AU2011202644A1 - Expressed joint facade system - Google Patents

Abstract

A panelized cladding system including a plurality of battens (2) securable to a building structure, each batten having a structure engaging surface and an integrally formed finish ready panel supporting surface (8). Fibre cement cladding panels (4) are 5 secured to or through the battens such that the finish ready panel supporting surface of each batten forms an external recessed surface of an expressed joint formed thereon. Preferably the panels are sealed and secured to the battens using finishing nails to minimise the need for patching. Optional backing strips (10) are provided for forming recessed joints along regions where there are no battens. Figure 2 4 10' Fig. I Fig. 2

Description

- 1 AUSTRALIA PATENTS ACT 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT ORIGINAL Name of Applicant/s: James Hardie Technology Limited Actual Inventor/s: James Gleeson and Jesper G. Jensen Address for Service is: SHELSTON IP 60 Margaret Street Telephone No: (02) 9777 1111 SYDNEY NSW 2000 Facsimile No. (02) 9241 4666 CCN: 3710000352 Attorney Code: SW Invention Title: EXPRESSED JOINT FACADE SYSTEM Details of Original Application No. 2007211837 dated 01 Feb 2007 The following statement is a full description of this invention, including the best method of performing it known to me/us: File: 48332AUP02 -2 EXPRESSED JOINT FACADE SYSTEM FIELD OF THE INVENTION The present invention relates to an expressed joint panelized cladding or facade system using panels formed predominantly from fibre cement. The system has 5 been designed primarily for use in residential dwelling. However, it will be appreciated that the invention is not limited to such application. BACKGROUND TO THE INVENTION Any discussion of the prior art throughout the specification should in no way be considered as an admission that such prior art is widely known or forms part of 10 common general knowledge in the field. Expressed joint panelized facade systems, having a pattern of discrete panels with feature joints formed therebetween, have been extensively used in commercial building applications. Fibre cement has been favoured as one of the preferred panel materials, as it is relatively durable, inexpensive, and allows a variety of finishes to be 15 applied directly to the board either on-site or through pre-finishers. Up until recently, all expressed joint fibre cement facade panel systems were specifically designed for the commercial market and usually comprised large sized high density panels that are installed on specially designed complex metal support framing structures. These framing systems comprise numerous components including 20 joining battens, intermediate battens, sealing strips, corner brackets, window and door opening fixtures and the like. Recent architectural trends have moved towards creating a similar expressed joint panelized cladding finish for residential properties. However, the majority of existing commercial systems have a structural design, in relation to both the panel and -3 the supporting framing system, which is excessive for residential construction. This makes them generally cost prohibitive, or at least uncompetitive, when compared to other residential wall building and finishing techniques. Furthermore, the need to specify, use and source a wide variety of different fixing and sealing elements in each 5 installation, makes the commercial systems unattractive to builders working in the residential market. While there has been some recent attempt to provide alternative systems specifically configured for the residential market, these have generally comprised simply a lighter weight version of existing commercial systems, using thinner facade 10 panels and similar but lighter weight metal support framing components made from a thinner gauge steel. Sealing strips and various specialty components for corners and windows and door openings are still required. As such, the component cost of these new residential facade systems may still be relatively expensive and most importantly are still fairly complex and thereby costly and time consuming to install. 15 It is an object of the present invention to provide an expressed joint panellised cladding system, an expressed joint clad wall and method of construction of an expressed joint clad wall that is particularly suited to the residential building market and which overcomes or ameliorates one or more of the above-discussed disadvantages of the prior art or which offers at least a useful alternative thereto. 20 SUMMARY OF THE INVENTION According to a first aspect of the invention there is provided an expressed joint panelized cladding system including: -4 a plurality of battens securable to a building structure, each batten having a structure engaging surface and an integrally formed finish ready panel supporting surface; and one or more fibre cement cladding panels; 5 the panels being securable directly to or through the battens such that said finish ready panel supporting surface of each batten may form an external recessed surface of an expressed joint formed thereon. The term "integrally formed finish ready surface" is used herein to refer to a surface that is at least partially weather resistant (either by treatment such as coating, 10 painting or by virtue of inherent material properties) and is either fully finished or ready for optional further finishing, such as painting, if required. Preferably, the fibre cement cladding panels have sealed front and rear surfaces. In particularly preferred forms, the cladding panels are sealed on all six sides. 15 Desirably the battens are made from a non-metallic, preferably nailable, material. Most preferably the battens are made from a low density nailable fibre cement. In at least one preferred form, the batten is of sufficient thickness and has sufficient nail holding properties, such that once the batten has been secured to the 20 underlying building structure using appropriate fasteners, the panels can be supported solely by attachment to the battens. In other embodiments, a thinner batten may be used and the panels secured by means of fasteners that extend through the battens and into the underlying building structure.

