AU2019101571A4 - A starter channel - Google Patents
A starter channel Download PDFInfo
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- AU2019101571A4 AU2019101571A4 AU2019101571A AU2019101571A AU2019101571A4 AU 2019101571 A4 AU2019101571 A4 AU 2019101571A4 AU 2019101571 A AU2019101571 A AU 2019101571A AU 2019101571 A AU2019101571 A AU 2019101571A AU 2019101571 A4 AU2019101571 A4 AU 2019101571A4
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- Australia
- Prior art keywords
- channel
- section
- floor section
- weep
- wall section
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Classifications
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F13/00—Coverings or linings, e.g. for walls or ceilings
- E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
- E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
- E04F13/0801—Separate fastening elements
- E04F13/0803—Separate fastening elements with load-supporting elongated furring elements between wall and covering elements
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/64—Insulation or other protection; Elements or use of specified material therefor for making damp-proof; Protection against corrosion
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F13/00—Coverings or linings, e.g. for walls or ceilings
- E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
- E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
- E04F13/0862—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements composed of a number of elements which are identical or not, e.g. carried by a common web, support plate or grid
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F13/00—Coverings or linings, e.g. for walls or ceilings
- E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
- E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
- E04F13/0875—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements having a basic insulating layer and at least one covering layer
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F13/00—Coverings or linings, e.g. for walls or ceilings
- E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
- E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
- E04F13/18—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements of organic plastics with or without reinforcements or filling materials or with an outer layer of organic plastics with or without reinforcements or filling materials; plastic tiles
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F2290/00—Specially adapted covering, lining or flooring elements not otherwise provided for
- E04F2290/04—Specially adapted covering, lining or flooring elements not otherwise provided for for insulation or surface protection, e.g. against noise, impact or fire
- E04F2290/045—Specially adapted covering, lining or flooring elements not otherwise provided for for insulation or surface protection, e.g. against noise, impact or fire against fire
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- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Physics & Mathematics (AREA)
- Electromagnetism (AREA)
- Building Environments (AREA)
Abstract
A starter channel for use with a wall cladding of a building, the channel comprising a front wall section, a rear wall section, and a floor section, wherein the floor section is located intermediate between the front wall section and the rear wall section; and wherein the floor section comprises at least one of: at least one weep slot or a series of weep slots orientated diagonally relative to a longitudinal axis of the floor section; and at least one layer of a material having heat-resistant or water-repellent properties, or a combination thereof. 124d 122 124c 124b13 124a Figure 2 kol 132 130 135 Figure 2
Description
2019101571 12 Dec 2019
HUNTSMAN CHEMICAL COMPANY AUSTRALIA PTY LIMITED
AUSTRALIA
Patents Act 1990
PATENT SPECIFICATION FOR THE INVENTION ENTITLED “A STARTER CHANNEL”
This invention is described in the following statement:-22019101571 12 Dec 2019
A STARTER CHANNEL FIELD OF THE INVENTION [0001] The present invention relates to a starter channel for a wall cladding and, in particular, to a starter channel having an enhanced performance characteristic for use together with a wall cladding of a building.
BACKGROUND TO THE INVENTION [0002] Cladding systems for use on the exterior walls of buildings are known. Such systems typically involve cladding, or the use of an in-fill panel, which is made of expanded polymeric materials that provide a lightweight, insulating and cost-effective alternative to the use of concrete or brick. One such system, known as the Exterior Insulation and Finishing System (EIFS), is a reinforced, lightweight, insulated cladding system, which is made from expanded polystyrene.
[0003] A cladding system is first inserted into a starter channel, which is attached to a frame and/or concrete slab of the building. The starter channel provides support for the cladding system that is used. Render materials are then applied to an exterior surface of the cladding and the front wall of the channel to form the exterior surface of the wall, thereby protecting the cladding from the environment.
[0004] During wet weather conditions, cladding materials are vulnerable to being exposed to water, which is known to damage the internal wall frame of buildings and to accelerate deterioration of expanded polymeric cladding materials. Water also promotes mildew, mould and other biological growth.
[0005] Damage can also occur to cladding material in other ways, such as, for example, by fires, which also pose a significant safety risk. Accordingly, cladding and render materials may also be treated with additional fire-resistant materials to improve the fire resistance thereof during fire conditions.
[0006] It would be desirable to provide an improved Exterior Insulation and Finishing System (EIFS), which is better able to withstand harsh conditions, and preferably, one
2019101571 12 Dec 2019
-3 which does not require modification of the cladding or the render or both. It would be desirable to address or at least ameliorate one or more of the aforementioned problems and/or to provide a useful commercial alternative.
SUMMARY OF THE INVENTION [0007] In its broadest form, the invention relates to a starter channel for a wall cladding of a building; to a method of manufacturing the channel; and to a method of installing the channel on a building.
[0008] The invention provides a starter channel for a wall cladding, having at least one performance-enhanced characteristic. Advantageously, the channel of the invention provides at least one or more of the characteristics of improved fire resistance and improved water drainage.
[0009] According to a first aspect, there is provided a starter channel for use with a wall cladding of a building, the channel comprising a front wall section, a rear wall section, and a floor section, wherein the floor section is located intermediate the front wall section and the rear wall section; and wherein the floor section comprises at least one of:
a. at least one weep slot or a series of weep slots orientated diagonally relative to a longitudinal axis of the floor section; and
b. at least one layer of a material having heat-resistant or water-repellent properties, or a combination thereof.
[0010] According to a second aspect, there is provided a method of manufacturing a channel for use with a wall cladding of a building, the method comprising the steps of: (i) providing a sheet of material; (ii) stamping at least one weep slot, or a series of weep slots, through a surface of the sheet of material, wherein the or each weep slot is orientated diagonally relative to a longitudinal axis of the sheet; and (iii) folding the sheet of material in a configuration to form a front wall section, a rear wall section, and a floor section, wherein the floor section is located intermediate between the front wall section and the rear wall section.
[0011] In one embodiment of the second aspect, the step of stamping the at least one weep slot, or a series of weep slots, through the surface of the sheet of material occurs prior to
-42019101571 12 Dec 2019 folding the sheet of material. In other embodiments, the step of stamping the at least one weep slot, or a series of weep slots, through the surface of the sheet of material occurs after folding the sheet of material.
[0012] According to a third aspect, there is provided a method of manufacturing a starter channel for use with a wall cladding of a building, the method comprising the steps of: (i) providing a sheet of material comprising a floor section; (ii) stamping at least one weep slot or a series of weep slots through a surface of the sheet of material, wherein the or each weep slot is orientated diagonally relative to a longitudinal axis of the sheet; and (iii) joining the sheet of material comprising the floor section to a front wall section and to a rear wall section, such that the floor section is located intermediate between the front wall section and the rear wall section.
[0013] In one embodiment of the third aspect, the step of stamping the at least one weep slot, or a series of weep slots, through the surface of the sheet of material occurs prior to joining the sheet of material. In other embodiments, the step of stamping the at least one weep slot, or a series of weep slots, through the surface of the sheet of material occurs after joining the sheet of material.
[0014] In another embodiment of the third aspect, the step of joining the sheet of material comprising the floor section to the front wall section and to the rear wall section comprises fusing the aforementioned sections by the application of heat, or by adhering the aforementioned sections using an adhesive material.
[0015] In one embodiment of the second or third aspect, the method further comprises the further step of: (iv) positioning at least one layer of a material having heat-resistant or water-repellent properties, or a combination thereof, on the floor section.
[0016] In another embodiment of the second or third aspect, the method further comprises the further step of: (v) adhering at least one layer of a material having heat-resistant or water-repellent properties, or a combination thereof, to the floor section with an adhesive.
[0017] According to a fourth aspect, there is provided a method of installing a starter channel for use with a wall cladding of a building, the method comprising the steps of: (i) positioning the channel at an installation area; and (ii) attaching the channel to the building
2019101571 12 Dec 2019
-5 with at least one fastener or adhesive material, wherein the channel comprises a channel according to the first aspect of the invention.
[0018] In one embodiment of the fourth aspect, the method further comprises the step of: (iii) positioning at least one layer of a material having heat-resistant or water-repellent properties, or a combination thereof, on the floor section.
[0019] In another embodiment of the fourth aspect, the at least one layer of a material is a heat-resistant material comprising at least one fibre-reinforced cement sheet. Preferably, the or each fibre-reinforced cement sheet is pre-coated with polyurethane.
[0020] According to a fifth aspect, there is provided a method of installing a starter channel for use with a wall cladding of a building, the method comprising the steps of: (i) positioning the channel at an installation area, wherein the installation area is a substantially flat horizontal surface of a rebated edge area; and (ii) positioning a wall cladding in the channel, wherein the channel comprises a channel according to the first aspect of the invention.
