GB2403958A

GB2403958A - Composite building panel

Info

Publication number: GB2403958A
Application number: GB0313954A
Authority: GB
Inventors: Tim J Crump; Keith Charles Rimmer
Original assignee: T J CRUMP OAKWRIGHTS Ltd
Current assignee: T J CRUMP OAKWRIGHTS Ltd
Priority date: 2003-06-16
Filing date: 2003-06-16
Publication date: 2005-01-19
Anticipated expiration: 2023-06-16
Also published as: GB0313954D0; GB2403958B

Abstract

A panel comprises a rendered 12 outer panel 18, which has a plastered 13 insulation panel 30 on its inner side. In use the panel infills openings 11 defined by beams 10 of a timber framed building. Preferably the beams 10 have channels 15 which receive the edges of the outer panel 18. The plaster 13 may comprise plaster board 32 having intumescent edges 17 which provide a seal. The intumescent material 17 may be located in grooves 16 in the beams. Compressible insulation 31 may additionally be located in the space between the insulation panel or board 30 and the opening. The outer face of the panel 18 may be provided with a membrane 21 to protect against ingress of materials from the outside. The render 12 is preferably applied within a beaded 24 marginal area. The render 12 preferably fills the openings 11 between the beams 10, leaving the beams exposed. The panel may be secured together by adhesive. The combination of seals ensure a full seal even tough the frame may shrink and move after erection. Also claimed is a method of constructing a building using the components of the above panel.

Description

Building Infill Panel This invention relates to building infill panel in

particular for use in timber framed buildings in which the timber frame defines openings, the panels being located in such openings.

In the traditional construction of timber framed buildings, usually of oak, it is necessary to fill the openings defined between the frame members, usually so that the timber frame is exposed externally and internally of the building structure. Traditional methods of filling the openings are time consuming and expensive. Moreover it is now necessary to construct buildings complying with modern building regulations which specify insulation qualities and effective seals between the components. Although modern, non traditional methods have been evolved for filling the opening, these have been the subject of criticism by the building regulation authorities.

Accordingly, an object of the invention is to provide infill panels for timber frame constructions which are capable of complying with the requirements for insulation, air and water tightness even under conditions in which the timber frame may shrink after the building is erected.

According to one aspect of the invention, an infill panel for a building structure including a wooden frame with openings therethrough, comprises an outer panel dimensioned to fit closely within an opening in the frame, an insulation panel applied and secured to the outer panel over the inner surface thereof, render applied to the outer panel on the outer side thereof, and plaster applied to the inner side of the insulation panel.

The outer is panel is secured at its edges to the frame, preferably by forming channel means along the inner edges of the opening and locating the edges of the outer panel into the channel means.

Conveniently, the channel means is formed as channels in the frame members of the The plaster may include plaster board members which, at their edges are associated S with intumescent material which is located between the wooden frame members and said edges, and provides a seal at said edges in the event of a fire within the building structure.

Preferably the intumescent material is located in groove means formed in the wooden frame members at positions adjacent the edges of the plasterboard.

The insulation panel is conveniently insulation board sized according to the size of the opening to be filled, but in any space between the insulation panel and the opening, there may be located compressable insulation material such as rockwool, which is resilient so as to fill any gaps and to allow for shrinkage and other movement of the frame by expansion into such gap.

The outer face of the outer panel, preferably made of plywood, has secured to it one or more membranes of sheet materials whereby the outer side is sealed against ingress of water or other materials.

The outer face normally also includes beading fitted towards the outer edge of opening and within which beading render may be applied to define the outer surface of the building. The render occupies the openings between the frame members leaving the frame externally exposed with the openings closed, sealed and insulated between the frame members.

According to another aspect of the invention, there is provided a method of constructing a building in which wooden beams are used to define a wooden frame of the building, the beams defining openings between the beams, the method including forming channels in the beams adjacent the openings, the channels being arranged to receive outer panels shaped to the size of the openings, locating the panels into the channels to close the openings, the outer panels each having an inner and outer face, securing to the inner face of each outer panel an insulation panel, applying plaster to the inner face of the insulation panel and applying render onto the outer face of the outer panel.