-5 Desirably, the majority of battens are secured vertically to the building structure so as to allow for natural drainage through the gap formed therebetween. In such cases a plurality of thin backing strips may be provided for creating a sealable horizontal external recessed surface of an expressed joint spanning between the 5 battens. Alternatively, the battens can be secured horizontally using additional framing support where required, and further battens or backing strips used to define additional joint surfaces as required. In one form the building structure comprises a building frame made preferably from timber or steel. However, the system is adaptable to other building structures 10 such as brickwork or concrete blocks or panels. According to another embodiment there is provided a panel supporting batten in the form of a longitudinal nailable fibre cement strip having a building structure engaging surface and a panel supporting surface, the batten being finish ready (as defined above) on at least its panel supporting surface so that it is ready for painting as 15 and if required. In one form, the fibre cement is finish ready by means of a suitable surface coating. Other embodiments may rely on the inherent weather resistance of most fibre cement formulations or use a modified formulation with enhanced weather proofing properties. Preferably, the fibre cement is a low density nailable fibre cement. 20 Desirably, the batten has a thickness of at least 18mm and a width of about 40mm to I 00mm. Most preferably, the width range is 45mm to 70mm. Desirably, the batten is made from fibre cement having a density range of approximately 0.8 to 1.3 g/cc and more preferably 0.8-1.2 g/cc. Optionally, the fibre cement has a composition that includes density modifiers such as: inorganic hollow or foamed microparticles -6 and all other additives as disclosed in WO 01/68547 the entirety of which is incorporated herein by reference; calcium silicate hydrate; entrained air and other suitable density reducing additives, or any combination thereof In the preferred form the expressed joint panelized cladding system of the first 5 aspect includes battens in accordance with the second aspect. In accordance with a third aspect of the invention there is provided an expressed joint panelized clad wall including: a building structure; a plurality of battens secured to the building structure, each batten having a 10 structure engaging surface and an integrally formed finish ready panel supporting surface; one or more fibre cement cladding panels secured directly to or through the battens; the panels being disposed such that said finish ready panel supporting surface 15 of at least some of said battens forms an external recessed surface of an expressed joint formed thereon. Desirably, the panels have sealed front and rear surfaces. Preferably, the building structure comprises a frame that is nailable and preferably made of timber and the battens are made of a nailable material, most 20 preferably a nailable fibre cement. Preferably, a suitable drainage plane such as a building wrap, rigid barrier, foil or sarking is secured to the building structure underneath the battens. Where the structure is a timber frame the battens may be nailed through the drainage plane to the timber building frame therebelow.

-7 In the preferred form, the fibre cement cladding panels are also preferably made of a nailable fibre cement and are connected to the battens using impact fasteners such as nails or staples, most preferably using a small head finishing style nail such as a T-head Brad nail or flat head nail or equivalent. Alternatively, the fibre 5 cement cladding panels may be connected to the battens using a suitable adhesive which may also serve as a sealant. In other forms, the panels are secured to the battens using screws or a combination of impact fasteners (including finishing style nails) and adhesive. In another embodiment using a steel frame, the battens are secured to the 10 frame using suitable fasteners such as self drilling screws and the fibre cement panels are then secured to the battens by any of the appropriate means discussed above. In accordance with a fourth aspect of the invention there is provided a method of constructing an expressed joint panelized clad wall, said method including the steps of: 15 erecting a building structure; securing a plurality of battens to the building structure, each batten having a structure engaging surface and an integrally formed finish ready panel supporting surface; and securing one or more fibre cement cladding panels directly to or through the 20 battens; whereby the panels are positioned such that said finish ready panel supporting surface on at least some of said battens forms an external recessed surface of an expressed joint formed thereon.