[0021] In one embodiment of the fifth aspect, the method further comprises the step of: positioning at least one layer of a material having heat-resistant or water-repellent properties, or a combination thereof, on the floor section prior to positioning the wall cladding onto the channel.
[0022] In one embodiment of any of the above aspects, the at least one weep slot, or series of weep slots, may be offset (to the front or the rear) from the longitudinal axis of the sheet. Where the at least one weep slot is a series of weep slots, each weep slot may be of any elongate shape. Preferably, each weep slot is an obround shape (i.e., a shape having two parallel sides and two semi-circular ends). Preferably, each pair of weep slots is identical in size and configuration. In some embodiments, the at least one weep slot may be in combination with at least one circular weep hole. In certain embodiments, the series of weep slots comprises one or more repeat sets of two slots spaced apart from one another and formed in a V-shaped, or Λ-shaped (i.e., an upside-down “V”), configuration running in a zig-zag-like pattern along a length of the channel. That is, the orientation of each series of weep slots may alternate relative to its adjacent weep slot, wherein each subsequent weep slot may be in a mirror image orientation of its adjacent weep slot. In this embodiment, the channel having a zig-zag-like pattern of weep slots allows for a greater
-62019101571 12 Dec 2019 number of slots to be present per unit area compared with a straight dashed pattern of weep slots. The pattern of zig-zag-like configured weep slots provides an increased open area in the floor section to allow for a greater rate of fluid drainage through the weep slots.
[0023] In certain embodiments, each slot may be angled at about 85°, about 80°, about 75°, about 70°, about 65°, about 60°, about 55°, about 50°, about 45°, about 40°, about 35°, about 30°, about 25°, about 20°, about 15°, about 10°, or about 5°, relative to the longitudinal axis of the floor section. Preferably, provided that the number of slots per unit length of the channel is maintained, a drainage area of from about 40mm2 to about 44mm2 per slot is provided per about 40mm length of the channel, so as to meet Bushfire Attack Level (“BAL”) 29 compliance requirements, as tested in accordance with AS1530.8.12007. In certain embodiments, a first slot of the set of two slots may be angled at about 85°, about 80°, about 75°, about 70°, about 65°, about 60°, about 55°, about 50°, about 45°, about 40°, about 35°, about 30°, about 25°, about 20°, about 15°, about 10°, or about 5°, relative to the longitudinal axis of the floor section, and a second slot of the set of two slots may be angled at about 175°, about 170°, about 165°, about 160°, about 155°, about 150°, about 145°, about 140°, about 135°, about 130°, about 125°, about 120°, about 115°, about 110°, about 105°, about 100°, or about 95°, relative to the longitudinal axis of the floor section. Preferably, provided that the number of slots per unit length of the channel is maintained, a drainage area of from about 40mm2 to about 44mm2 per slot is provided per about 40mm length of the channel, so as to meet BAL29 compliance requirements, as tested in accordance with AS 1530.8.1-2007. Most preferably, the first slot is angled at about 40° to 50° and the second slot is angled at about 130° to 140°, relative to the longitudinal axis of the floor section. More preferably, the first slot is angled at about 45° and the second slot is angled at about 135°, relative to the longitudinal axis of the floor section.
[0024] In certain embodiments, each slot may have a length of about 16.5mm, about 16.0mm, about 15.5mm, about 15.0mm, about 14.5mm, about 14mm, about 13.5mm, or about 13.0mm. Preferably, each slot may have a length of about 16.3mm to about 13.3mm and more preferably, about 14.8mm.
[0025] In certain embodiments, each slot may have a width of about 2.9mm, about 2.8mm, or about 2.7mm. These widths provide a minimum open drainage area for weatherproofing
2019101571 12 Dec 2019
-7compliance purposes. Furthermore, these widths may provide compliance with AS 39592009. Most preferably, each slot has a width of about 2.8mm.
[0026] In certain embodiments, the series of weep slots may be configured to satisfy the requirements of the National Construction Code (“NCC”) weatherproofing test for batten cavity systems. In other embodiments, the series of weep slots may be configured to comply with AS/NZS 4284:2008, including incorporating a suitable drainage path.
[0027] In certain embodiments, the channel comprising at least one weep slot, or a series of weep slots, meets AS 3959-2009 bushfire ember attack level resistance requirements.
[0028] In certain embodiments, the channel comprising at least one weep slot, or a series of weep slots, meets AS/NZS 4284:2008 weather-proofing verification.
[0029] In certain embodiments, the channel comprising at least one weep slot, or a series of weep slots, meets both AS 3959-2009 bushfire ember attack level resistance requirements and AS/NZS 4284:2008 weather-proofing verification requirements.
[0030] In one embodiment of any of the above aspects, the material, such as polyurethane, has a water-repellent property. One suitable polyurethane is a pre-polymerised diphenylmethane diisocyanate (MDI) comprising 4,4'-methylenediphenyl diisocyanate (30 to 60% by weight), polymethylenepolyphenylene isocyanate (0 to 10% by weight), diphenylmethane-2,4'-diisocyanate (10 to 30% by weight), poly [oxy(methyl-1,2ethanediyl)], alpha-hydro-omega-hydroxy-polymer with l,l'-methylenebis[4isocyanatobenzene] (10 to 30% by weight), available as Suprasec 2413® from Huntsman Polyurethanes (Australia) Pty Ltd. Other polyurethanes may be selected based on suitable viscosity and porosity characteristics and/or on the ease of application.
[0031] In one embodiment of any of the above aspects, the material is a heat-resistant material, such as a fibre-reinforced cement sheet, which can act as an insulating medium. In certain other embodiments, the heat-resistant material comprises two fibre-reinforced cement sheets. In certain embodiments, the heat-resistant material is comprised of three or more fibre-reinforced cement sheets.
[0032] In other embodiments, the heat-resistant material comprises two or more stacked fibre-reinforced cement sheets, preferably with each one adhered to its neighbouring sheet using an adhesive.
-82019101571 12 Dec 2019 [0033] In certain other embodiments, the heat-resistant material comprises at least one aperture, preferably a plurality of apertures, wherein each aperture is configured to align with at least one weep slot in the floor section. In other embodiments, the heat-resistant material comprises a plurality of apertures, wherein each of the plurality of apertures is configured to align with the series of weep slots in the floor section.
[0034] In certain embodiments, the material has a combination of heat-resistant and waterrepellent properties. In such embodiments, the material is a heat-resistant material which is coated with at least one waterproofing coating. Preferably, the waterproofing coating has a flash point of at least 100°C, typically a flash point above 130°C. Most preferably, the waterproofing coating is substantially non-combustible, or substantially non-flammable. In certain embodiments, the material is a fibre-reinforced cement sheet pre-coated with polyurethane, or another suitable non-flammable waterproofing coat.
[0035] One suitable polyurethane for coating the heat-resistant material is Suprasec 2413®, which is available from Huntsman Polyurethanes (Australia) Pty Ltd. Other coatings may be selected based on viscosity and porosity characteristics and/or on ease of application. Other suitable coatings include non-flammable waterproofing coatings.
[0036] In certain embodiments, the heat-resistant material comprises a polyurethane coating layer provided on all surfaces of the material.
[0037] In certain embodiments, the heat-resistant material having a polyurethane coating layer may advantageously impart water-resistance properties.
[0038] In certain embodiments, the heat-resistant material is provided with a polyurethane coating at an average coating weight of greater than about 250g/m2, about 240g/m2, about 230g/m2, about 220g/m2, about 210g/m2, about 200g/m2, about 190g/m2, about 180g/m2, about 170g/m2, about 160g/m2, or about 150g/m2. Preferably, the average coating weight is about 180g/m2 to about 220g/m2. More preferably, the average coating weight is about 200g/m2. Reducing the average coat weight below about 180g/m2 may affect the waterproofing property of the heat resistant material.
[0039] In certain embodiments, the heat-resistant material has a thickness of greater than about 5.0mm, about 4.9mm, about 4.8mm, about 4.7mm, about 4.6mm, or about 4.5mm. Preferably, the thickness of the heat-resistant material is about 4.5mm. Reducing the
-92019101571 12 Dec 2019 thickness of the heat-resistant material below about 4.5mm may reduce its heat-insulating capacity.
[0040] In certain embodiments, the heat-resistant material has a width of greater than about 150mm, about 145mm, about 140mm, about 135mm, about 130mm, about 125mm, about 120mm, about 115mm, about 110mm, about 105mm, about 100mm, about 95mm, about 90mm, about 85mm, about 80mm, about 75mm, about 70mm, about 65mm, about 60mm, about 55mm, or about 50mm. Preferably, the width of the heat-resistant material is about 90mm to about 110mm, and more preferably, about 100mm.
[0041] In certain preferred embodiments, the heat-resistant material has a thickness of about 4.5mm and a width of about 100mm.
