AU2023263540A1 - Façade system - Google Patents

Abstract

Described herein is facade system, support frame, method of assembly and kit of parts. A stone facade is enabled by the support frame that provides a fixing point for the stone tiles. The facade system a support frame system, of support frame sections, the support frame sections configured to be fastened to the substrate about a first face of each support frame section with an opposing second face of each support frame section facing outwards from the substrate. The facade system provides a gap between the substrate and stone tiles and allowance for movement of the various parts and avoidance of any stress build up or failure as a result of the movement. The facade system also provides the ability to cater for transitions in substrate orientation / change in plane. 26 to 210 b22 00 50 FIG. 1 1/19

Description

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FACADE SYSTEM RELATED APPLICATIONS

This application derives priority from New Zealand patent application number 794432 filed on

14 November 2022 with WIPO DAS code 260B incorporated herein by reference.

TECHNICAL FIELD

Described herein is a facade system. More specifically, a facade system, support frame, method of

assembly and kit of parts are described herein.

BACKGROUND ART

Creating a tiled facade on a building structure such as on a wall has been completed in the art.

For example, stone tiles may be adhered to building framing using cementitious adhesive. The resulting

stone facade is made up of various stone tiles that abut one another. This style of stone facade has

drawbacks in modern design as there are issues with load, retention, tile movement, substrate

movement, air movement and moisture movement between the stone tiles and framing - water may for

example become trapped behind the tiles leading to leaky buildings. This method of forming a stone

facade also does not allow for stone tile movement in the event of temperature expansion and

contraction, seismic movement and wind loading movement. Stone tiles or similar potentially brittle

materials may be prone to stress build up and can crack as a result causing a loss in water tightness.

AU2006202795 describes a method of creating a stone facade using a round discs that fit into

complementary recesses in the stone tiles of the facade, the disc being linked to a substrate such as

building framing. This stone facade has some bulk and requires machining of openings in the stone tiles.

As a result this method/product may be more time consuming to install and hence, costlier than simply

adhering stone tiles to a substrate.

The applicant's prior art product sold under the trade mark StrukteCT is useful in that it provides for

stone tile movement. A drawback of this facade may be that it is thicker as it has a cavity system hence,

intrudes well beyond the substrate. The system also requires a wall lining and a larger frame extrusion

and fixing hence, greater material cost.

It may be useful to provide a lower depth solution for provision of a stone facade that also addresses

movement of the stone facade and minimises the risk of stress concentrations and stone facade failure,

or at least provides the public with a choice.

Further aspects and advantages of the facade system, support frame, method of assembly and kit of parts will become apparent from the ensuing description that is given by way of example only.

SUMMARY

Described herein is facade system, support frame, method of assembly and kit of parts. A stone facade

is enabled by the support frame that provides a fixing point for the stone tiles, a gap between the

substrate and stone tiles and allowance for movement of the various parts and avoidance of any stress

build up or failure as a result of the movement.

In a first aspect, there is provided a facade system comprising:

a facade exterior formed from stone tiles;

a substrate on which the stone tiles are mounted; and

intermediate the substrate and the stone tiles, is a support frame system, wherein the support

frame system comprises:

support frame sections, each support frame section comprising an elongated planar shape,

opposing first and second faces and, opposing top and bottom ends; and

the support frame sections configured to be fastened to the substrate about the first face of

each support frame section with the opposing second face of each support frame section facing

outwards from the substrate; and

and adhesive on at least part of the opposing second face of the support frame sections to

which stone tiles are adhered to thereby forming the facade system.

In a second aspect, there is provided a support frame system configured for use in a facade system

comprising:

support frame sections, each support frame section comprising an elongated planar shape,

opposing first and second faces and, opposing top and bottom ends; and

the support frame sections configured to be fastened to a substrate about the first face of

each support frame section with the opposing second face of each support frame section facing

outwards from the substrate; and

and adhesive on at least part of the opposing second face of the support frame sections

configured to adhere to stone tiles used to form an exterior facade of the facade system.

In a third aspect, there is provided a method of assembling a facade on a substrate by:

selecting a facade system substantially as described above; and,

fastening the support frame sections to the substrate about the first face of each support frame

section with the opposing second face of each support frame section facing outwards from the substrate; and adhering stone tiles to adhesive on at least part of the opposing second faces of the support frame sections to thereby form the facade system.

In a fourth aspect, there is provided a kit of parts configured to manufacture a facade system over a

substrate comprising:

a support frame system substantially as described above; and

a set of assembly instructions.

The above facade system, support frame, method of assembly and kit of parts may provide a number of

benefits that are described further below but includes provision for part movement and the ability to

cater for transitions in substrate orientation / change in plane.

BRIEF DESCRIPTION OF THE DRAWINGS

Further aspects of the facade system, support frame, method of assembly and kit of parts will become

apparent from the following description that is given by way of example only and with reference to the

accompanying drawings in which:

Figure 1 illustrates a part assembled perspective view from above of a facade system fitted to a flat

wall;

Figure 2 illustrates a partial cross-section front elevation view of the facade system of Figure 1;

Figure 3 illustrates a partial cross-section plan elevation view of the facade system of Figure 1;

Figure 4 illustrates a partial cross-section end elevation view of the facade system of Figure 1;

Figure 5 illustrates a perspective view from above of the facade system of Figure 1 in a first

installation step;

Figure 6 illustrates a perspective view from above of the facade system of Figure 1 in a second

installation step;

Figure 7 illustrates a perspective view from above of the facade system of Figure 1 in a third

installation step;

Figure 8 illustrates a perspective view from above of the facade system of Figure 1 in a fourth

installation step;

Figure 9 illustrates a perspective view from above of the facade system of Figure 1 in a fifth

installation step;

Figure 10 illustrates a part assembled perspective view from above of a facade system fitted to a wall

about an externalcorner;

Figure 11 illustrates a partial cross-section front elevation view of the facade system of Figure 10;

Figure 12 illustrates a partial cross-section plan elevation view of the facade system of Figure 10;

Figure 13 illustrates a partial cross-section front elevation view of a facade system fitted to a wall

about an internalcorner;

Figure 14 illustrates a partial cross-section plan elevation view of the facade system of Figure 13

fitted to a wall about an internal corner;

Figure 15 illustrates a perspective view from above of the facade system of Figure 13 and Figure 14

in a first installation step;

Figure 16 illustrates a perspective view from above of the facade system of Figure 13 and Figure 14

in a second installation step;

Figure 17 illustrates a perspective view from above of the facade system of Figure 13 and Figure 14

in a third installation step;

Figure 18 illustrates a perspective view from above of the facade system of Figure 13 and Figure 14

in a fourth installation step and;

Figure 19 illustrates a perspective view from above of the facade system of Figure 13 and Figure 14

in a fifth installation step.