-8 Preferably the method includes the step of connecting a suitable drainage plane such as a building wrap, rigid barrier, foil, waterproof coating or sarking to the building structure prior to securing the battens. In the preferred form, the building structure comprises a frame made from 5 timber and the battens are made of fibre cement in accordance with the second aspect of the invention. In this embodiment, the battens are secured to the frame using suitable impact fasteners such as fibre cement nails or any other suitable fasteners. Preferably, the fibre cement cladding panels are sealed on front and rear surfaces and desirably are also of a nailable form and secured to the underlying fibre 10 cement battens by means of finishing nails such as flat head nails or T-head brad nails. Optionally, an adhesive may also be used with the finishing nails, the adhesive also optionally acting as a sealant. In the most preferred form, nailable fibre cement battens are secured to the vertical frame members and the method further comprises the step of attaching 15 backing strips along the horizontal edges of the panels, at least along those edges where there will be no underlying batten. In one form, the backing strip is a thin metal or polymeric strip optionally pre-connected to the rear sealed face of the FRC panel by means of an adhesive or a double-sided adhesive tape or other securing mechanism. These backing strips may be pre-finished or the exposed portion can be 20 painted after installation. In accordance with fifth aspect of the invention there is provided an expressed joint panelized cladding system including: a plurality of panel-supporting battens securable to a building structure, each batten being formed from a substantially solid nailable material and including a -9 structure facing surface and an integrally formed finish-ready panel facing surface; and a plurality of fibre cement cladding panels; the panels being securable to and/or through the battens such that a portion of 5 the finish-ready panel facing surface of at least one of the battens remains exposed to form an external recessed surface of an expressed joint defined by a gap between an adjacent pair of the panels on the batten. In accordance with another aspect of the invention there is provided a method of constructing an expressed joint panelized cladding wall, said method including the 10 steps of: erecting a building structure; securing a plurality of battens to the building structure, each batten being formed from a substantially solid nailable material and including a structure-facing surface and an integrally formed finish-ready panel-facing surface; and 15 securing a plurality of fibre cement cladding panels to and/or through the battens such that a portion of the finish-ready panel-facing surface of at least one of the battens remains exposed to form an external recessed surface of an expressed joint defined by a gap between an adjacent pair of the panels on the batten. BRIEF DESCRIPTION OF DRAWINGS 20 A preferred embodiment of the invention will now be described, by way of example only, with reference to the accompanying drawings in which: Fig. I is a perspective schematic view of a portion of a residential dwelling having the expressed joint panelized cladding system of the invention attached thereto; - 10 Fig. 2 is a perspective part view of the cladding system shown in Fig. 1, illustrating three panels and the underlying components and structure; Fig. 3 is a front view of a wall structure according to the invention illustrating typical wall fixing configurations; 5 Fig. 4 is a sectional part view illustrating securing details of a vertical expressed joint of the structure shown in Fig. 1; Fig. 5 is an enlarged sectional view showing the detail of an intermediate vertical connection of the structure shown in Fig. 1; Fig. 6 is an enlarged sectional part view illustrating a slab edge arrangement; 10 Fig. 7 is an enlarged sectional part view of an eave wall arrangement; Fig. 8 is an enlarged sectional part view showing an internal corner fixing arrangement; Fig. 9 is an enlarged sectional part view showing an external corner fixing arrangement; 15 Fig. 10 is an enlarged sectional part view showing a window head arrangement; and Fig. 11 is an enlarged sectional part view showing a window sill arrangement. DETAILED DESCRIPTION OF THE INVENTION Referring to the drawings, an expressed joint panelised cladding system 20 according to the invention is shown generally at 1. The system 1 includes a plurality of battens 2 securable to an underlying building structure in the form of a frame 3 and a plurality of fibre cement cladding panels 4 having front and rear sealed surfaces 5 and 6 respectively.