[0042] In certain embodiments, the heat-resistant material is adhered to the floor section within the channel using an adhesive material. In certain embodiments, the floor section is a base section. In certain embodiments, the heat-resistant material is pre-coated with polyurethane and then adhered to the floor section using an adhesive material. Preferably, the adhesive material has a relevant adhesion strength and has a flash point of at least about 100°C. More preferably, the adhesive material has both a relevant adhesion strength and is non-flammable. One suitable adhesive material is a Firesound™ fire-rated acoustic sealant/adhesive, which is available from H.B. Fuller Australia.
[0043] In certain embodiments, a first heat-resistant material is adhered to the floor section within the starter channel, using a fire-rated adhesive material, and then a second heatresistant material is adhered to the first heat-resistant material positioned within the channel using a fire-rated adhesive material. Preferably, the adhesive material comprises at least one polymeric material, crystalline silica and titanium dioxide. Most preferably, the adhesive material comprises at least one polymeric material, 30-50 wt.% crystalline silica and 1-5wt.% titanium dioxide.
[0044] A starter channel for use with a wall cladding of a building comprising a heatresistant material coated with an insulating layer in accordance with the present invention is advantageously configured to meet certain regulatory requirements, such as BAL29 performance. In certain embodiments, a starter channel, comprising a polyurethane-coated fibre-reinforced cement sheet is advantageously configured to meet AS 1530.8.1-2007
-102019101571 12 Dec 2019 requirements without needing to modify any component material/s that is incorporated into the fibre-reinforced cement sheet.
[0045] By positioning the heat-resistant material on the floor section of the channel, the heat-resistant material is able to act as an insulator to assist in shielding a wall cladding mounted thereon from any heat radiation passing through the channel and towards the cladding. The positioning of a heat-resistant material within the channel substantially retards any transfer of heat radiation to the cladding mounted thereon, such that the cladding is able to withstand exposure to heat radiation for longer periods of time. There are certain advantages to using the channel and heat-resistant material assembly of the present invention, particularly in bush fire conditions, in that it is able to withstand an increased period of exposure to heat radiation, relative to conventional channels which do not have the heat-resistant material mounted thereon.
[0046] In certain embodiments, the wall cladding includes expanded polystyrene (“EPS”) cladding and expanded polypropylene (“EPP”) cladding.
[0047] In certain embodiments, the wall cladding is an external wall of a residential dwelling. In other embodiments, the wall cladding is an external wall of a building or structure, such as that of a Class 1 (house) and Class 10 (non-habitable building or structure), as defined by the Australian Building Codes Board (“ABCB”) under the National Construction Code (“NCC”).
[0048] In certain embodiments, the starter channel is formed or fabricated from a metallic material, such as aluminium or stainless steel. Preferably, the channel is formed or fabricated from aluminium. More preferably, the channel is formed or fabricated from a sheet of aluminium.
[0049] In certain embodiments, use, under fire conditions, of the starter channel comprising at least one heat-resistant material may substantially extend the time taken to reach a temperature of about 100°C by at least about 4 minutes in a wall cladding mounted thereon. In certain other embodiments, use, under fire conditions, of the channel comprising two heat-resistant materials may extend the time taken to reach a temperature of about 80°C by about 17 minutes in a wall cladding mounted thereon. It is envisaged that a channel comprising three or more heat resistant materials should improve performance, thereby further extending the time taken to reach about 100°C. However, mounting more
-11 2019101571 12 Dec 2019 than two heat resistant materials would increase the weight of the channel assembly, which may in turn promote creep behaviour over time at the installation site.
[0050] In certain embodiments, use, under fire conditions, of the starter channel comprising at least one heat-resistant material may extend the time taken to reach the glass transition temperature by at least about 5 minutes of a preferably EPS-based wall cladding material mounted thereon.
[0051] In certain embodiments, use, under fire conditions, of the starter channel comprising at least one heat-resistant material may extend the time taken to reach the glass transition temperature of a wall cladding material mounted thereon by at least about 60%, or at least about 70%, when compared with a channel not having a heat-resistant material mounted thereon. In other embodiments, use of the channel comprising one fibrereinforced cement sheet may extend the time taken to reach the glass transition temperature of a preferably EPS-based wall cladding mounted thereon by at least about 60%, or by at least about 62%. In certain other embodiments, use, under fire conditions, of the channel comprising two fibre-reinforced cement sheets may extend the time taken to reach a temperature of 80°C in a wall cladding mounted thereon by about 17 minutes.
[0052] In other embodiments, use, under fire conditions, of the channel comprising at least one heat-resistant material may extend the time taken to reach the glass transition temperature of a preferably EPS-based wall cladding material mounted thereon by at least about 60%, about 55%, about 50%, about 45%, about 40%, about 35%, about 30%, about 25%, about 20%, about 15%, about 10% or about 5%, in comparison with the channel not having a heat-resistant material mounted thereon. These specified percentage values may be achieved by providing a certain thickness of heat-resistant material, wherein successively thinner heat-resistant materials may provide successively shorter times to reach the glass transition temperature of the wall cladding. Typically, a heat-resistant material, such as a fibre-reinforced cement sheet having a thickness of about 4.5mm, when used under fire conditions, extends the time taken to reach the glass transition temperature of a wall cladding by about 60%, compared with a channel not having a heat-resistant material mounted thereon.
[0053] In certain embodiments, the channel comprising at least one heat-resistant material is formed from aluminium and the use of such a channel under fire conditions may extend
- 122019101571 12 Dec 2019 the time taken to reach at least 100°C in a preferably EPS-based wall cladding material mounted thereon by about 60% to about 5%, about 60% to about 10%, about 60% to about 15%, about 60% to about 20%, about 60% to about 25%, about 60% to about 30%, about 60% to about 35%, about 60% to about 40%, about 60% to about 45%, about 60% to about 50%, or about 60% to about 55%, when compared to the use of the channel not having a heat-resistant material mounted thereon.
[0054] In certain preferred embodiments, the channel comprising at least one heat-resistant material is formed from aluminium and the use of such a channel under fire conditions may extend the time taken to reach the glass transition temperature of a wall cladding mounted thereon by about 60% to about 5%, about 60% to about 10%, about 60% to about 15%, about 60% to about 20%, about 60% to about 25%, about 60% to about 30%, about 60% to about 35%, about 60% to about 40%, about 60% to about 45%, about 60% to about 50%, or about 60% to about 55%, when compared to the use of the channel not having a heat-resistant material mounted thereon.
[0055] In certain more preferred embodiments, the channel comprising at least one heatresistant material is formed from aluminium and the use of such a channel under fire conditions may extend the time taken to reach at least 100°C in a preferably EPS-based wall cladding material mounted thereon by about 60%, about 55%, about 50%, about 45%, about 40%, about 35%, about 30%, about 25%, about 20%, about 15%, about 10% or about 5%, when compared to the use of the channel not having a heat-resistant material mounted thereon.
[0056] In certain more preferred embodiments, the channel comprising at least one heatresistant material is formed from aluminium and the use of such a channel under fire conditions may extend the time taken to reach the glass transition temperature of a wall cladding mounted thereon by about 60%, about 55%, about 50%, about 45%, about 40%, about 35%, about 30%, about 25%, about 20%, about 15%, about 10% or about 5%, when compared to the use of the channel not having a heat-resistant material mounted thereon.
[0057] The channel of the present invention is preferably configured to comply with bush fire resistance test criteria, according to Bushfire Attack Levels (BAL 29, 19 and 12.5), as tested in accordance with AS 1530.8.1-2007.
- 13 2019101571 12 Dec 2019 [0058] In some situations, the time taken to reach the glass transition temperature of a wall cladding, such as EPS-based wall cladding, in the absence of at least one layer of heatresistant material, was up to 60% faster when EPS-based wall cladding was mounted directly onto an aluminium channel and was subsequently exposed to fire conditions. Accordingly, EPS-based wall cladding in direct contact with a certain aluminium channel may fail to meet the minimum criteria for BAL 29 performance, as tested in accordance with AS1530.8.1-2007.
[0059] In contrast thereto, the time taken under fire conditions to reach the glass transition temperature of a wall cladding, such as an EPS-based wall cladding, wherein there is at least one heat-resistant material sandwiched between an aluminium channel and the EPSbased wall cladding, may be extendable by up to about 60% when compared to a certain aluminium channel in the absence of heat-resistant material/s. An EPS-based wall cladding mounted on an aluminium channel comprising at least one layer of heat-resistant material should meet the minimum criteria for BAL 29 performance, as tested in accordance with AS1530.8.1-2007.
[0060] In certain embodiments, the building is a residential dwelling or a non-habitable building or structure, as defined by the ABCB of the NCC.