DETAILED DESCRIPTION

As noted above, described herein is facade system, support frame, method of assembly and kit of parts.

A stone facade is enabled by the support frame that provides a fixing point for the stone tiles, a gap

between the substrate and stone tiles and allowance for movement of the various parts and avoidance

of any stress build up or failure as a result of the movement.

For the purposes of this specification, the term 'about' or 'approximately' or 'substantially' and

grammatical variations thereof mean a quantity, level, degree, value, number, frequency, percentage,

dimension, size, amount, weight or length that varies by as much as 30, 25, 20, 15, 10, 9, 8, 7, 6, 5, 4, 3,

2, or 1% to a reference quantity, level, degree, value, number, frequency, percentage, dimension, size,

amount, weight or length.

The term 'comprise'and grammatical variations thereof shall have an inclusive meaning - i.e. that it will

be taken to mean an inclusion of not only the listed components it directly references, but also other

non-specified components or elements.

The term 'stone' is used for ease of reference which, for the purposes of this specification, encompasses

materials comprising: high density mineralised materials, ceramics, porcelain, thin stone, sintered stone,

composite materials, compressed cement board, aluminium composite panels, aluminium honeycomb composite, metallic panels, composite plastic panels, glass composite panels, sign board, fibreglass, mineralised panel, and combinations of these materials.

First Aspect - Support Frame System

In a first aspect, there is provided a facade system comprising:

a facade exterior formed from stone tiles;

a substrate on which the stone tiles are mounted; and

intermediate the substrate and the stone tiles, is a support frame system, wherein the support

frame system comprises:

support frame sections, each support frame section comprising an elongated planar shape,

opposing first and second faces and, opposing top and bottom ends; and

the support frame sections configured to be fastened to the substrate about the first face of

each support frame section with the opposing second face of each support frame section facing

outwards from the substrate; and

and adhesive on at least part of the opposing second face of the support frame sections to

which stone tiles are adhered to thereby forming the facade system.

Second Aspect - Fagade System

In a second aspect, there is provided a support frame system configured for use in a facade system

comprising:

support frame sections, each support frame section comprising an elongated planar shape,

opposing first and second faces and, opposing top and bottom ends; and

the support frame sections configured to be fastened to a substrate about the first face of

each support frame section with the opposing second face of each support frame section facing

outwards from the substrate; and

and adhesive on at least part of the opposing second face of the support frame sections

configured to adhere to stone tiles used to form an exterior facade of the facade system.

Third Aspect - Method of Assembly

In a third aspect, there is provided a method of assembling a facade on a substrate by:

selecting a facade system substantially as described above; and, fastening the support frame sections to the substrate about the first face of each support frame section with the opposing second face of each support frame section facing outwards from the substrate; and adhering stone tiles to adhesive on at least part of the opposing second faces of the support frame sections to thereby form the facade system.

Fourth Aspect - Kit of Parts

In a fourth aspect, there is provided a kit of parts configured to manufacture a facade system over a

substrate comprising:

a support frame system substantially as described above; and

a set of assembly instructions.

Fagade

The term facadee' as used herein refers to the frontage or face of a wall, ceiling, soffit, roof, reveal, head,

sill or other building planar structure.

Further, unless stated different, a facade in the context of this specification may be an internal feature

e.g. an interior/internal wall of a building and/or an exterior/external feature such as an external wall

face.

The inventor has found that the support frame system and facade system described herein may be

useful for interiors in part because the support frame system does not intrude far into the internal area

of the building. As a result, the facade system minimises any loss of internal room area/volume.

The support frame system and facade system described herein may also be useful for internal walls since

there may be less need for air movement, (or at least a lower volume of air movement), needed

between the stone tiles and substrate than may be required for an external wall exposed to rain and

moisture in general.

Support Frame System

The support frame system may be configured to be obscured once the facade system is assembled. The

support frame system may be configured to be obscured once stone tiles are installed on the support

frame system.

The support frame system may be configured to distribute stress evenly. This may be useful to avoid

producing areas of higher stress loading where load/tension fractures may otherwise begin, for example,

in a seismic event or due to wind loading or simply due to general building movement and settlement.

The support frame system may separate the stone tile facade from the substrate. Separation may be

useful for example, to prevent electrolytic and galvanic action which may otherwise occur with direct

fixing over existing buildings. Separation also importantly allows for minor structure movement.

The support frame system may be configured to have a minimal depth and minimise intrusion beyond

the substrate face. A depth between an outer face of the facade exterior of stone tiles and substrate

once the facade system is assembled may be less than 30, or 25, or 20, or 15, or 10mm. As noted above,

this may be a particular advantage for interiors where it may be beneficial to minimise intrusion into the

room area.

The support frame system when fastened to the substrate may not have a cavity opening and may not

require battens, packers or other spacer members. The support frame system when fastened to the

substrate may however be configured to have open channels between the substrate and stone tile

facade. These openings may be 0.5 to 5mm in depth. The openings may be approximately 100 to 1000,

or 200-900, or 300-700, or 400-600, or approximately 500mm wide between support frames. The

support frames themselves may be configured to have a shape to provide a gap or gaps between the

substrate and the first face of the support frame.

Optionally, if a cavity is desired, a cavity may be produced by adding 20mm+ backing block.

Support Frame Sections and Relationship Between Sections

The support frame system may comprise support frame sections. The support frame sections may be

orientated top to bottom so a longitudinal axis of each support frame section runs parallel to other

support frame sections.