- 11 In the preferred form, the battens 2 are in a simple strip form and have a frame engaging surface 7 and an integrally formed finish-ready panel supporting surface 8. In use, the exposed portion of this surface 8 forms an external recessed surface of an expressed joint as shown in the drawings. The battens 2 are preferably made from a 5 medium to low-density nailable fibre cement which is either sealed on at least the finish-ready surface 8 or has a composition that makes the outer surfaces inherently weather resistant and finish-ready. Desirably the density is in the range 0.8 to 1.3 g/cc and more preferably 0.8-1.2 g/cc. Preferably, the batten material is formulated to meet the requirements of Australian Standard AS/NZS 2908.2:2000 relating to Type 10 A external sheets, or similar. In preferred forms the fibre cement batten composition includes density modifiers such as: inorganic hollow or foamed microparticles (see for example WO 01/68547); calcium silicate hydrate; entrained air and other suitable density reducing additives, or any combination thereof. It should be noted that while the form of batten illustrated has a flat frame 15 engaging surface 7, this surface and/or the main body of the batten could have ridges or functionally equivalent formations that would allow fluid flow therethrough if required. This is particularly useful where the battens are to be secured horizontally and can also facilitate additional ventilation when mounted in other orientations. The preferred battens have a thickness of at least 18-19mm and a width of 20 between 45mm and 70mm. These are ideally constructed from a medium to low density fibre cement that has density modifying additives in the form of spherical inorganic hollow microparticles such as those described in patent application WO 01/68547. The batten minimum thickness ensures sufficient fastener holding power to enable the cladding panels to be secured to the battens without the need to fix through - 12 to the underlying building structure. This thickness of batten also provides an air gap of sufficient depth to act as an effective insulating barrier to resist heat transfer and increase the overall "R" value rating of the structure. The cladding panels 4 are preferably made from a medium density nailable 5 fibre cement, which is at least partially weather resistant on it's front and rear faces. In the preferred form the panels are coated on all six sides using a radiation curable sealer. Ideally, these panels also meet the requirements of AS/NZS 2908.2:2000 or similar standard. In preferred forms the fibre cement panel composition includes density modifiers such as: inorganic hollow or foamed microparticles (see for example 10 WO 01/68547); calcium silicate hydrate; entrained air and other suitable density reducing additives, or any combination thereof. Also forming part of the preferred form of the system are optional backing strips 10. In one form, the strip is made from thin gauge metal or polymeric material and has an outwardly protruding ridge 11 along the joint region as shown that spans 15 between the battens forming the backing of an expressed joint in the same plane as the batten surface 8. The starting structure before the installation of the expressed joint facade system should be typical of the state ready for conventional cladding installation. This preferably includes the installation of a drainage plane 12, which most commonly 20 comprises a pliable building membrane or moisture barrier such as a sarking, building wrap or building paper. For example, the requirements of suitable building membranes and underlays for use in Australia is set out in AS/NZS 4200.1:1994. However, rigid barriers could also be used.

- 13 Optionally, a vent strip 13 is then installed at the bottom of the framing base plate 14 adjacent the concrete slab 15 which may be rebated (as shown) or square, with the edge of the bent strip level or slightly lower than the bottom of the framing as shown in Fig. 6. This is preferably done prior to the installation of the battens 2. 5 In this next step, the fibre cement battens 2 are fastened to the sub-framing in the position shown in the drawings. The sub-frame is generally framing timber but can be other framing materials such as steel. Fastening into timber framing is done with nails, preferably 65 mm galvanised ring-shanked flathead nails. Fastening into steel framing may be done with screws, preferably 40 mm long HardiDrive screws or 10 similar self-driving screws with corrosion-resistance. Of course, any suitable fastener or securing means may be used to secure the battens 2 to the sub-framing. The vertical battens 2 are positioned to coincide with vertical joint positions, plus any necessary intermediate support positions. The vertical battens are usually positioned on vertical framing members and the layout of vertical joints are designed 15 to coincide where possible, but if no framing member is available then auxiliary framing members can be added to the sub-frames to support the batten. Battens can also be used to form internal and external expressed corner joints as shown in Figs. 8 and 9. The battens may also be used to form the joint between vertical and horizontal surfaces or junctions to form an expressed joint at the junction, 20 or just to support the horizontal edge. Where horizontal battens are used, it is preferable to provide ventilation through or around the batten as good building practice for moisture control in building envelopes. This can be done by means of leaving suitable gaps, or using battens having ventilation passages formed therein, usually on the rear frame engaging surface of battens.

