast so that the panels become an integral cladding of a cast building structure: alternatively they can be applied to an existing wall. Brick slips 8 are then applied using mortar bed 9 and pointed 10; L - shaped slips may co-operate with a window- or door- receiver 11 as shown. Grooves 5 can be used to align the panels to ensure that the slip -receiving channels are in correct register.

Description

2363404 WALL CLADDING SYSTEM The invention relates to an external wall

cladding system, to be known by the name TERMO WALL CLADDING SYSTEM.

DESCRIPTION

Residential buildings and their supporting community buildings are in demand now world wide, whether as result of expanding populations and raising social standards, or from man made disasters such as the wars or the natural disasters of earthquake, tornado and flood which have so horrendously struck in recent time on all continents. Construction companies need a range of construction methods to best compete in many markets and to use the skills available in the locations. There is also an increasing need to build low cost, sustainable housing overseas and in the UK. Improved methodologies are required to achieve performance and profitability targets and this has lead to the generation of quicker, easier and less robust methods of construction of houses and commercial buildings. In areas of high demand and high activity, alternative construction methods will be avidly sought to try to provide more units both within a time unit and a cost unit, I In the construction of houses and other buildings, alternatives are sought to address the problems of lack of availability of skilled brick layers and to address the quest for cost and time economics and ways of compliance with more stringent regulations. Alternatives to the traditional brick and block construction in the provision of the structural shell of the building, include timber frame and galvanised steel frame. These are then cladded, either by a traditional finish or a modem lighter panel type construction. Another alternative is to use prefabricated masonry construction.

To encourage work on site but to permit adoption of a factory like process, the Termo House System (GB 2340530) offers a system of forming the structural shell of the building by pouring concrete into an aluminium mould. In order to retain a traditional appearance for the completed building, the concrete structural wall may be faced with brick slip cladded thermal insulation, as an alternative to a double concrete sandwich wall.

The panel systems available however are relatively expensive and most are not completed on site. Also they are not designed to be included into an on-site moulding formwork system.

The present invention provides an elevation facing panel system, comprising of a contoured and partially, mesh and concrete coated 4, high strength, rigid, extruded polystyrene, thermal insulation board 1, to which brick slips are applied.

The panels 1 are assembled, fitting together by their tongue and groove 2 shaping and C1 secured together by adhesive, within the aluminium mould of the Termo House System.

c 2 The formed walls of cladding panels are separated from the face of the inner mould panels and secured against the face of the outer mould panels by spacer rods. The assembled panels are also secured round the window and door openings by location within the PVC window and door receivers 11.

The pattern on the inside face 5 gives guidance to the alignment of the profiling on the outside face, to ensure that the intended brick beds are normally aligned. The rough and contoured surface of the inside face 5 of the panel is to provide good cohesion and bonding 7 to the concrete of the structural wall.

Alternatively, the panels can be secured to a completed masonry wall.

Following completion of the structural wall and exposure of the insulation panelling, brick slips 8 are applied to the exposed outer face of the panel, located along the tracks 3 between the protruding guides, with adhesion by waterproof and low water mortar 9; between the bricks is pointed 10. L-shaped brick slips are applied round the reveals of the window and door openings, extending to cover over the PVC receiver I I edge trim.

Figure I shows the tongue and groove thermal insulation board 2, typically but not of necessity 600 mm long and 250 mm wide, and the thickness of 80 mm may be increased to satisfy stringent thermal regulations or requirements. The face 5 to be in contact with the concrete of the superstructure shell is shown with a contouring of indentations which mirror the protrusions of the outer face 3.

3 Figure 2 illustrates the covering to the outer face 3, comprised of a polypropylene mesh embedded in a thin fibre concrete covering 4. The protrusions on the coated insulation board are vertically spaced, such as centre to centre at 75 mm, to neatly receive a brick slip or brick tile.

Figure 3 shows a typical window sill and head vertical section with the insulation panel as it is secured round the window opening by the PVC receiver 11, with the profile shaped to allow coverage of the insulation I by the surface of the PVC profile.