[0061] In certain preferred embodiments, the channel comprises a front wall section, a rear wall section, and a floor section, wherein the floor section extends substantially horizontally from the rear wall section and comprises a front floor section side and a rear floor section side, the rear wall section extends upwardly from the rear floor section side and comprises at least one aperture for receiving a fastener for attaching the channel to the building, and the front wall section extends upwardly from the front floor section side. In certain preferred embodiments, the front wall section further comprises a plurality of openings on at least a portion of a face of the front wall section, wherein the openings provide a gripping area to adhere any render materials applied to the front wall section.
[0062] In certain embodiments, the front wall section may be mesh-like. In other embodiments, the front wall section may comprise an area of expanded mesh and a plurality of projections that extend upwardly from the expanded mesh.
[0063] In certain embodiments, the floor section comprises an internal surface, wherein the internal surface receives at least one heat-resistant material. In certain embodiments, the
- 142019101571 12 Dec 2019 intemal surface receives at least one sheet of heat-resistant material, wherein a bottom face of the sheet is laid against the internal surface. In other embodiments, the internal surface receives two or more stacked sheets of heat-resistant material.
[0064] In certain embodiments, the floor section comprises an internal surface, wherein the internal surface comprises an adhesive material and the at least one heat-resistant material, wherein the adhesive material secures the heat-resistant material to the internal surface of the floor section. In certain embodiments, the internal surface comprises an adhesive material and at least one sheet of heat-resistant material, wherein a bottom face of the sheet is laid against the adhesive material to secure the heat-resistant material in the channel. In some embodiments, the adhesive material may be applied as a layer of adhesive material on the internal surface. In other embodiments, the adhesive material may comprise a plurality of adhesive materials applied as spots on the internal surface. In other embodiments, the adhesive material may be applied to the heat-resistant material to allow positioning on and adherence to the internal surface of the floor section.
[0065] In certain embodiments, the floor section has a width of greater than about 150mm, about 145mm, about 140mm, about 135mm, about 130mm, about 125mm, about 120mm, about 115mm, about 110mm, about 105mm, about 100mm, about 95mm, about 90mm, about 85mm, about 80mm, about 75mm, about 70mm, about 65mm, about 60mm, about 55mm, or about 50mm. Preferably, the width of the base floor section is about 75mm to about 100mm, more preferably about 75mm or 100mm. In some embodiments, the floor section has a width of about 75mm, where the width may be 75mm, 76mm, or 77mm to accommodate variations in EPS-based wall cladding panel manufacturing tolerances. In other embodiments, the floor section has a width of about 100mm, where the width may be 100mm, 101mm, or 102mm to accommodate variations in EPS-based wall cladding panel manufacturing tolerances.
[0066] In one embodiment of any of the above aspects, the channel further comprises at least one spacer attached to an underside surface of the floor section. In this embodiment, the channel is not free-standing and the floor section is positioned above the spacer to provide a clearance space beneath the floor section. The clearance space may assist in clearing any fluids by allowing them to drain through the weep slots.
- 15 2019101571 12 Dec 2019 [0067] In certain embodiments, the spacer has heat-resistant or water-repellent properties, or a combination thereof. In one embodiment, the spacer comprises a block of heatresistant material, such as a fibre-reinforced cement packer, which may additionally assist as an insulating medium.
[0068] Preferably, the fibre-reinforced cement packer has a rectangular parallelepiped (cuboid) body. In certain embodiments, the fibre-reinforced cement packer is a cuboid body having a length of about 50mm to about 150mm, a width of about 15mm to about 30mm, and a height of about 5mm to about 15mm. More preferably, the fibre-reinforced cement packer is a cuboid body having a length of about 105mm, a width of about 20mm, and a height of about 9mm, or the fibre-reinforced cement packer is a cuboid body having a length of about 105mm, a width of about 20mm, and a height of about 10mm. In certain embodiments, the length of the fibre-reinforced cement packer corresponds substantially to the width of the starter channel, so that the channel is directly supported by the fibrereinforced cement packer and the plane of the floor section of the channel is substantially horizontally orientated when mounted on the fibre-reinforced cement packer. In other embodiments, the width of the fibre-reinforced cement packer corresponds to a distance equal to, or less than, the distance between two adjacent weep slots, so that the fibrereinforced cement packer does not overlap with a weep slot when attached to the underside of the channel. In other embodiments, the height of the fibre-reinforced cement packer corresponds to a certain raised position of the starter channel, as required. In a preferred embodiment, the length of the fibre-reinforced cement packer corresponds substantially to the width of the starter channel; the width of the fibre-reinforced cement packer corresponds to a distance equal to, or less than, the distance between two adjacent weep slots; and the height of the fibre-reinforced cement packer corresponds to a certain raised position of the starter channel, as required.
[0069] In certain embodiments, the spacer comprises a combination of heat-resistant and water-repellent properties. In this embodiment, the spacer is a block of heat-resistant material, such as a fibre-reinforced cement packer, which is pre-coated with at least one waterproofing coating. Preferably, the waterproofing coating has a flash point of at least 100°C, more preferably, a flash point above 130°C. Most preferably, the waterproofing coating is substantially non-combustible, or substantially non-flammable. In certain embodiments, the spacer is a fibre-reinforced cement packer pre-coated with a polyurethane, or with another suitable non-flammable waterproofing coating, which may
- 162019101571 12 Dec 2019 be selected based on its viscosity and porosity characteristics and/or on its ease of application. One preferred suitable polyurethane for coating the heat-resistant spacer is Suprasec 2413®, which is available from Huntsman Polyurethanes (Australia) Pty Ltd.
[0070] In certain embodiments, the heat-resistant spacer comprises a polyurethane coating layer provided on all surfaces thereof, which coating may advantageously also impart water-resistance properties.
[0071] In certain embodiments, the spacer is attached to the underside surface of the floor section with an adhesive material. Preferably, the adhesive material has a relevant adhesion strength and has a flash point of at least about 100°C. More preferably, the adhesive material has both a relevant adhesion strength and is non-flammable. The adhesive material comprises any one or more of thermoplastic or thermosetting polymeric materials selected from 4,4’-methylenediphenyl diisocyanates (“MDI”), polymethylenepolyphenylisocyanates (“PPG”), methylenediphenylene diisocyanate polypropylene glycol polymers, diphenylmethane diisocyanates, isocyanic acid polymethylene polyphenylene esters, styrene butadiene polymers, and benzene ethenyl polymers with 1,3-butadienes prepolymers thereof. Preferably, the adhesive material comprises a thermoplastic polymer. A thermoplastic polymer adhesive material provided for adhesion between a spacer and channel should tolerate any thermal movement between building components without reducing adhesive strength.
[0072] Suitable adhesive materials for adhering the spacer to the underside surface of the floor section can be selected from Selleys® Liquid Nails, Selleys® Liquid Nails Fast Grab, or Selleys® Liquid Nails Instant Hold construction adhesives, which are available from Selleys® Pty Ltd (Australia).
[0073] In certain embodiments, a first spacer is attached to the underside floor section using an adhesive material and at least a second spacer is attached to the underside floor section at a distance away from the first spacer using an adhesive material. Preferably, the spacers are positioned about 300mm apart. Most preferably, the spacers are positioned about 300mm apart from each other and are attached to the underside of the channel between weep slots, without covering any weep slot openings. Most preferably, additional spacers are successively positioned about 300mm apart and are attached to the underside of the channel between weep slots without covering any weep slot openings
- 172019101571 12 Dec 2019 [0074] In one embodiment, a first end spacer is attached to the underside of the channel at a first lengthwise end of the channel, and a second end spacer is attached to the underside of the channel at a second lengthwise end of the channel. In other embodiments, the first end spacer is attached to the underside of the channel and is positioned in between two slots located at a first lengthwise end of the channel, and the second end spacer is attached to the underside of the channel and is positioned in between two slots located at a second lengthwise end of the channel.
[0075] In another embodiment, the first end spacer is attached to the underside of the channel at a first lengthwise end of the channel, and the second end spacer is attached to the underside of the channel at a second lengthwise end of the channel, and wherein at least eight weep slots are present between the spacers.
[0076] The length of the starter channel may be of any length as required. Preferably, each spacer attached to the underside of the channel is evenly spaced apart along a length of the channel. More preferably, substantially all spacers are evenly spaced apart along a length of the channel. Most preferably, each spacer is positioned between two weep slots.
[0077] In another embodiment, the length of a starter channel is about 2500mm. In this embodiment, nine (9) spacers are attached to the underside of the channel, wherein a first end spacer is attached at a first lengthwise end of the channel, and each first intermediate spacer up to the seventh intermediate spacer is attached to the underside of the channel successively intermediate its length with about eight (8) weep slots present in between each spacer; and a second end spacer is attached to the underside of the channel at a second lengthwise end of the channel. In certain embodiments, the second end spacer is attached to the underside of the channel at the second lengthwise end of the channel, wherein at least about seven (7) weep slots are present in between the seventh intermediate spacer and the second end spacer. Preferably, all spacers attached to the underside of the channel do not cover any weep slot openings. The positioning of the spacers between weep slots ensures that a maximum open drainage area is provided for achieving a maximum fluid drainage rate.