- 14 Positioning of the battens adjacent eave to wall corners can be straightforward as shown in Figure 7 with a small gap 16 being left above the batten 2 (and cladding panel 4) to allow location of the eave sheet 17 as shown. Ventilation through the framing above the eave sheet can also provide venting to the roof space and via a roof 5 vent to the outside of the building. This passage of air can be provided by framing provisions such as packers, grooves at the back of the eave framing, gaps in the eave framing against the wall framing or drilled holes in the eave framing. If installed without a gap at 16, the wall cavity can be closed at the cladding/eave sheet junction or vented to allow passage of rising hot air to pass to the 10 outside of the building at the eave level. Setting adjacent window heads and sills is similarly very simple as shown in Figures 10 and 11. In the illustrated window head arrangement, the upper end of the flashing 18 is inserted behind the sarking 19 and the batten 2 is then screwed over the flashing and sarking by fastening through to the sub frame 3. The lower part of the 15 flashing 18 then extends over the window head 20 in the usual manner. With the sill arrangement, the batten thickness is such that the sill 21 simply sits on, and is sealed against, an upper edge of the panel 4. In other variations the panel can be fitted inside, rather than abutting the outer window flange depending on either the window flange size and width or the position of the window in the opening. 20 Once the battens 2 are fastened to the sub-framing 3, the first panel 4 is installed, preferably the bottom corner panel, from which subsequent panels are spaced. Where the use of backing strips 10 is required, these are usually pre connected to the panels, ideally using double sided adhesive tape. The panel is usually fixed level and plumb, but can be angled to produce an unusual architectural - 15 look if the framing and battens are set up to suit. The panels are fixed to the battens with screws or nails. Typical nails used are 30 mm x 2.8 mm diameter galvanized fibre cement nails, but more suitable for ease of installation is the use of corrosion resistant finishing nails, T-head nails or brad nails that are quickly and easily installed 5 by nail guns which, when the nail gun is set to leave the nail flush with the surface, need no patching prior to painting. An example of a suitable gun is the "Paslode Impulse 250 II Bradder". A typical brad nail used is a "Paslode" 25 mm long stainless steel or galvanised "Paslode" Cl or ND brad. Typical screws for attaching panels to battens 2 include various panhead, waferhead, countersunk and hexagon head screws, 10 typically 25 mm long and 8 or 10 gauge. The selection of screw will depend on the desired finish and whether the fasteners are intended to be concealed. Other alternate fixing methods to attach the panel to the battens are with adhesive or double-sided tape. A typical adhesive is James Hardie Joint Sealant (JHJS) or a moisture polyurethane or hot melt adhesive, but other adhesives can also 15 be used. Preferably the adhesive is applied as a continuous bead and also serves the dual function of sealing the panel top and side edges and optionally also the bottom edge. A typical example of a double-sided tape suitable for use to connect backing strips to panels and panels to battens is 3MTM or VHBTM double-sided tape, preferably 0.5 mm to 2 mm thick and 5 mm to 30 mm wide. However, other double 20 sided tapes can be used. Any combination of fastener and adhesive or fastener and double-sided tape can be used to supplement attachment to either reduce the number of fasteners visible, or that need patching, or to achieve the necessary wind load resistance.

- 16 If adhesive has not been used as the whole or partial means to attach the panel to the battens, then preferably a sealant is used to seal the panel top and side edges and optionally the bottom edge between the panel edge and the batten or horizontal backing strip. 5 Once the first panel is secured, further panels are attached to the battens by maintaining or offsetting the alignment of the first panel and attaching in a similar fashion to the previous panel. The gap between the panels is typically 0 to 20 mm, but is preferably about 10 mm to express the joint to be visible when approaching the building and is usually in a predetermined configuration and pattern. The means of 10 fixing, adhering and sealing are then repeated as described above. As shown, it is the exposed strip of the integral panel supporting surface of the batten that forms the external recessed surface of the expressed joint. Where countersunk screws or punched nails are used to fasten the panels 4 to the frame 3, patching compounds can be used to fill over the fasteners so that the 15 holes are flush with the surface of the panels. The patching material is typically a two-part epoxy such as megapoxy PI or Hilti CA125. Where the temperature is below 15'C, the use of Hilti CA 273 is preferred. The holes over the fasteners are filled flat or slightly proud of the surface of the panel. After the patching material is set, sanding of the patching may be necessary in some areas to blend the patch surface 20 to the same surface as the surrounding panel. Once all the panels are secured, the panels are finished in situ. Typically, this is achieved through applying a minimum of two coats of exterior grade paint. Where the surfaces of the expressed joints are to be coloured the same as the panels, this is usually done as a simple post-installation painting process when painting the panels.