Figure 4 shows, the cladding panel detail in horizontal section at a typical window reveal, with the brick slips 8 applied to the exposed outer face of the panel by waterproof and low water mortar 9 and L-shaped brick slips into the reveal.

Referring back to Figure 2, the arrangement of the indentations and protrusions can be altered to accommodate the application of bricks of a different size, tiles of a different size and shape and surface covering components such as timber boarding or timber effect boarding.

4 Termo Wall Cladding System Patent Application Figure Titles 1. Tongue and groove thermal insulation board 2. Detail of coated and profiled insulation board 3. Typical window sill and head vertical section 4. Typical window reveal horizontal section Annotation Key for Figures I to 4.

1. High compressive strength, CFC-free extruded, polystyrene 2. Tongue and groove ends of polystyrene board 3. Profiled face of insulation board 4. Polypropylene mesh embedded in high strength fibre concrete coating 5. Rough surfaced and profiled face of insulation board 6. Dense concrete with synthetic fibres 7. Bonded surfaces 8. Brick slip (or other cladding) 9. Mortar bed 10. Mortar pointing 11. PVCu Receiver for door and window

Claims

1. An elevation facing panel system, comprising of a contoured and partially mesh and concrete coated, high strength, rigid, extruded polystyrene, thermal insulation board, to which brick slips or other claddings are applied.

2. The panels are assembled on site, fitted together by their tongue and groove shaping and secured together edgewise by adhesive.

3. Within the aluminium mould of the Termo House System the formed walls of insulation panels are separated from the face of the inner mould aluminium panels and secured against the face of the outer mou ld panels by spacer rods.

4. The assembled insulation panels are secured round the window and door openings by location within the PVC window and door receivers.

5. The pattern on the inside face gives guidance to the alignment of the profiling on the outside face, therefore ensuring that the intended brick beds are normally aligned.

6. The rough textured and contoured surface of the inside face of the panel ensures good cohesion and bonding to the concrete of the structural wall, and plastic fixings may be included for additional connection security.

7. Alternatively, the panels will be secured to a completed masonry wall.

8. Brick slips are applied to the exposed outer face of the panel, located along the tracks between the protruding guides, with adhesion by waterproof and low water mortar and between the bricks is pointed.

9. L-shaped brick slips are applied round the openings, extending to cover over the PVC edge trim of the receiver.

10. The cladding system as described in claims I to 9 above is illustrated in figures I to 4 inclusive.

7 Amendments to the claims have been filed as follows I CLAIMS 1. An elevation facing panel system, comprising of a contoured and partially mesh and concrete coated, high strength, rigid, extruded polystyrene, thermal insulation board, to which brick slips or other claddings are applied.

I A system as in claim 1, in which the panels are assembled on site, fitted together by tongues and grooves and secured together edgewise by adhesive.

3. A method of installing the panels of claim I or 2, comprising locating the panels separated from the face of the inner mould aluminium panels, securing the panels against outer mould panels by spacer rods, and casting into the mould such that the panels become incorporated into the outer face of the cast wall structure.

4. A method as in claim 3 wherein the insulation panels are secured round the window and door openings by location within the PVC window and door receivers.

5. A system as in claim 1, wherein the outer face of the panel is profiled to provide beds for the receipt of brick slips, and the inner face is patterned to provide guidance ensuring that the intended brick beds and normally aligned.

6. A system as in claiml wherein the inside face of the panel is rough textured and contoured to ensure good adhesion and bonding to the concrete of the structural wall, plastic fixings being optionally included for additional connection security.

Ci 7. A system as in claim 1, secured to a completed masonry wall.

8. A system as in claim 1, wherein brick slips are applied to the exposed outer face of the panel, located along the tracks between the protruding guides, with adhesion by waterproof and low water mortar and between the bricks is pointed.

9. A system as in claim 8, wherein L-shaped brick slips are applied round the openings, extending to cover over the PVC edge trim of the receiver, 10. A system as in claim 8, wherein whole facing bricks or other facing materials are applied to "the exposed outer face of the panel.

11. The cladding system as described in claims 1 to 9 above is illustrated in figures I to 4 inclusive.

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