The support frame sections may be spaced apart across the substrate to which they are to be fastened

to. The support frame sections may be spaced apart equally across the substrate. Centre to centre, the

support frame sections may be spaced apart at approximately 100 to 1000, or 200-900, or 300-700, or

400-600, or approximately 500mm intervals. The spacing may be at centres specific to a load

requirement.

The exact spacing may be governed by the stone tile width, the side of each stone tile terminating about

the centre of the width of each support frame section.

Multiple stone tiles may be adhered to the support frame overall height. The sides of two stone tiles

may be adhered to either side of each support frame section leaving a common gap between the

multiple stone tile sides.

Support Frame Section Shape/Materials

Each support frame section may have a uniform cross-section shape.

The elongated length of each support frame section may be adjusted to suit the substrate to which the

facade system is to be applied to. By way of example, longer support frame sections may be used for tall

walls while shorter support frame sections may be used about detail wall or overhang sections, such as a

bulkhead or varied angle ceiling or wall to ceiling transition.

Each support frame section may be an extrusion with a uniform cross-section shape of infinite length, cut

to suit the substrate to which each support frame section is to be fastened to.

The support frame section may be an aluminium extrusion although other materials may be used.

Aluminium may be useful due to the longevity of this material and the light weight of aluminium.

The overall width of a support frame section may be 20-200, or 30-180, or 40-160, or 50-150, or 75-125,

or approximately 50mm.

Each support frame may have a cross-section shape comprising a flattened U-shape. Each support frame

cross-section flattened U-shape may have flanged sides.

A first face of the flanged sides may bear on the substrate. Fasteners may pass through the flanged sides

and into the substrate.

The flattened U-shape may be configured to form at least one smaller opening between a central width

portion of a support frame section. This at least one small opening may remain open and not obscured

for air flow once the facade system is assembled. This small opening created between the substrate and

support frame section may be useful to allow for expansion and contraction variation between the

substrate, support frame section and stone tiles. This at least one small opening may be from 0.5 to 5, or

1-3, or 1-2mm in depth from the substrate face to the central portion of the support frame section

opposing face.

There may be two smaller openings, one on each side of a centre of the support frame section

segregated by a smaller U-shape channel. Where two small openings are present, each small opening

may have a width of approximately 8-12, or 9-11, or approximately 10mm.

At a transition in cross-section shape from the flanged sides to an outward edge of the flattened U

shape, channels may be provided on the first face of each support frame section. These channels may be

used to mate with guide strips described further below.

A smaller U-shape channel may be located about a central width portion of a cross-section of each

support frame section, an opening of the smaller U-shape channel opening further to the second face of

each support frame section. This smaller U-shape channel may be provided to located a backer rod

described further below. The smaller U-shape channel may also act as a channel for moisture capture

and egress from the support frame section (in a vertical alignment), out of the bottom of the smaller U

shape channel and support frame section.

Substrate

The substrate referred to herein may be building frontage or face.

Examples of substrate to which the facade system and support frame system may be applied comprise: a

wall, overhang, ceiling, soffit, roof, reveal, head, sill, door, gate, fence, signage, or other planar face or

frontage. That is, the facade system and support frame system may not be limited to placement on a

vertically orientated face and may be used on angled faces or even horizontal plane faces, such as a

ceiling or soffit.

For ease of reference, the facade system and support frame system is described in the context of a

vertically aligned wall, top being the ceiling side of the wall and bottom being towards the floor of the

building. Reference to a wall or vertical plane or alignment in the context of the facade system and

support frame system should not be seen as limiting.

The facade system may also traverse a transition in direction e.g. from vertically aligned wall to

horizontally aligned ceiling. Again, reference to only use on a wall and one alignment should not be seen

as limiting.

The substrate itself may be manufactured from timber, steel, concrete or SIP panel(s). It is envisaged

that the facade system and support frame system may be fastened to the substrate e.g. framing, in a

building structure.

No wall lining may be needed. The support frame sections may be directly fastened to the substrate and

it may not be necessary to apply intermediate layers such as a wall lining separates battens or spacer

members between the substrate and support frame section.

As noted elsewhere in this specification, the substrate may be an interior/internal or exterior/external

wall. The facade system described is not limited to only interior or exterior features.

The substrate may be a planar wall.

The substrate may be a transition from one planar wall face to another planar wall face, each wall face at

a different orientation to one another e.g. a 90 degree transition. For example, the substrate may be an

external or internal corner transition.

The substrate may be a wall to ceiling or soffit transition e.g. from a vertically orientated planar wall to a

horizontally orientated (or near horizontal orientation) planar ceiling or soffit.

The substrate may also traverse transitions between ceiling sections, soffit sections and ceiling to soffit

transitions.

Fastened

As noted above, the support frame sections may be fastened to the substrate.

Fastening may be directly from the support frame sections to the substrate with no intermediate layer or

layers.

Fastening may be by use of one or more mechanical fasteners such as screws, nails, rivets and so on.

Fasteners may be placed through the support frame sections at points coincident with substrate

locations e.g. coincident with where the support frame sections align with underlying framing in the

substrate. This may mean that the fasteners are fitted to the support frame sections in a varied or offset

orientation, at least in a horizontal plane, and not in a symmetrical manner.

Fasteners may be fitted in an even vertical plane and about opposing distal sides of each support frame

section extending from the second face, through the first face and into the substrate.

Adhesive

As noted above, adhesive may be used to adhere the support frame section to stone tiles.

The adhesive may adhere to only part of the second face of each support frame section and to only part

of the stone tiles.

The adhesive may extend as an elongated strip along a longitudinal axis of each support frame section

from the top end of each support frame section to the bottom end of each support frame section.

A single strip may adhere to part or all of a stone tile. Two strips of adhesive may be located on each

support frame section located on either side of a width of each support frame section and each strip of

adhesive may adhere to a separate stone tile, multiple stone tiles being used to form the facade exterior

of stone tiles.

Adhesive may be placed on a support frame section once the support frame section is fastened to the

substrate. Alternatively, adhesive may be located on a support frame section when delivered to a site

and prior to installation. In this case, a removable backing may be located over the adhesive to avoid

contamination of the adhesive prior to stone tile adhering.