[0078] Further aspects and features of the present invention will become apparent from the following detailed description with reference to the attached figures.
BRIEF DESCRIPTION OF THE FIGURES
- 182019101571 12 Dec 2019 [0079] In order that the present invention may be readily understood and put into practical effect, reference will now be made to the accompanying illustrations, wherein like reference numerals refer to like features and wherein:
[0080] Figure 1 is a perspective view of a starter channel of indeterminate length, according to one embodiment of the present invention.
[0081] Figure 2 is an end view of the channel of Figure 1.
[0082] Figure 3 is a top view of the channel of Figure 1.
[0083] Figure 4 is a bottom view of the channel of Figure 1.
[0084] Figure 5 is a rear view of the channel of Figure 1.
[0085] Figure 6 is a front view of the channel of Figure 1.
[0086] Figure 7 is a perspective view of a starter channel of indeterminate length comprising a heat-resistant material according one embodiment of the present invention.
[0087] Figure 8 is a perspective view of a spacer for use with a starter channel of Figure 1 or Figure 7.
[0088] Figure 9 is a perspective view of a starter channel of indeterminate length comprising at least one spacer, according to one embodiment of the present invention.
[0089] Figure 10 is an end view of the channel of Figure 9.
[0090] Figure 11 is a top view of the channel of Figure 9.
[0091] Figure 12 is a rear view of the channel of Figure 9.
[0092] Figure 13 is a perspective view of a starter channel of indeterminate length comprising a heat-resistant material and at least one spacer, according to one embodiment of the present invention.
[0093] Figure 14 is a starter channel of indeterminate length comprising at least two spacers, according to one embodiment of the present invention.
- 192019101571 12 Dec 2019 [0094] Figure 15 is a graph showing the time taken to reach the glass transition temperature of expanded polystyrene (“EPS”) in a starter channel comprising a heatresistant material under bushfire temperature conditions.
DETAILED DESCRIPTION OF THE INVENTION [0095] The following description refers to specific embodiments of the present invention and is in no way intended to limit the scope of the present invention to those specific embodiments.
[0096] As used herein the phrase “improved fire resistance” means better resistance to fire damage to a starter channel compared with a starter channel without a heat-resistant material.
[0097] As used herein, the phrase “improved water drainage” means removing a greater volume of water from a starter channel comprising weep slots, which are orientated diagonally relative to a longitudinal axis of the starter channel, when compared to a starter channel comprising annular weep holes or a starter channel without weep slots.
[0098] Figure 1 shows a perspective view of a starter channel 100 according to one embodiment of the invention. The length of the channel 100 is variable in different embodiments, as is depicted in Figure 1. The channel is generally fabricated from metal (e.g., aluminium or steel). In the embodiment depicted in Figure 1, the channel 100 is fabricated from a single aluminium sheet.
[0099] The channel 100 comprises a front wall section 110, a floor section 130 and a rear wall section 120. The front wall section 110 extends upwardly from the floor section 130 and comprises a plurality of openings 112 through a front face 113. The plurality of openings is positioned in a staggered configuration. Each opening has a diameter of about 5mm and is positioned about 10mm relative to an adjacent opening 112. The openings 112 provide a gripping area to adhere any render materials 152 (not shown) applied to the front wall section 110. In certain embodiments (not shown), the front wall section 110 comprises an area of expanded mesh. In other embodiments (not shown), the front wall section 110 comprises an area of expanded mesh and a plurality of projections that extend upwardly from the expanded mesh.
-202019101571 12 Dec 2019 [0100] The floor section 130 is located intermediate between the front wall section 110 and the rear wall section 120. The floor section 130 extends substantially horizontally from the front wall section 110 at a front floor section side 131 to a rear floor section side 132. The floor section 130 comprises a series of weep slots 133.
[0101] The rear wall section 120 extends upwardly from the floor section 130 and comprises a plurality of apertures 124 through a rear face 122. As shown in Figure 1, differently sized and orientated apertures 124 are located on the rear wall section 120, including horizontally orientated aperture 124a, vertically orientated aperture 124b, a first circular aperture 124c and a second circular aperture 124d. The horizontally orientated aperture 124a is of an obround shape, having a length of about 18mm and a width of about 8mm. The vertically orientated aperture 124b is of an obround shape having a length of about 18mm and a width of about 8mm. The first circular aperture 124c has a diameter of about 8mm, and the second circular aperture 124d has a diameter of about 5mm. The plurality of apertures 124 are lined along the length of the rear wall section 120 and positioned about 4mm from the top edge 126. Each aperture 124 may accommodate a fastener 154 (not shown), as required, for attachment of the channel 100 to a building 156 (not shown).
[0102] The series of weep slots 133 may comprise a repeat set of two slots in a V-shaped, or Λ-shaped (z.e., an upside-down “V”) configuration running in a zig-zag-like pattern along a length of the channel 100. However, the series of weep slots 133 shown in Figure 1 comprises a repeating set of two slots in a V-shaped, or Λ-shaped (z.e., an upside-down “V”) configuration and a single slot in a “/’’-shaped configuration in a zig-zag-like pattern along a length of the channel 100. In this embodiment, each weep slot 133 has a length of about 14.8mm, a width of about 2.8mm. The nearest point is positioned at about 12.6mm from the rear floor section side 132 and is orientated at an angle of about 45° relative to the longitudinal axis of the channel 100. In this embodiment, each weep slot 133 is positioned about 27.4mm away from an adjacent weep slot along the length of the channel 100. In different embodiments, the length, width, angle and position of weep slots 133 may vary.
[0103] The channel 100 incorporating a zig-zag-like weep slot pattern allows a greater number of slots 133 to be present per unit area compared with a straight dashed pattern. The pattern of zig-zag-like weep slots 133 provides an increased open area in the floor section 130 to allow for a greater rate of fluid drainage through the weep slots 133.
-21 2019101571 12 Dec 2019 [0104] Figure 2 shows an end view of the channel 100. The channel 100 is fabricated from a single sheet of aluminium by folding along fold lines defined by the front floor section side 131 and the rear floor section side 132, respectively. The rear wall section 120 has a height of about 48mm extending at about 90° relative to the horizontal plane of the floor section 130. A floor channel 135 runs along the length of the channel 100. The floor channel 135 as shown is a V-shaped channel having an outermost width of about 4.7mm and a channel opening fanning out at about 90°. The floor channel 135 is located at about 21.5mm from the front floor section side 131. A bead 116 located at the front floor section side 131 supports a bead wall 117 extending into the font wall section 110. The bead wall 117 is angled at about 45° relative to the horizontal plane of the floor section 130 and extends at about 3.2mm upwardly towards the rear wall section 120. The front wall section 110 is angled at about 85° relative to the horizontal plane of the floor section 130 and extends upwardly towards the rear wall section 120. The total combined height of the font wall section 110 and the bead wall 117 from the horizontal plane of the floor section 130 is about 35mm. The stepped angles of the bead wall 117 and front wall section, respectively, are provided to urge the front wall section 110 upwardly towards the rear wall section 120, so that any render material 152 (not shown) laid over the front wall section 110 is maintained against a wall cladding 150 (not shown) mounted on the channel 100.
[0105] Figure 3 and Figure 4 show a top and a bottom view of the channel, respectively. As mentioned above, the floor channel 135 can clearly be seen running along the length of the channel 100.
[0106] Figure 5 and Figure 6 show a rear view and a front view of the channel 100, respectively. As mentioned above, the rear wall section 120 comprises a plurality of apertures 124 through a rear face 122. It would be understood by the skilled person that the configuration of these apertures 124 should not be limited as shown and can be in any position or orientation on the rear face 122. It would also be understood by the skilled person that at least one of these apertures 124 can be used to accommodate a fastener 154 (not shown) for attachment of the channel 100 to a building 156 (not shown), as required by a user.
[0107] Figure 7 shows a perspective view of a channel 100 of indeterminate length as shown in Figure 1 and further comprising a heat-resistant material 140 of indeterminate
-222019101571 12 Dec 2019 length therein. In this embodiment, the heat-resistant material 140 shown in Figure 7 further comprises a coating of Suprasec 2413® applied thereto.
[0108] The heat-resistant material 140 has a width of about 100mm and a thickness of about 4.5mm. The embodiment shown in Figure 7 shows the heat-resistant material 140 having a shorter width compared with the width of the floor section 130, where an edge of the heat-resistant material 140 is positioned adjacent to the bead 116, and the heat-resistant material 140 is adhered to the floor section 130 using an adhesive material 142, where an adhesive outline is shown with dashed lines indicating that adhesive material 142 is located under the heat-resistant material 140 to adhere it to the floor section 130 of the aluminium channel.