Preferably, the plaster is applied as plasterboard to the insulation panel, and along the edges of the plasterboard is located intumescent material whereby to provide a barrier in the event of fire.

Conveniently, the insulation panel is secured by adhesive applied between the facing surfaces of the outer panel and the insulation panel. Similarly, the insulation panel may be secured to the plasterboard by adhesive between the respective facing surfaces.

Further features of the invention will appear from the following description of embodiments of the invention given by way of example only and with reference to the drawings in which, Fig. 1 is a section through a frame and infill panel, Fig. 2 is a partial section at a right-angle to that of Fig. 1, Fig. 3 is a section through a wooden frame in which the panel is omitted, and Fig. 4 is a section corresponding to Fig. 1 of the second embodiment, and Fig. 5 is a further section corresponding to Fig. 1 of a third embodiment.

Referring to the drawings, there is shown a typical section through a timber framed building in which the invention is employed. The building has a timber frame made up from substantial beams which are intended to be presented at the outside and the inside of the building. Such beams, identified with numeral 10 in the drawings, define between them various openings 11, which need to be infilled to seal, insulate and secure the building whilst presenting externally a rendered finish 12 and, internally, a plaster finish 13.

In the illustrated arrangement, the timber beams 10, preferably of oak, are formed with channels, grooves or slashes 15 and 16 prior to the frame being assembled. Otherwise the oak frame is made and erected in conventional manner.

The slashes 16 have located within them a strip of intumescent material for a purpose to be explained. The slashes 15 face one another across both sides of the opening 11 and are arranged to receive a panel 18 of plywood, the plywood panel being engaged in the slashes 15 seated on a layer of mastic material which is located in the space around the panel to provide a seating and a seal.

The panels 18 are located successively in the openings 11 as erection of the frame proceeds. Subsequently, sealing elements 20 are located as a continuous seal into the slashes 15 between the outer side of the panel 18 and the edge of the slashes 15.

Breather membrane 21 is applied to the outer face of the panel 18 and fixed thereto by stainless steel staple. On top of the membrane 18 is located and fitted tanking membrane which is also fixed to the panel 18 by stainless steel staples. Along the upper, lower and side edges of the opening 11 is fitted a continuous seal 23 and a render bead 24 fitted against the adjacent oak beam and stapled to the panel 23. Along the lower side of the opening is located a lower bell bead 25 again using stainless steel staples engaging with the panel 23. Render 27 can then be located over the infill area utilising the render bead 24 and bead 25 to locate the render. The opening may also have located along the bottom edge lead sheet 29.

On the internal face of the panel 18 insulation in the form of an insulation board 30, dimensioned to size, is a&Bred by adhesive to the inner face of the panel 18. Between the board 30 and the side edges of the opening 11 are located bats 31 of rockwool, under compression, around the perimeter of the insulation board 20. Against the board and glued thereto with adhesive is located foil backed plasterboard 32, the outer edges of which are located against the slashes 16 and adjacent the intumescent material 17. The inner face of the plaster board 32 is then ready for receiving the internal finish for the building, as required, usually a plaster skin.

The described instill for the opening 11 provides a secure, sealed and insulated construction by which the required outer finish or render can be applied, and the desired plaster or other finish on the inner side.

Referring now to Fig. 4 there is provided an alternative construction. Instead of the individual installation of the plywood panel 18 and the insulation board 30 with the plaster board 32 applied thereto, there may be provided a composite panel, prefabricated off site, comprising the plywood panel 18 and a plasterboard panel 32 between which is sandwiched the insulation board, and the plywood panel and plasterboard panel protrudes beyond the perimeter of the board (and any associated rockwool bats) to be located in corresponding channels or slashes 15 and 40 respectively formed in the timber frame beam 10 flanking the sides of the opening 11.

In this way, during frame construction, the composite infill panel can be located in the opening during erection of the frame. In this case, any plaster skim can be applied to the inner plasterboard panel 32 at its inner face at some later stage. In addition, the previously described arrangement of membranes 21,32 and beads 24,25 can be applied to the outer face of the plywood panel 18 at a later stage, as previously described. In pre-assembling the composite panel, the plywood panel, the insulation board and plaster board are interconnected and assembled with one another using adhesive between adjacent faces, as before. In locating the plasterboard panel 32 in the corresponding slashes 40, mastic may be located in the slashes to locate the panel in sealing engagement. This arrangement is shown in Figure 4 using the same reference numbers or similar parts.