The adhesive used may be a commercially available product with a curing time dependent on the type of

adhesive used. The adhesive bond longevity may be at least 10 years.

The adhesive may be a chemical adhesive. The adhesive may have elastomeric properties to provide

some resilience and allow for some movement.

Stone Tile

The stone tile may be a large format surface or panel.

The term 'large' in this context refers to an oblong tile shape or sheet with a width and/or height of at

least 0.5m. Stone tiles envisaged for use with this facade system described herein may vary in width from 1, or 1.5, or 2, or 2.5, or 3, or 3.5 ,or 4, or 4.5, or 5, or 5.5, or 6, or 6.5, or 7, or 7.5, or 8, or 8.5, or 9, or 9.5, or 10m and may vary in height from 1, or 1.5, or 2, or 2.5, or 3, or 3.5,or 4, or 4.5, or 5, or 5.5, or

6, or 6.5, or 7, or 7.5, or 8, or 8.5, or 9, or 9.5, or 10m. They may be generally larger sheets or panels and

the term 'tile' as used herein may refer to this larger format of tile.

Multiple stone tiles may be used to create the final facade system.

Each support frame section may comprise at least two stone tiles adhered to the support frame section.

Each support frame section may comprise at least two stone tiles adhered to each support frame section

with a gap located between the two stone tiles, the gap aligned along a longitudinal axis of each support

frame section and aligned centrally across a width of the second face of each support frame section.

A small gap may be left between the stone tile sides to allow for expansion and contraction of the tiles

relative to the support frame section. Small in this context refers to a gap of 0.5 to 10, or 1-8, or 2-8, or

3-6, or 3-5mm in width.

The gap between the tile sides may run continuously along a length of each support frame section and is

common to multiple stone tiles adhered to the support frame sections from the top to the bottom of the

support frame sections. This gap may be common to multiple stone tiles adhered to the support frame

section from the bottom to the top of the support frame section.

The stone may be sintered stone. The stone may be a natural stone such as limestone, or bluestone.

Many different stone facade products exist and the problem of how to mount such products is common

to many if not all of these products.

Stone is a useful facade product given the longevity of the material (50+ lifespan material), thermal

properties and aesthetics.

Note that the term stone as used herein is used for brevity. Stone tiles may be substituted for other

materials with similar properties, examples including wood, plastics and composite materials. Use of the

term stone should not be seen as limiting.

Corners

The support frame may be used on a flat substrate and also used about a corner, for example where one

wall meets another wall of a different orientation. The corner may be an external corner or internal

corner.

Where a corner occurs, a support frame section may be used that has a complementary angled bend

about the central longitudinal axis of the support frame. By way of example, if the substrate is a wall and

that wall bends 90 degrees about a corner, a support frame section may be selected that has a 90 degree

bend in the support frame section cross-section corresponding to the wall bend (internal or external

bend). The bend may be orientated so that the first face of the support frame section bears on one side to a first piece of wall and on a second side to a second piece of wall, the wall corner located about the central bend axis.

In other respects, the support frame section remains the same as that described above. Stone tiles may

be adhered to one half of the support frame section and, on the other half, further stone tiles may be

adhered at 90 degrees to the first half of the stone tiles.

Note that to make an aesthetically pleasing finish, in a corner arrangement, the stone tile facade

abutting faces may be cut on an angle so as to allow the faces of each stone tile facade to reach a point

about the corner and leave only a small gap between the corner sections. Conversely, in a flat finish

without a corner, the tile edges may have a flat cut and butt up to one another albeit leaving a gap as

described elsewhere between the stone tiles that make up the facade.

Guide Strips

The facade system may further comprise at least one guide strip. The facade system may comprise two

to more guide strips.

The at least one guide strip may be located about a transition from the top of one support frame section

to the bottom of another support frame section.

As noted elsewhere in this specification, support frame sections may have opposing top and bottom

ends. The support frame sections may also be supplied in a set length. The top end of one support

frame section may be aligned with the bottom end of another support frame section. The transition

between support frame sections may be to traverse a high wall or wall that is taller than a single support

frame section. The transition may also be between a wall mounted frame support section and a ceiling

or soffit mounted frame support section i.e. the joint between frame support sections may be located at

a transition in substrate face alignment.

Guide strips may be used about a transition from one support frame section to another support frame

section. These transitions may be located about the opposing top or bottom ends of the support frame

sections. Each guide strip may be configured to orientate separate support frame sections in a common

alignment and provide lateral stability between support frame sections.

A guide strip may be elongated in shape with a longitudinal length, opposing first and second ends, and a

guide strip width and guide strip depth. Each guide strip used may be mounted to the substrate via a

first guide strip face, the opposing second guide strip face facing away from the substrate.

The, or each, guide strip may be mounted to the substrate via at least one fastener e.g. grub screws.

The, or each, guide strip may be aligned on the substrate so that the, or each, guide strip longitudinal

axis is parallel to the longitudinal axis of the support frame section.

The guide strip width, depth and at least part of a guide strip length may complement a width, depth and length of an opening in the support frame section.

Each guide strip may interlink with the opening in the support frame section via a tongue and groove

style coupling. For example, the guide strip may have a T-shape cross-section and the opening in the

support frame section may have a complementary T-shape opening. The guide strip and opening in the

support frame section may fit together as a male female fitting. The support frame section may slidingly

fit over the guide strip or guide strips.

The guide strip or guide strips once mated with the support frame section may act to restrain movement

of one support frame section relative to an adjoining support frame section. Movement referred to may

be in a substantially lateral direction perpendicular to the longitudinal axis of the support frame section

and guide strip or guide strips.

Each guide strip may extend only partly into either the top or bottom of the adjoining support frame

sections. That is, the guide strips may not extend fully through the support frame section length. The

ratio of support frame section longitudinal length to extent of guide strip extension into the support

frame section may less than Ito 0.1, or 0.05, or 0.01, or 0.005, or 0.001. For example, if the support

frame section is 2 metres in longitudinal length, the guide strip may extend no more than approximately

200, or 100 or 20, or 10, or 5mm into one end of the support frame section. Each guide strip may extend

an equal distance into either support frame section e.g. if the guide strip is 100mm long and extends

50mm into either end of adjoining support frame sections.