[0109] In other embodiments (not shown), the heat-resistant material 140 may have the same width as the width of the base floor section 130, so that it can be snugly positioned within the channel 100. In these embodiments, the heat-resistant material 140 may comprise a plurality of apertures 141 (not shown), where each aperture 141 is configured to align with a weep slot 133 in the floor section 130. The heat-resistant material 140 would be positioned within the channel 100 and would be adhered to the floor section 130 using an adhesive material 142 (not shown). The aligning of the plurality of apertures 141 with the weep slots 133 would advantageously provide a pathway for moisture drainage, similar to other embodiments described above.
[0110] A wall cladding or in-fill panel 150 (not shown), such as EPS, is mountable in the channel 100. Once the wall cladding 150 is positioned over the heat-resistant material 140, a suitable render material 152 is coated over the wall cladding 150. The openings 112 in the front wall section 110 provide a gripping area for adhesion with the render material 152.
[0111] Figure 8 shows a perspective view of a spacer 145 for use with a starter channel 100. The spacer 100 is a rectangular parallelepiped (cuboid) body of heat-resistant material, such as a fibre-reinforced cement packer. The spacer 145 may comprise a coating of Suprasec 2413® applied thereto. In the embodiment shown, the spacer 145 has a length of about 105mm, a width of about 20mm, and a height of about 10mm.
[0112] The spacer 145 is able to additionally assist as an insulating medium.
-23 2019101571 12 Dec 2019 [0113] Figures 9, 10, 11, 12 and 13 show a starter channel 100 as depicted in Figures 1, 2, 3, 5 and 7, respectively, which further comprises at least one spacer 145 attached to the underside of the channel 100, according to an embodiment of the invention.
[0114] The length of the spacer 145 corresponds substantially to the width of the channel 100, so that when at least two spacers 145 are adhered to the underside of the floor section 130, the channel 100 is directly supported by the spacers 145. The cuboid shape of the spacer advantageously allows the plane of the floor section 130 to be substantially horizontal.
[0115] The width of the spacer 145 corresponds to a width that is less than the distance between two adjacent weep slots 133. In this embodiment, each spacer 145 does not overlap with a weep slot 133 when positioned between any two adjacent weep slots 133. Further, the height of the spacer 145 corresponds to a height of a raised position of the starter channel 100, as required, to create a clearance space beneath the floor section 130. The clearance space assists in clearing any accumulated fluids in allowing them to drain away through the weep slots 133.
[0116] Figure 14 shows two spacers 145 attached to the underside of channel 100. Use of two or more spacers 145 advantageously stabilises the orientation of the channel 100 when installed for use with a wall cladding 150 of a building 156. Advantageously, a clearance space is created beneath the floor section 130 without requiring fasteners 154. In this embodiment, the channel 100 no longer requires fastening to a concrete slab rebate edge (not shown) with fastener 154 through aperture 124 to an installation height, as required. In this embodiment, the channel is not free-standing and the floor section 130 is positioned above spacers 145.
[0117] The at least one spacer 145 is attached to the underside surface of the floor section 130 with an adhesive material 142 (not shown), such as Selleys® Liquid Nails. Preferably, a thermoplastic polymer adhesive material 142 is used for adhesion between a spacer 145 and channel 100 to tolerate any thermal movement between building components without reducing adhesive strength.
[0118] As show in Figure 14, at least two (2) spacers are attached to the underside floor section 130, wherein each spacer 145 is attached at each end of the channel 100 with an adhesive material 142. A first end spacer 145a is attached to the underside floor section
-242019101571 12 Dec 2019
130 using an adhesive material 142, and another spacer 145b is attached to the underside floor section at a distance away from the first end spacer 145a using an adhesive material 142. Each spacer 145a, 145b is attached to the underside of the floor section 130 and is positioned in between two weep slots 133, such that openings of weep slots 133 are not covered with spacers 145a, 145b. Additional spacers 145 may be successively positioned at about 300mm apart and adhered to the underside floor section 130, as required (not shown).
[0119] In certain embodiments, the channel 100 has a length of about 2500mm, wherein nine (9) spacers are adhered to the underside of the channel 100 (not shown). In this embodiment, a first end spacer 145a is attached at a first lengthwise end of the channel 100, and each intermediate spacer 145c (comprising the first intermediate spacer to the seventh intermediate spacer), as required, is attached to the underside of the channel 100 successively intermediate its length with eight (8) weep slots 133 present in between each of the intermediate spacers 145c; and a second end spacer 145b is attached to the underside of the channel 100 at a second lengthwise end of the channel with seven (7) weep slots 133 present in between the seventh intermediate spacer 145c and the second end spacer 145b. It is most preferable that none of the spacers 145 adhered to the underside of the channel cover any of the weep slot openings 133.
[0120] The positioning of the spacers 145 in between the weep slots 133 ensures that a maximum open drainage area is provided to ensure a maximum fluid drainage rate is achieved. It would be understood that the number of spacers 145 attached to the underside of the channel 100 is variable, as required by the length of the channel 100.
[0121] Figure 15 is a graph illustrating the temperature reached in an EPS-based wall cladding mounted on select embodiments of the channel 100 when exposed to bushfire temperature conditions. The graph compares channel 100, incorporating at least one heatresistant material 140 comprising a fibre-reinforced cement sheet/s, with controls. The acronym FC refers to fibre cement and the corresponding number denotes the number of fibre cement sheets. Acronyms TE, TR and TC refer to test areas denoting Test Eeft, Test Right and Test Centre, respectively.
[0122] The graph of Figure 15 shows that a control channel comprising EPS-based wall cladding in the absence of heat-resistant material reaches a softening point of 85°C in
-252019101571 12 Dec 2019 about 7 minutes; and a glass transition temperature of about 108°C in about 8 minutes, under bushfire temperature conditions (FC x 0 TC). A channel 100 comprising EPS-based wall cladding and one fibre-reinforced cement sheet reaches a softening point of 85°C in about 11 minutes and 20 seconds; and a glass transition temperature of about 108°C in about 13 minutes and 10 seconds, under bushfire temperature conditions (FC x 1 TC). Advantageously, a channel 100 comprising EPS-based wall cladding and two sheets of heat-resistant material does not reach a temperature of 80°C until at least about 17 minutes, under bushfire temperature conditions (FC x 2 TC).
[0123] Table 1 shows the temperatures reached as a function of time for the various channel systems tested, when exposed to bushfire temperature conditions.