- 17 However, where the surfaces of the expressed joint are required to be in a contrasting colour such as black, the open edges of the joint may be pre-finished prior to installation or at least prior to painting the panels. For example, the edges of the panels can be painted in the required contrasting colour and the panel mounting 5 surface 8 of the battens 2 similarly pre-painted at least along a generally centrally located region where the defined joint will be positioned. The advantages of this system over the prior art are numerous. For example, the provision of simple strip-like battens that also integrally provide the exposed recessed external surface at the base of the expressed joint simplifies the entire 10 system. In prior art systems that utilise complex metal "top hat" style mounting battens or use wood battens and require a further seal component between the panel and the batten, it was necessary to provide two widths, one complex wide member used to support the panels and form the expressed joints and a narrower more simple section for use as intermediate support. By contrast, the preferred form of the present 15 system allows the use of one batten size and shape of preferably 18 to 19 mm thick and approximately 50 to 70 mm in width for all applications. This is enabled by the solid material nature of the preferred batten which allow close fastener spacing and the fact that no spaced apart mounting flanges are required. Similarly, no separate complex corner battens or window or door opening supports are required, the simple 20 battens of the invention being readily adaptable to such applications as shown, for example, in Figs. 7 to 11. Another advantage relating to the batten thickness of the preferred embodiment is that conventional domestic market windows can still be used without the need for complex setting, as the overall frame to outer surface distance is - 18 comparable to other cladding systems. By contrast, most of the other expressed joint systems using top hat battens and the like require either the use of more expensive commercial windows which accommodate a larger overall cladding depth or extra finishing and setting work if domestic windows are used. The preferred thickness of 5 18-19mm also provides an effective insulating air gap between the building structure and the cladding panels. Furthermore, the majority of prior art systems require the use of separately manufactured sealing components that are located intermediate the outermost surface of the battens and the rear surfaces of the cladding panel system. In some cases, these 10 sealing components comprise separate metal or polymeric strips with integrally attached gasket-type elements, and in other cases comprise separate strips of compressible sealing material that can be made of any number of suitable materials. However, in the system according to the invention, the battens have an integrally formed finish-ready panel supporting surface which, in use, forms an exposed surface 15 of the expressed joint formed thereon. Sealing, if required, is achieved either by means of the adhesive, that may optionally be used to secure the panels to the battens and backing strips (where used), or by use of a manually applied spreadable sealant which can be applied after the panels are installed and which in any event are required for use with most of the prior art systems in addition to the other sealing mechanisms 20 provided. In the preferred form of the invention where brad nails or other finishing nails are used to secure the fibre cement panels to the battens, there are also significant savings in terms of mounting and finishing the panels. Firstly, the use of finishing nails means that there is no pre-drilling of the cladding panels, as has been required in -19 many of the commercial systems, and secondly, high speed nail guns can be used. Most importantly, careful use of finishing nails can obviate the need for any filling or patching prior to painting. In embodiments of the system utilising the preferred thick section nailable 5 fibre cement batten, even further advantages are conferred arising from the dimensional stability of the batten material and the fact that by using like materials for the batten and the cladding panels, issues relating to differing thermal coefficients of expansion and the like are unlikely to adversely affect the integrity of the panel to batten connection. Accordingly, problems such as fasteners "popping" or loosening in 10 other modes are substantially eliminated or at least significantly reduced. Another advantage of the preferred form of the present invention is that by using a relatively solid batten having good fastener holding properties, there is no need for the panel to be anchored back to the framing. This also potentially facilitates the use of smaller, less expensive fasteners than some of those used in the prior art. 15 While some of the advantages discussed above relate to the preferred use of nailable fibre cement as the batten material, the use of appropriately treated timber battens is also contemplated by the invention, as many of the advantages of the system relating to its simplicity and ease of installation are still achieved with this material. Similarly, battens of other, preferably nailable, materials such as polymeric materials 20 or various nailable composites, are also considered to fall within the scope of the invention. The invention also contemplates the use of thin section battens wherever the panels are anchored by fasteners extending through these and into the underlying building structure, with significant advantages still arising from the simplified batten defining the recessed surface of the expressed joint.

- 20 It should also be appreciated that whilst the preferred embodiment described is a system adapted for securement to a building structure in the form of a building frame most preferably of timber, it can easily be adapted for use with other building structures including those made of masonary and/or concrete. 5 Accordingly, it can be concluded that while the invention has been described in relation to preferred embodiments; the invention can be embodied in many other forms.