A guide strip may be straight or angled about a mid-point of the guide strip longitudinal length, the

shape or angle being complementary to a transition in angle of the substrate. For example, if two

adjoining support frame sections follow on from each other on a vertically orientated wall, the guide

strip may be straight and not angled so as to complement the flat form of the wall. Alternatively, if one

support frame section is on a vertically aligned wall and the next on a horizontally aligned ceiling, the

guide strips used may have a 90 degree bend about the guide strip centre. Other angles between guide

strip ends may also be used complementary to the substrate shape and angle variations.

The guide strips described may be useful to interlink sections of support frame and thereby cater for

varying heights and changes in plane. The guide strips may for example interlink to produce a return

soffit above doorway or bulkhead.

Note that the support frame may stop or separate at changes in floor levels. This may be done to allow

for seismic slip joint detailing.

Fixing Tape

The above facade system and support frame system may further comprise fixing tape.

The fixing tape may be configured to provide a rapid bond between the support frame sections and

stone tiles during installation to provide an immediate bond and which holds the stone tiles in place while the adhesive has time to cure and adhere the stone tiles.

The fixing tape may be a double sided tape with a first side of the fixing tape adhered to the second face

of each support frame section along a longitudinal axis of each support frame section from the top to the

bottom of each support frame section.

Two fixing tape strips may be used, one on either side of a centre of a width of each support frame

section so as to bond to sides of opposing stone tiles located on either side of the width of each support

frame section.

Fixing tape may be used to provide a rapid bond between the support frame section and stone tile

facade. This may be helpful during installation to speed bonding in that the fixing tape may provide an

immediate bond which holds stone tiles in place while the chemical adhesive has time to cure and

adhere the stone tiles more permanently to the support frame sections. The fixing tape may eventually

deteriorate however, after the adhesive cures, the load may be substantially taken up by the adhesive

and not the fixing tape. The fixing tape may in essence be a sacrificial short term adherent to allow the

adhesive to form an enduring bond.

The fixing tape may be a double sided tape. At installation, a first side of the tape may be adhered to the

second face of the support frame section. The fixing tape may be adhered to the support frame section

along the support frame longitudinal axis from the top to the bottom of the support frame section. Two

fixing tape strips may be used, one on either side of the centre of the support frame section width so as

to bond to the sides of opposing stone tiles located on either side of the support frame section width.

Once the fixing tape is bonded to the support frame section, a removable backing may be removed from

the tape to expose the outer surface of the tape and stone tiles then pushed onto the fixing tape to bond

the tile and support frame section together (after adhesive is also applied or already present on the

second face of the support frame section).

The fixing tape may have a thickness of 0.5 to 5mm e.g. via a resilient internal foam or similar material to

provide the thickness. This added thickness may allow for movement of the stone tiles relative to the

substrate and support frame section.

The fixing tape may also provide a moisture seal. Any moisture that enters gaps between adjoining

stone tiles may be blocked from tracking outwards from the centre of the support frame section by the

fixing tape.

The exact type of fixing tape used may vary however, in the inventor's experience a commercially

available product with an instant bond strength may be more than sufficient to provide the desired

features noted above. The exact bond strength may vary depending on the load requirements to be

achieved.

Backer Rod

A backer rod may be located intermediate a centre of each support frame section and a gap between the

stone tiles, the backer rod being a resilient foam and the resilient foam shaped to bear on an opening

defined by the gap and opposing sides of the support frame section, thereby filling the opening defined

between the gap and the support frame section.

The gap noted above between stone tiles may, as described elsewhere, be centrally located across the

support frame section width and extend continuously from the top to the bottom of the support frame

section once the stone tiles are adhered to the support frame sections.

This gap may be left open. In this case, moisture may enter the gap and then runs down the support

frame section about the gap to exit from the bottom the support frame section in a vertically orientated

arrangement. Water egress laterally beyond the centre of the width of a support frame section may be

prevented as noted above by the fixing tape and beyond that, by the adhesive.

Optionally, a backer rod may be located intermediate the support frame section centre and the gap

between the stone tile sides. A backer rod may be used in external facade systems to limit moisture

ingress.

The backer rod may be made from a resilient foam. The resilient foam may be shaped to bear on the

gap opening and opposing side of the support frame section thereby filling the opening between the gap

and support frame section. The backer rod may not be impermeable to moisture but may act to deter

gross ingress of moisture and to also avoid materials entering the gap between the stone tile sides.

The backer rod may be seated on one side partly within and extending in width and depth from the

smaller U-shape channel of the support frame section.

Sealant

Optionally, all gaps between stone tiles (top, bottom and sides) may be filled (partly or fully) with

sealant. All gaps may be filled between the stone tiles.

The sealant may be substantially resilient. The sealant may be elastomeric. The sealant may expand and

contract with the surrounding materials and parts. The sealant may be silicon sealant or polyurethane

sealant.

The sealant may be applied after adhering of the stone tiles to the support frame sections.

If the backer rod is used as described above, the sealant may bear on the gap face of the backer rod and

not extend further through the gap between the stone tiles.

Optional Bracket

A bracket or brackets may be used complementary to the support frame sections and stone tiles. The bracket or brackets may be located between the support frame section and stone tiles.

Brackets of this nature may be used for heavier stone tiles or where high movement is anticipated in the

stone tiles, for example, due to higher degree of material expansion and contraction and/or high wind

loadings.

Movement Provisions

The assembled facade system described may have provision to allow for movement of the stone tiles,

support frame and substrate.

By way of example, an expansion joint may be provided for between the stone tile sides to allow for

lateral movement orthogonal to the direction of a gap between tile sides.

Gaps between the top and bottom of the stone tiles may also allow for some movement parallel to the

support frame longitudinal axis.

The support frame itself may have a small opening between the substrate and support frame section

which allows for some z-axis, depth movement.

Further, the adhesive used to adhere the stone tiles to the support frame sections may only adhere a

small strip of each stone tile to the support frame section and not adhere over a wider surface area. In

the inventors experience, this appears to avoid diagonal or construction joint stress concentrations

common to scenarios where adhesive is spread all over or more randomly about the stone tile

underside.