Table 1: Tabulated time results of various channel systems exposed to bushfire temperature conditions
| Time (min) | FCxO TL (°C) | FCxO TR (°O | FCxO TC (°C) | FCx 1 TL (°C) | FCxl TR (°C) | FCxl TC (°C) | FCx 2 TL (°C) | FCx 2 TR (°C) | FCx 2 TC (°C) |
| 0:00 | 29 | 23 | 22 | 23 | 22 | 23 | 24 | 24 | 24 |
| 0:10 | 29 | 23 | 22 | 23 | 22 | 23 | 24 | 24 | 23 |
| 0:20 | 29 | 23 | 22 | 23 | 22 | 23 | 24 | 23 | 23 |
| 0:30 | 29 | 23 | 22 | 23 | 22 | 23 | 24 | 23 | 23 |
| 0:40 | 29 | 23 | 23 | 23 | 22 | 23 | 24 | 23 | 23 |
| 0:50 | 29 | 23 | 22 | 23 | 22 | 23 | 24 | 23 | 23 |
| 1:00 | 29 | 23 | 23 | 23 | 23 | 23 | 24 | 23 | 23 |
| 1:10 | 29 | 23 | 23 | 23 | 23 | 23 | 24 | 23 | 23 |
| 1:20 | 29 | 23 | 23 | 23 | 23 | 23 | 24 | 23 | 23 |
| 1:30 | 29 | 23 | 23 | 23 | 23 | 23 | 24 | 23 | 23 |
| 1:40 | 29 | 23 | 23 | 23 | 23 | 23 | 24 | 23 | 23 |
| 1:50 | 29 | 23 | 23 | 23 | 23 | 23 | 24 | 23 | 23 |
| 2:00 | 30 | 23 | 23 | 23 | 23 | 23 | 24 | 23 | 23 |
| 2:10 | 30 | 24 | 24 | 23 | 23 | 23 | 24 | 23 | 23 |
| 2:20 | 31 | 24 | 24 | 23 | 23 | 24 | 24 | 23 | 23 |
| 2:30 | 31 | 24 | 24 | 23 | 23 | 25 | 24 | 23 | 23 |
| 2:40 | 32 | 25 | 25 | 23 | 23 | 26 | 24 | 23 | 24 |
| 2:50 | 33 | 25 | 25 | 23 | 23 | 27 | 24 | 24 | 24 |
-262019101571 12 Dec 2019
| 3:00 | 35 | 26 | 26 | 23 | 23 | 28 | 24 | 24 | 24 |
| 3:10 | 37 | 27 | 27 | 23 | 24 | 29 | 24 | 24 | 24 |
| 3:20 | 39 | 29 | 28 | 24 | 24 | 29 | 24 | 24 | 25 |
| 3:30 | 42 | 29 | 29 | 24 | 24 | 30 | 24 | 24 | 25 |
| 3:40 | 44 | 32 | 30 | 24 | 24 | 31 | 24 | 24 | 25 |
| 3:50 | 49 | 35 | 31 | 24 | 25 | 33 | 24 | 24 | 26 |
| 4:00 | 53 | 38 | 33 | 25 | 25 | 34 | 25 | 25 | 26 |
| 4:10 | 57 | 41 | 34 | 25 | 25 | 35 | 25 | 25 | 27 |
| 4:20 | 63 | 46 | 36 | 25 | 26 | 36 | 25 | 25 | 27 |
| 4:30 | 70 | 51 | 37 | 26 | 26 | 38 | 25 | 25 | 28 |
| 4:40 | 75 | 57 | 38 | 27 | 27 | 40 | 25 | 26 | 29 |
| 4:50 | 82 | 63 | 39 | 27 | 27 | 42 | 26 | 26 | 29 |
| 5:00 | 89 | 70 | 41 | 28 | 28 | 42 | 26 | 26 | 30 |
| 5:10 | 95 | 75 | 43 | 29 | 29 | 45 | 26 | 27 | 31 |
| 5:20 | 101 | 84 | 44 | 30 | 29 | 47 | 27 | 27 | 32 |
| 5:30 | 110 | 91 | 47 | 31 | 30 | 49 | 27 | 28 | 33 |
| 5:40 | 118 | 99 | 49 | 32 | 31 | 50 | 27 | 28 | 33 |
| 5:50 | 123 | 108 | 52 | 33 | 32 | 53 | 28 | 29 | 33 |
| 6:00 | 129 | 115 | 57 | 34 | 33 | 54 | 28 | 30 | 34 |
| 6:10 | — | 123 | 60 | 35 | 34 | 56 | 29 | 30 | 35 |
| 6:20 | - | 129 | 64 | 37 | 35 | 58 | 29 | 31 | 36 |
| 6:30 | — | — | 66 | 38 | 36 | 59 | 30 | 32 | 37 |
| 6:40 | — | — | 70 | 40 | 37 | 61 | 31 | 33 | 38 |
| 6:50 | - | - | 74 | 41 | 39 | 62 | 31 | 33 | 38 |
| 7:00 | — | - | 80 | 42 | 40 | 63 | 32 | 34 | 39 |
| 7:10 | — | - | 84 | 44 | 41 | 65 | 33 | 35 | 40 |
| 7:20 | - | — | 89 | 45 | 42 | 66 | 33 | 36 | 41 |
| 7:30 | — | — | 95 | 46 | 43 | 67 | 34 | 37 | 42 |
| 7:40 | — | — | 101 | 48 | 44 | 68 | 35 | 38 | 42 |
| 7:50 | - | - | 105 | 49 | 46 | 70 | 36 | 39 | 43 |
| 8:00 | - | - | 107 | 50 | 47 | 71 | 37 | 40 | 44 |
| 8:10 | — | - | 112 | 52 | 48 | 72 | 39 | 41 | 45 |
| 8:20 | - | - | 118 | 53 | 49 | 73 | 40 | 42 | 46 |
-272019101571 12 Dec 2019
| 8:30 | — | — | 125 | 55 | 50 | 74 | 41 | 43 | 47 |
| 8:40 | - | — | 130 | 56 | 52 | 75 | 42 | 45 | 48 |
| 8:50 | - | - | — | 57 | 52 | 76 | 43 | 46 | 49 |
| 9:00 | — | — | — | 58 | 54 | 76 | 44 | 47 | 50 |
| 9:10 | — | — | — | 59 | 55 | 77 | 45 | 48 | 51 |
| 9:20 | — | - | — | 59 | 56 | 78 | 46 | 49 | 52 |
| 9:30 | - | - | - | 60 | 57 | 79 | 47 | 50 | 53 |
| 9:40 | - | - | - | 60 | 58 | 79 | 48 | 51 | 54 |
| 9:50 | - | - | — | 62 | 59 | 80 | 49 | 52 | 55 |
| 10:00 | — | — | — | — | 60 | 80 | 50 | 54 | 56 |
| 10:10 | — | — | — | — | 60 | 81 | 51 | 55 | 57 |
| 10:20 | — | - | — | — | — | 82 | 52 | 56 | 57 |
| 10:30 | - | — | — | — | — | 82 | 53 | 57 | 58 |
| 10:40 | - | - | — | — | — | 82 | 54 | 58 | 59 |
| 10:50 | — | — | — | — | — | 83 | 55 | 59 | 60 |
| 11:00 | — | — | — | — | — | 83 | 56 | 60 | 61 |
| 11:10 | — | — | — | — | — | 83 | 56 | 61 | 62 |
| 11:20 | - | - | - | - | - | 85 | 57 | 62 | 63 |
| 11:30 | - | - | - | - | - | 86 | 58 | 63 | 64 |
| 11:40 | - | - | — | - | - | - | 59 | 64 | 64 |
| 11:50 | — | - | — | — | — | — | 60 | 65 | 65 |
| 12:00 | — | — | — | — | — | — | 60 | 66 | 66 |
| 12:10 | — | — | — | — | — | — | 61 | — | 67 |
| 12:20 | - | — | — | — | — | — | 62 | - | 67 |
| 12:30 | - | - | — | — | — | — | - | - | 68 |
| 12:40 | — | — | — | — | — | — | - | — | 68 |
| 12:50 | — | - | — | — | — | — | — | — | 69 |
| 13:00 | — | — | — | — | — | — | — | — | 70 |
| 13:10 | — | — | — | — | — | — | — | — | 70 |
| 13:20 | - | - | - | - | - | - | - | - | 71 |
| 13:30 | - | - | — | - | - | - | - | - | 71 |
| 13:40 | — | - | — | — | — | — | - | — | 72 |
| 13:50 | - | - | - | - | - | - | - | - | 73 |
-282019101571 12 Dec 2019
| 14:00 | — | — | — | — | — | — | — | — | 73 |
| 14:10 | - | — | — | — | — | — | - | - | 73 |
| 14:20 | - | - | — | — | — | — | - | — | 74 |
| 14:30 | — | — | — | — | — | — | — | — | 74 |
| 14:40 | — | — | — | — | — | — | — | — | 75 |
| 14:50 | — | - | — | — | — | — | - | — | 75 |
| 15:00 | - | - | - | - | - | - | - | - | 76 |
| 15:10 | - | - | - | - | - | - | - | - | 76 |
| 15:20 | - | - | — | - | - | - | - | - | 76 |
| 15:30 | — | — | — | — | — | — | — | — | 77 |
| 15:40 | — | — | — | — | — | — | — | — | 77 |
| 15:50 | — | - | — | — | — | — | — | — | 77 |
| 16:00 | - | — | — | — | — | — | - | - | 78 |
| 16:10 | - | - | — | — | — | — | - | - | 78 |
| 16:20 | — | — | — | — | — | — | - | — | 78 |
| 16:30 | — | — | — | — | — | — | — | — | 78 |
| 16:40 | — | — | — | — | — | — | — | — | 79 |
| 16:50 | - | - | - | - | - | - | - | - | 79 |
| 17:00 | - | - | - | - | - | - | - | - | 79 |
| 17:10 | - | - | — | - | - | - | - | - | 79 |
| 17:20 | — | - | — | — | — | — | - | — | 80 |
| 17:30 | — | — | — | — | — | — | — | — | 80 |
| 17:40 | — | — | — | — | — | — | — | — | 80 |
| 17:50 | - | — | — | — | — | — | - | - | 81 |
| 18:00 | - | - | — | — | — | — | - | - | 81 |
| 18:10 | — | — | — | — | — | — | - | — | 81 |
| 18:20 | — | - | — | — | — | — | — | — | 81 |
| 18:30 | — | — | — | — | — | — | — | — | 82 |
| 18:40 | — | — | — | — | — | — | — | — | 82 |
| 18:50 | - | - | - | - | - | - | - | - | 82 |
| 19:00 | - | - | — | - | - | - | - | - | 82 |
| 19:10 | — | - | — | — | — | — | - | — | 83 |
-292019101571 12 Dec 2019 [0124] Table 2 shows water immersion results for fibre-reinforced cement sheet pre-coated with various insulating materials. The total immersion time is 24 hours and 20 minutes. The results obtained show that Samples 3 and 4, which represent a sheet of heat-resistant material comprising a single coat of Suprasec 2413®, absorbed the least amount of water volume and percent water uptake by weight.