Claims (47)

1. An expressed joint panelized cladding system including: a plurality of battens securable to a building structure, each batten having a 5 structure engaging surface and an integrally formed finish ready panel supporting surface; and one or more fibre cement cladding panels; the panels being securable directly to or through the battens such that said finish ready panel supporting surface of each batten may form an external recessed surface of 10 an expressed joint formed thereon.

2. An expressed joint panelized cladding system according to claim I wherein the fibre cement cladding panels have sealed front & rear surfaces.

3. An expressed joint panelized cladding system according to claim 1 or claim 2 wherein the battens are made from a non-metallic nailable material. 15

4. An expressed joint panelized cladding system according to any one of the preceding claims wherein the batten is of sufficient thickness and has sufficient nail holding properties, such that once the batten has been secured to the underlying building structure using appropriate fasteners, the panels can be supported solely by attachment to the batten. 20

5. An expressed joint panelized cladding system according to any one of claims I to 3 wherein the panels are secured by means of fasteners that extend through the battens and into the underlying building structure.

6. An expressed joint panelized cladding system according to any one of the preceding claims wherein a plurality of thin backing strips, each having a protruding -22 central ridge, are provided for creating a sealable external recessed surface of an expressed joint along edges of panels that are not aligned with a batten.

7. An expressed joint panelized cladding system according to any one of the preceding claims wherein the majority of battens are secured vertically to the building 5 frame.

8. An expressed joint panelized cladding system according to any one of claims I to 6 wherein the battens are secured horizontally using additional framing support where required and further battens or backing strips are used to define additional joint surfaces as required. 10

9. An expressed joint panelized cladding system according to any one of the preceding claims wherein the cladding panels are secured using small head finishing nails such as T-head or brad nails or similar.

10. An expressed joint panelized cladding system according to any one of claims 1 to 8 wherein the panels are secured to the battens using an appropriate form of adhesive 15 system.

11. A panel supporting batten in the form of a longitudinal nailable fibre cement strip having a building structure engaging surface and a panel supporting surface, the batten being finish ready (as herein defined) on at least its panel supporting surface.

12. A panel supporting batten according to claim 11 wherein the panel supporting 20 surface is made finish ready by means of a suitable surface coating.

13. A panel supporting batten according to claim I I wherein the panel supporting surface is finish ready by virtue of inherent weather resistant characteristics of the fibre cement formulation.

14. A panel supporting batten according to any one of claims 11 to 13 wherein the 25 fibre cement is a low density nailable fibre cement. - 23

15. A panel supporting batten according to any one of claims 11 to 14 having a thickness of at least 18 mm and a width of about 40 mm to 100 mm.

16. A panel supporting batten according to claim 15 wherein the width ranges from 45 mm to 70 mm. 5

17. A panel supporting batten according to any one of claims 11 to 16 made from fibre cement having a density range of approximately 0.8 to 1.3 g/cc.

18. A panel supporting batten according to claim 17 wherein the fibre cement has density range of 0.8 to 1.2 g/cc.

19. An expressed joint panelized cladding system according to any one of claims I to 10 9 including battens in accordance with any one of claims 11 to 18.

20. An expressed joint panelized clad wall including: a building structure; a plurality of battens secured to the building structure, each batten having a structure engaging surface and an integrally formed finish ready panel supporting 15 surface; one or more fibre cement cladding panels secured directly to or through the battens; the panels being disposed such that said finish ready panel supporting surface of at least some of said battens forms an external recessed surface of an expressed joint 20 formed thereon.

21. An expressed joint panelized clad wall according to claim 20 wherein the panels have sealed front and rear surfaces.

22. An expressed joint panelized clad wall according to claim 20 or claim 21 wherein the building structure comprises a frame that is nailable. -24

23. An expressed joint panelized clad wall according to any one of claims 20-22 wherein the battens are made of a nailable material.

24. An expressed joint panelized clad wall according to claim 23 wherein the battens are made of a nailable fibre cement. 5

25. An expressed joint panelized clad wall according to any one of claims 20-24 wherein a suitable drainage plane such as a building wrap, rigid barrier, foil or sarking or similar is secured to the building structure underneath the battens.