Overall, it is the inventors experience, that the stone facade provided offers considerably better

movement than other methods of forming a stone facade and hence provides for movement and long

term durability and finish.

Advantages

As may be appreciated from the above description, the facade system, support frame, method of

assembly and kit of parts may provide a number of benefits in respect of providing a stone facade.

These benefits may comprise one or more of the following:

- Prevention of the concentration of stress in adhesion surfaces;

- The support frame described may enable the joining of different types of facade materials to a

substrate;

- Seismic resilience in that the facade system may provide for movement between stone tile

facade joints to let the stone tile facade move separately from each other at least to some

extent - the transfer of energy from the substrate is dissipated;

- Transitions in substrate orientation / change in plane may be addressed and catered for;

- The stone facade may reduce or eliminate the transfer of vibration from the facade to the main

substrate;

- The stone facade (or at least the support frame) may be light weight, strong, stiff and durable;

- The stone facade may provide a thermal barrier to heat transfer through the wall yet is

impermeable to moisture to the substrate;

- The stone facade may provide excellent acoustic insulation and fire resistance;

- The support frame may be hidden and may not affect the facade's exterior appearance.

The embodiments described above may also be said broadly to consist in the parts, elements and

features referred to or indicated in the specification of the application, individually or collectively, and

any or all combinations of any two or more said parts, elements or features.

Further, where specific integers are mentioned herein which have known equivalents in the art to which

the embodiments relate, such known equivalents are deemed to be incorporated herein as if individually

set forth.

WORKING EXAMPLES

The above described facade system, support frame, method of assembly and kit of parts are now

described by reference to specific examples, Figures 1 to 19 and the following items:

1 Faeade system

10 Substrate

10a Flat substrate

10b Cornered substrate

20 Support frame system

21 Support frame section

22a, 22bOpposing first and second faces

23a, 23bOpposing top and bottom ends

24 Open channels between the substrate and stone tile facade

25 Support frame flattened U-shape

26a, 26bSupport frame flanged sides

27 Opening in the support frame section for a guide strip

28 Smaller U-shape channel

X Depth outer edge of the stone tile facade and substrate

Y Support frame section spacing

30 Adhesive

40 Fasteners

50 Stone tile

51 Gap between the two stone tile sides

52 Gap between the top and bottom of stone tiles

60 Guide strip

61 Guide strip longitudinal length

62a, 62bGuide strip opposing first and second ends

63 Guide strip width

64 Guide strip depth

70 Guide strip fastener

80 Fixing tape

90 Backerrod

100 Sealant

EXAMPLE 1

In this example a flat wall facade system and method of assembly is described with reference to Figures

1-9.

As shown in Figures 1-4, the assembled facade system 1 comprises a stone tile 50 facade exterior, a

substrate 10 shown as a flat wall made up of timber framing 10a on which the facade system 1 is

mounted; and intermediate the substrate 10 and stone tile 50 facade exterior, a support frame system

20 is shown. The support frame system comprises support frame sections 21 (one shown in Figures 1-9).

Each support frame section comprises an elongated planar shape, opposing first and second faces 22a,

22b and, opposing top and bottom ends 23a, 23b. The support frame sections 21 are fastened using

fasteners 40 to the substrate 10 about the flanges 26a, 26b of each support frame section 21. The

opposing second face 22b of each support frame section 21 faces outwards from the substrate 10.

Adhesive 30 shown as a strip is located on the second face 22b of the support frame section 21 to which stone tiles 50 are adhered to thereby forming the facade system 1.

As shown, the support frame 20 is hidden behind the stone tiles 50 once the facade system 1 is

assembled.

The support frame 20 separates the stone tile 50 facade from the substrate 10 but with a minimal depth

to minimise intrusion beyond the substrate 10. The depth X between an outer edge of the stone tile 50

facade and substrate 10, once the facade system 1 is assembled, may be less than 30 mm.

The support frame 20 as shown when fastened to the substrate 10 does not have a cavity opening and

does not require battens, packers or other spacer members. The support frame 20 when fastened to the

substrate 10 does have open channels 24 best seen in Figure 3 between the substrate 10 and stone tile

50 facade.

The support frame 20 may comprise multiple support frame sections 21 spaced apart along the substrate

10. For ease of description, the use of multiple support frame sections is not shown in Figures 1-9 noting

that the way the parts interact is repeated for each support frame section 21.

In this case, the support frame sections 21 have a generally flat shape corresponding to the flat face of

the substrate 10 - in this case a flat section of wall. Each support frame section 21 may be an aluminium

extrusion of a uniform cross-section shape.

The elongated length of each support frame section 21 may be adjusted to suit the substrate to which

the facade system 1 is to be applied to.

The support frame section 21 cross-section shape have a flattened U-shape 25 best seen in Figure 3. The

support frame section 21 has flanged sides 26a, 26b. A first face 22a of the flanged sides 26a, 26b bears

on the substrate 10 and fasteners 40 pass through the flanged sides 26a, 26b and into the substrate 10

to fix the support frame section 21 to the substrate 10.

At a transition in cross-section shape from the flanged side 26a, 26b to the outward edge or ends of the

flattened U-shape 25, channels 27 may be provided for on the first side 22a of the support frame

sections 21. These channels 27 may be used to mate with guide strips 60.

A smaller U-shape channel 28 is located about a central portion of the support frame section 21 cross

section. An opening of the smaller U-shape channel 28 open to the second face 22b or exterior of the

support frame section 21. This smaller U-shape channel 28 locates a backer rod 90.

The adhesive 30 may extend as an elongated strip best seen in Figure 1 and Figure 2 along the

longitudinal axis of the support frame section 21. Two strips of adhesive 30 are shown, located on the

support frame section 21on either side of a width of the support frame section 21and each strip of

adhesive 30 adheres to a separate stone tile 50.

Each support frame section 21 has at least two stone tiles 50 adhered to the support frame section 21.

A gap 51 is located between the two stone tile sides and above the below 52 the tiles 50. The tile 50 side gap 51 is aligned along the longitudinal axis of the support frame section 21 and aligned centrally across the width of the second face 22b of the support frame section 21. This gap 51 between the tile 50 sides runs continuously along the length of a support frame section 21from the support frame section top 23a to bottom 23b and may be common to multiple stone tiles 50 adhered to the support frame section 21 from the bottom to the top of the support frame section 21.