As a further alternative to the previously described embodiments and with reference to Fig. 5 the infill for the opening 11 may be provided in a similar manner to that previously described except that the plywood panel 18 would, instead of being located in the slashes 15 at its outer edges be dimension to locate with its periphery up against the sides of the opening 11 and then located in position by securing the panel 18 to battens 42 secured against the beams 10 by fixing means, such as screws 43, so that the panel can be connected to the battens 42 at its outer edge by further fixing means such as screws 44. This arrangement avoids the requirement of providing slashes in the beams 10 by which the panel 18 is located in position, the panel 18 being located securely in relation to the battens 42 which are in turn fixed to the beams 10. In other respects, the infill arrangement is as previously described having the membranes 22, 23 beads 24, 25 and render 27 applied to the outer face of the panel 18 and insulation boards adhered to the inner face of the panel with, in turn, plasterboard 32 adhered to the inner face of the insulation board. This arrangement is illustrated in Fig. 5. It is to be noted that there is a weather seal 45 extending into grooves in the beams 10 to adequately seal the infill assembly.

Claims

Claims 1. An infill panel for a building structure including a wooden

frame with openings therethrough, which comprises an outer panel dimensioned to fit closely within an opening in the frame, an insulation panel applied and secured to the outer panel over the inner surface thereof, render applied to the outer panel at the outer side thereof, and plaster applied to the inner side of the insulation panel.
2. An infill panel according to claim 1, wherein the outer panel is secured at its edges to the frame by forming channel means along the inner edges of the openings in the frame, and locating the edges of the outer panel into the channel means.
3. An infill panel according to claim 2 wherein the channel means is formed as channels in the frame members of the wooden frame.
4. An infill panel according to any one of the preceding claims wherein the plaster includes plaster board members which, at their edges, are associated with intumescent material which is located between the wooden frame members and said edges and is arranged to provide a seal at said edges in the event of a fire.
5. An infill panel according to claim 4 wherein the intumescent material is located in groove means formed in the wooden frame members at positions adjacent the edges of the plaster.
6. An infill panel according to any one of the preceding claims wherein the insulation panel is insulation board, sized according to the size of the opening to be filled.
7. An infill panel according to claim 6 wherein compressible insulation material is located in the space between the insulation panel and the opening, the compressible insulation material being resilient to fill any gaps and allow for shrinkage and other movement of the frame by expansion into such gap.
8. An infill panel according to any one of the preceding claims wherein the outer face of the outer panel has secured to it one or more membranes of sheet material whereby the outer side of said panel is sealed against ingress of materials from the outside.
9. An infill panel according to any one of the preceding claims wherein the outer side of the outer panel includes beading towards the outer edge of the opening within which render is applied to define the outer surface of the building.
10. An infill panel according to claim 9 wherein the render occupies the openings within the frame members leaving the frame members externally exposed.
11. A method of constructing a building in which wooden beams are used to define a wooden frame of the building, the beams defining openings between the beams, the method including forming channels in the beams adjacent the openings, the channels being arranged to receive outer panels shaped to the size of the openings, locating the panels into the channels to close the openings, the outer panels each having an inner and outer face, securing to the inner face of each outer panel an insulation panel, applying plaster to the inner face of the insulation panel and applying render to the outer face of the outer panel.
12. A method according to claim 11 wherein the plaster is applied as plasterboard to the insulation panel, and along the edges of the plaster board is located intumescent material whereby to provide a barrier in the event of fire.
13. A method according to claim 11 or 12 wherein the insulation panel is secured by adhesive applied between the facing surfaces of the outer panel and the insulation panel.
14. A method according to any one of claims 11, 12 and 13 wherein the insulation panel is secured to the plaster by adhesive between the respective facing surfaces.
15. An infill panel system substantially as described with reference to the drawings.