26. An expressed joint panelized clad wall according to any one of claim 25 wherein the battens are nailed through the drainage plane to the building frame therebelow. 10

27. An expressed joint panelized clad wall according to any one of claims 20-26 wherein the fibre cement cladding panels are made of a nailable fibre cement and are connected to the battens using impact fasteners.

28. An expressed joint panelized clad wall according to claim 27 wherein the preferred impact fastener is a small head finishing style nail such as T-head Brad nail or 15 flat head nail or similar.

29. An expressed joint panelized clad wall according to any one of claims 20-26 wherein the fibre cement cladding panels are secured to the battens using a suitable adhesive system.

30. An expressed joint panelized clad wall according to any one of claims 20-26 20 wherein the panels are secured to the battens using any combination of screws, impact fasteners and adhesive systems.

31. An expressed joint panelized clad wall according to any one of claims 20-30 wherein an optional vent strip is incorporated adjacent the base of the frame.

32. A method of constructing an expressed joint panelized clad wall, said method 25 including the steps of: - 25 erecting a building structure; securing a plurality of battens to the building structure, each batten having a structure engaging surface and an integrally formed finish ready panel supporting surface; and 5 securing one or more fibre cement cladding panels directly to or through the battens; whereby the panels are positioned such that said finish ready panel supporting surface on at least some of said battens forms an external recessed surface of an expressed joint formed thereon. 10

33. A method according to claim 32 including the step of connecting a suitable drainage plane such as a building wrap, rigid barrier, foil, waterproof coating or sarking to the building structure prior to securing the battens.

34. A method according to claims 32 and 33 wherein the building structure comprises a frame made from timber and the battens are made of fibre cement in 15 accordance with any one of claims 11 to 19.

35. A method according to any one of claims 32 to 34 wherein the fibre cement cladding panels are nailable and are secured to two or through the underlying fibre cement battens by means of finishing nails.

36. A method according to any one of claims 32 to 35 including the step of attaching 20 backing strips along the horizontal edges of panels where there will be no underlying batten.

37. A method according to claim 36 wherein the backing strip is optionally pre connected to the rear sealed face of the fibre cement panel.

38. A method according to any one of claims 32 to 37 including the step of installing 25 a vent strip adjacent the base of the frame. - 26

39. An expressed joint panelized cladding system including: a plurality of panel-supporting battens securable to a building structure, each batten being formed from a substantially solid nailable material and including a structure facing surface and an integrally formed finish-ready panel facing surface; and 5 a plurality of fibre cement cladding panels; the panels being securable to and/or through the battens such that a portion of the finish-ready panel facing surface of at least one of the battens remains exposed to form an external recessed surface of an expressed joint defined by a gap between an adjacent pair of the panels on the batten. 10

40. An expressed joint panelized cladding system according to claim 39 wherein the battens are formed from strips of substantially flat non-metallic material, adapted such that with the battens secured to the building structure, the panels can be supported solely by the battens.

41. An expressed joint panelized cladding system according to claim 39 or claim 40 15 wherein a sealant or adhesive is applied to substantially seal joins between the panels and the respective battens.

42. An expressed joint panelized cladding system according to any one of claims 39 to 41, wherein the battens are secured to the building structure by means of nails or screws, and wherein the panels are secured independently to the battens by means of 20 nails or screws.

43. A method of constructing an expressed joint panelized cladding wall, said method including the steps of: erecting a building structure; -27 securing a plurality of battens to the building structure, each batten being formed from a substantially solid nailable material and including a structure-facing surface and an integrally formed finish-ready panel-facing surface; and securing a plurality of fibre cement cladding panels to and/or through the battens 5 such that a portion of the finish-ready panel-facing surface of at least one of the battens remains exposed to form an external recessed surface of an expressed joint defined by a gap between an adjacent pair of the panels on the batten.

44. An expressed joint panelized cladding system substantially as herein described with reference to any one of the embodiments of the invention illustrated in the 10 accompanying drawings and/or examples.

45. A panel supporting batten substantially as herein described with reference to any one of the embodiments of the invention illustrated in the accompanying drawings and/or examples.

46. An expressed joint panelized clad wall substantially as herein described with 15 reference to any one of the embodiments of the invention illustrated in the accompanying drawings and/or examples.

47. A method of constructing an expressed joint panelized clad wall substantially as herein described with reference to any one of the embodiments of the invention illustrated in the accompanying drawings and/or examples. 20