Guide strips 60 as shown are used about a transition from one support frame section 21 to another

support frame section 21. These transitions are located about the opposing top 23a or bottom 23b ends

of the support frame sections 21. Each guide strip 60 may be configured to orientate separate support

frame sections 21 in a common alignment and provide lateral stability between support frame sections

21.

A guide strip 60 may be elongated in shape with a longitudinal length 61, opposing first 62a and second

62b ends, and a guide strip width 63 and guide strip depth 64 best seen in Figure 5. The guide strips 60

may be mounted to the substrate 10 via at least one fastener e.g. the grub screws 70 as shown in the

Figures.

The guide strip 60 shape complements the shape of the openings 27 in the support frame section 21.

The shape of the guide strip 60 and opening 27 may have a male/female style fit such as a T shape that

acts to allow sliding fit of the support frame section 21 over the guide strips 60 and which locks the

support frame section 21 and guide strips 60 together in at least two dimensions.

Each guide strip 60 may extend only partly into either the top 23a or bottom 23b of the adjoining

support frame sections 21.

Fixing tape 80 may be used to provide a rapid bond between the support frame section 21 and stone

tiles 50. The fixing tape 80 may provide an immediate bond which holds stone tiles 50 in place while the

adhesive has time to cure and adhere the stone tiles 50 more permanently to the support frame section

21. The fixing tape 80 as shown is a double sided tape. At installation, a first side of the tape may be

adhered to the second face 22b of the support frame section 21. The fixing tape 80 may be adhered to

the support frame section 21 along the support frame section 21longitudinal axis. Two fixing tape strips

80 may be used, one on either side of the centre of the support frame section 21 width so as to bond to

the sides of opposing stone tiles 50 located on either side of the support frame section 21 width.

Once the fixing tape 80 is bonded to the support frame section 21, a removable backing may be removed

from the tape 80 to expose the outer surface of the tape 80 and stone tiles 50 then pushed onto the

fixing tape to bond the tile 50 and support frame section 21 together (after adhesive 30 is also applied or

already present on the second face 22b of the support frame section 21).

The fixing tape 80 may have a thickness of 0.5 to 5mm e.g. via a resilient internal foam or similar material

to provide the thickness. This added thickness may allow for movement of the stone tiles relative to the

substrate 10 and support frame section 21.

A backer rod 90 may be located intermediate the support frame section 21 centre and the gap 51

between the stone tile 50 sides. The backer rod 90 may be made from a resilient foam shaped to bear

on the gap 51 opening and opposing side of the support frame section 21 thereby filling the opening

between the gap 51and support frame section 21. The backer rod 90 may be seated on one side partly

within and extending in width and depth from the smaller U-shape channel 28 of the support frame

section 21.

Optionally, all gaps 51, 52 between stone tiles 50 (top, bottom and sides) may be filled (partly or fully)

with sealant 100.

Figures 5 to 9 illustrate a method of assembly of the facade system 1 shown in Figures 1-4. In Figure 5,

the guide strips 60 are fastened to the flat substrate 10a using grub screws 70. In Figure 6, the support

frame section 21 is slid over the guide strips 60, the guide strips 80 being received into openings 27 in

the support frame section 21. A backer rod 90 is placed into the centrally located smaller U-shape

channel 28 of the support frame section 21 extrusion. Figure 7 shows the fasteners 40 in place to fix the

support frame section 21 to the substrate 10a. Figure 8 shows the placement of adhesive 30 to the

support frame section 21 on either side of the section 21. Figure 9 shows the stone tiles 50 placed on

the section 21leaving a gap 51 between the tiles 50. This gap may be filled with sealant 100. Further

tiles 50 may be place above or below the tiles 50 shown to complete the facade, a gap 52 retained above

and below each tile 50.

EXAMPLE 2

In this example an external corner wall facade system is described with reference to Figures 10-12.

As shown, the flattened U-shape of the support frame section 21 is bent 90 degrees about the centre of

the section 21 so that the first face 22a of the section 21 bears on both the first wall section 10b and

second wall section 10b on either side of the corner.

As can be seen in Figures 10-12, in other respects, the facade system 1 and frame system 20 is identical

to that described in Example 1 in that the facade system 1 comprises a section 21, in this case bent 90

degrees, stone tiles 50, a backer rod 90, adhesive 30, fixing tape 80, fasteners 40 and guide strips 60.

EXAMPLE 3

In this example an internal corner wall facade system and method of assembly is described with

reference to Figures 13-19.

As shown, the flattened U-shape of the support frame section 21 is bent 90 degrees about the centre of

the section 21 so that the first face 22a of the section 21 bears on both the first wall section 10b and

second wall section 10b on either side of the corner in this case backed into an internal corner, hence the 90 degree bend is the opposite of that described in Example 2 above.

As can be seen in Figures 13 to 19, in other respects, the facade system 1 and frame system 20 is

identical to that described in Example 1 in that the facade system 1 comprises a section 21, in this case

bent 90 degrees, stone tiles 50, a backer rod 90, adhesive 30, fixing tape 80, fasteners 40 and guide strips

60.

Figures 15 to 19 illustrate a method of assembly of the internal corner facade system 1 shown in Figures

13 and 14. In Figure 15, the support frame section 21 is fitted against the internal corner of the

substrate 10b. . In Figure 16, the guide strips 60 are slid into the support frame section 21 the guide

strips 60 being received into openings 27 in the support frame section 21. A backer rod 90 is placed into

the centrally located smaller U-shape channel 28 of the support frame section 21 extrusion. Figure 17

shows the fasteners 40 in place to fix the support frame section 21 to the substrate 10b. Figure 18

shows the placement of adhesive 30 and tape 80 to the support frame section 21 on either side of the

section 21. Figure 19 shows the stone tiles 50 placed on the section 21leaving a gap 51 between the

tiles 50. This gap may be filled with sealant 100. Further tiles 50 may be place above or below the tiles

50 shown to complete the facade, a gap 52 retained above and below each tile 50.