Table 2: Water immersion results with fibre-reinforced sheet pre-coated with Polyurethane
| Sample | Name | Initial Weight (g) | Final Weight (g) | Volume absorbed in ml | % water uptake by weight |
| 1 | Suprasec 2413/Primer Dalto YG 10010 Top Coat | 137.18 | 141.63 | 4.45 | 3.24 |
| 2 | Suprasec 2413/Primer Dalto YG 10010 Top Coat | 132.06 | 133.81 | 1.74 | 1.32 |
| 3 | Suprasec 2413 1 Coat | 128.84 | 130.58 | 1.74 | 1.35 |
| 4 | Suprasec 2413 1 Coat | 128.01 | 129.98 | 1.96 | 1.53 |
| 5 | VitraGroup Solvent Al | 265.44 | 275.69 | 10.25 | 3.86 |
| 6 | VitraGroup Solvent A2 | 273.61 | 284.76 | 11.15 | 4.08 |
| 7 | VitraGroup Solvent A3 | 275.62 | 287.61 | 11.99 | 4.35 |
| 8 | VitraGroup Solvent A4 | 271.87 | 282.43 | 10.56 | 3.88 |
| 9 | No Coating | 130.71 | 162.53 | 31.83 | 24.35 |
| 10 | No Coating | 96.20 | 119.41 | 23.21 | 24.12 |
[0125] Sample 1, which represents a fibre-reinforced cement sheet having a coating combination of Suprasec 2413® and primer Dalto YG 10010 Top Coat, absorbed a larger volume of water and a higher percent water uptake by weight compared with that of Samples 3 and 4.
[0126] Sample 2, which represents a fibre-reinforced cement sheet having a coating combination of Suprasec 2413® and primer Dalto YG 10010 Top Coat, absorbed a comparable amount of water volume and percent water uptake by weight compared with that of Samples 3 and 4. From this observation, it can be seen that use of primer Dalto YG 10010 Top Coat does not appear to provide any significant advantage and would be an unnecessary additional cost, without providing additional benefit.
[0127] Samples 5 to 8, which represent a fibre-reinforced cement sheet having a VitraGroup Solvent Al, VitraGroup Solvent A2, VitraGroup Solvent A3 and VitraGroup Solvent A4, respectively, showed that a larger water volume and a higher percent water
-302019101571 12 Dec 2019 uptake by weight was observed compared with that of Samples 3 and 4. The VitraGroup Solvent range used in the water immersion tests was supplied by VitraGroup Pty Ltd (Australia).
[0128] Samples 9 and 10, which represent a fibre-reinforced cement sheet having no precoating, showed that a significantly larger water volume and a significantly higher percent water uptake by weight was observed compared with that of Samples 3 and 4.
[0129] These results demonstrate that a fibre-reinforced cement sheet 140, having a precoating of polyurethane applied thereto, being water-repellent, significantly reduces water absorption, which in turn may improve moisture drainage through the weep slots 133 and/or may assist a channel 100 to achieve compliance with AS 1530.8.1-2007 (BAL29 compliance). Accordingly, a channel 100 comprising weep slots 133, having a width of less than 3mm, would reduce ember attack and/or meet AS/NZS 4284:2008 weatherproofing verification, and furthermore, when comprising a fibre-reinforced cement sheet 140, having heat-resistant and insulating properties, should improve moisture drainage.
[0130] Other embodiments and uses of this invention will be apparent to those having ordinary skill in the art upon consideration of the Specification and Figures of the invention disclosed herein. The Specification and specific Figures given should be considered exemplary only, and it is contemplated that the appended Claims will cover any other such embodiments or modifications that fall within the scope of the invention disclosed herein.
Claims (15)
1. A starter channel for use with a wall cladding of a building, the channel comprising a front wall section, a rear wall section, and a floor section, wherein the floor section is located intermediate between the front wall section and the rear wall section; and wherein the floor section comprises at least one of:
a. at least one weep slot or a series of weep slots orientated diagonally relative to a longitudinal axis of the floor section; and
b. at least one layer of a material having heat-resistant or water-repellent properties, or a combination thereof.
2. The channel of Claim 1, wherein the channel further comprises at least one fibrereinforced cement packer spacer attached to an underside surface of the floor section.
3. The channel of Claim 2, wherein the at least one spacer is pre-coated with polyurethane.
4. The channel of Claim 3, wherein the series of weep slots comprise one or more repeat sets of two slots spaced apart from one another and being formed in a V-shaped or Λ-shaped configuration running in a zig-zag-like pattern along a length of the channel.
5. The channel of any one of Claims 1 to 4, wherein the material is a heat-resistant material comprising fibre-reinforced cement sheet.
6. The channel of Claim 5, wherein the fibre-reinforced cement sheet is pre-coated with polyurethane.
7. A method of manufacturing a starter channel for use with a wall cladding of a building, the method comprising the steps of:
(i) providing a sheet of material;
-322019101571 12 Dec 2019 (ii) stamping at least one weep slot or a series of weep slots through a surface of the sheet of material, wherein the or each weep slot is orientated diagonally relative to a longitudinal axis of the sheet; and (iii) folding the sheet of material in a configuration to form a front wall section, a rear wall section, and a floor section, wherein the floor section is located intermediate between the front wall section and the rear wall section.
8. A method of manufacturing a starter channel for use with a wall cladding of a building, the method comprising the steps of:
(i) providing a sheet of material comprising a floor section;
(ii) stamping at least one weep slot or a series of weep slots through a surface of the sheet of material, wherein the weep slot is orientated diagonally relative to a longitudinal axis of the sheet; and (iii) joining the sheet of material comprising the floor section to a front wall section and to a rear wall section, such that the floor section is located intermediate between the front wall section and the rear wall section.
9. A method of installing a starter channel for use with a wall cladding of a building, the method comprising the steps of:
(i) positioning the channel at an installation area; and (ii) attaching the channel to the building with at least one fastener or adhesive material;
wherein the channel comprises a front wall section, a rear wall section, and a floor section, wherein the floor section is located intermediate between the front wall section and the rear wall section; and wherein the floor section comprises at least one of:
a. at least one weep slot or a series of weep slots orientated diagonally relative to a longitudinal axis of the floor section; and
-33 2019101571 12 Dec 2019
b. at least one layer of a material having heat-resistant or water-repellent properties, or a combination thereof.
10. A method of installing a starter channel for use with a wall cladding of a building, the method comprising the steps of:
(i) positioning the channel at an installation area, wherein the installation area is a substantially flat horizontal surface of a rebated edge area; and (ii) positioning a wall cladding in the channel;
wherein the channel comprises a front wall section, a rear wall section, and a floor section, wherein the floor section is located intermediate the front wall section and the rear wall section; and wherein the floor section comprises at least one of:
a. at least one weep slot or a series of weep slots orientated diagonally relative to a longitudinal axis of the floor section; and
b. at least one layer of a material having heat-resistant or water-repellent properties, or a combination thereof.
11. The method of any one of Claims 7 to 10, further comprising the step of: positioning at least one layer of a material having heat-resistant or water-repellent properties, or a combination thereof, on the floor section.
12. The method of Claim 11, wherein the at least one layer of a material is a heatresistant material comprising at least one fibre-reinforced cement sheet.
13. The method of Claim 12, wherein the or each fibre-reinforced cement sheet is pre-coated with polyurethane.
14. The method of any one of Claims 7 to 13, wherein the method comprises attaching at least one fibre-reinforced cement packer spacer to an underside surface of the floor section with an adhesive material.
15. The method of Claim 14, wherein the at least one spacer is pre-coated with polyurethane.
Applications Claiming Priority (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| AU2018904725 | 2018-12-12 | ||
| AU2018904725A AU2018904725A0 (en) | 2018-12-12 | A channel | |
| AU2019900912A AU2019900912A0 (en) | 2019-03-19 | A channel | |
| AU2019900912 | 2019-03-19 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| AU2019101571A4 true AU2019101571A4 (en) | 2020-01-23 |
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ID=69166897
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| AU2019101571A Active AU2019101571A4 (en) | 2018-12-12 | 2019-12-12 | A starter channel |
Country Status (1)
| Country | Link |
|---|---|
| AU (1) | AU2019101571A4 (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN114562042A (en) * | 2022-03-16 | 2022-05-31 | 四川华远建设工程有限公司 | Assembled building externally-hung wallboard drainage structures |
-
2019
- 2019-12-12 AU AU2019101571A patent/AU2019101571A4/en active Active
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN114562042A (en) * | 2022-03-16 | 2022-05-31 | 四川华远建设工程有限公司 | Assembled building externally-hung wallboard drainage structures |
| CN114562042B (en) * | 2022-03-16 | 2024-05-24 | 四川华远建设工程有限公司 | Drainage structure of externally hung wallboard of assembled building |
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