Aspects of the facade system, support frame, method of assembly and kit of parts have been described

by way of example only and it should be appreciated that modifications and additions may be made

thereto without departing from the scope of the claims herein.

Claims (29)

WHAT IS CLAIMED IS:

1. A support frame system configured for use in a facade system comprising:

support frame sections, each support frame section comprising an elongated planar

shape, opposing first and second faces and, opposing top and bottom ends; and

the support frame sections configured to be fastened to a substrate about the first face

of each support frame section with the opposing second face of each support frame section

facing outwards from the substrate; and

and adhesive on at least part of the opposing second face of the support frame sections

configured to adhere to stone tiles used to form an exterior facade of the facade system.

2. The support frame system as claimed in claim 1 wherein the support frame sections are

orientated top to bottom so a longitudinal axis of each support frame section runs parallel to

other support frame sections.

3. The support frame system as claimed in claim 1 wherein the support frame sections are spaced

apart equally across the substrate.

4. The support frame system as claimed in claim 1 wherein each support frame section is an

extrusion with a uniform cross-section shape of infinite length, cut to suit the substrate to which

each support frame section is to be fastened to.

5. The support frame system as claimed in claim 1 wherein each support frame section has a cross

section shape comprising a flattened U-shape with flanged sides.

6. The support frame system as claimed in claim 5 wherein a first face of the flanged sides bears on

the substrate and fasteners pass through the flanged sides and into the substrate.

7. The support frame system as claimed in claim 5 wherein the flattened U-shape is configured to

form at least one smaller opening between a central width portion of a support frame section.

8. The support frame system as claimed in claim 7 wherein there are two smaller openings, one on

each side of a centre of the support frame section segregated by a smaller U-shape channel.

9. The support frame system as claimed in claim 5 wherein at a transition in cross-section shape

from the flanged sides to an outward edge of the flattened U-shape, channels are provided on

the first face of each support frame section.

10. The support frame system as claimed in claim 5 wherein a smaller U-shape channel is located

about a central width portion of a cross-section of each support frame section, an opening of the

smaller U-shape channel opening further to the second face of each support frame section.

11. A facade system comprising:

a facade exterior formed from stone tiles; a substrate on which the stone tiles are mounted; and intermediate the substrate and the stone tiles, is a support frame system, wherein the support frame system comprises: support frame sections, each support frame section comprising an elongated planar shape, opposing first and second faces and, opposing top and bottom ends; and the support frame sections configured to be fastened to the substrate about the first face of each support frame section with the opposing second face of each support frame section facing outwards from the substrate; and and adhesive on at least part of the opposing second face of the support frame sections to which stone tiles are adhered to thereby forming the facade system.

12. The facade system as claimed in claim 11 wherein the support frame system is configured to be

obscured once stone tiles are installed on the support frame system.

13. The facade system as claimed in claim 11 wherein a depth between an outer face of the facade

exterior of stone tiles and substrate once the facade system is assembled is less than 30mm.

14. The facade system as claimed in claim 11 wherein the substrate comprises: a building wall,

overhang, ceiling, soffit, roof, reveal, head, sill, door, gate, fence, signage, or other planar face or

frontage.

15. The facade system as claimed in claim 11 wherein the adhesive adheres to only part of the

second face of each support frame section and to only part of the stone tiles.

16. The facade system as claimed in claim 11 wherein the adhesive extends as an elongated strip

along a longitudinal axis of each support frame section from the top end of each support frame

section to the bottom end of each support frame section.

17. The facade system as claimed in claim 11 wherein two strips of adhesive are located on each

support frame section located on either side of a width of each support frame section and each

strip of adhesive adheres to a separate stone tile, multiple stone tiles being used to form the

facade exterior of stone tiles.

18. The facade system as claimed in claim 11 wherein each support frame section comprises at least

two stone tiles adhered to each support frame section with a gap located between the two stone

tiles, the gap aligned along a longitudinal axis of each support frame section and aligned centrally

across a width of the second face of each support frame section.

19. The facade system as claimed in claim 18 wherein the gap runs continuously along a length of

each support frame section and is common to multiple stone tiles adhered to the support frame

sections from the top to the bottom of the support frame sections.

20. The facade system as claimed in claim 11 wherein the facade system further comprises at least one guide strip, the at least one guide strip located about a transition from the top of one support frame section to the bottom of another support frame section.

21. The facade system as claimed in claim 11 wherein the facade system further comprises fixing

tape, the fixing tape configured to provide a rapid bond between the support frame sections and

stone tiles during installation to provide an immediate bond and which holds the stone tiles in

place while the adhesive has time to cure and adhere the stone tiles.

22. The facade system as claimed in claim 21 wherein the fixing tape is a double sided tape with a

first side of the fixing tape adhered to the second face of each support frame section along a

longitudinal axis of each support frame section from the top to the bottom of each support frame

section.

23. The facade system as claimed in claim 21 wherein two fixing tape strips are used, one on either

side of a centre of a width of each support frame section so as to bond to sides of opposing stone

tiles located on either side of the width of each support frame section.

24. The facade system as claimed in claim 21 wherein the fixing tape has a thickness of 0.5 to 5mm.

25. The facade system as claimed in claim 11 wherein a backer rod is located intermediate a centre

of each support frame section and a gap between the stone tiles, the backer rod being a resilient

foam and the resilient foam shaped to bear on an opening defined by the gap and opposing sides

of the support frame section, thereby filling the opening defined between the gap and the

support frame section.

26. The facade system as claimed in claim 25 wherein the gap between stone tiles is filled with

sealant.

27. A method of assembling a facade system on a substrate by:

selecting a facade system as claimed in claim 11; and,

fastening the support frame sections to the substrate about the first face of each support

frame section with the opposing second face of each support frame section facing outwards from

the substrate; and

adhering stone tiles to adhesive on at least part of the opposing second faces of the support

frame sections to thereby form the facade system.

28. A kit of parts configured to manufacture a facade system over a substrate comprising:

a support frame system as claimed in claim 1; and

a set of assembly instructions.

29. The kit of parts as claimed in claim 28 wherein the kit further comprises stone tiles.