CA2173842A1

CA2173842A1 - Improvements in or relating to preformed building materials

Info

Publication number: CA2173842A1
Application number: CA002173842A
Authority: CA
Inventors: Ian Conrad Holyoake
Original assignee: Individual
Current assignee: Individual
Priority date: 1993-10-10
Filing date: 1994-10-10
Publication date: 1995-04-20
Also published as: WO1995010674A1; AU686243B2; EP0726991A1; EP0726991A4; AU7824594A

Abstract

A method of forming a preformed building element by applying a protective coating to a substrate such as hydrocarbon-based foams where the protective coating comprises cement and/or sand, and an acrylic polymer.

Description

wo 9~ 74 - L C-l/i~4/00103 Impro~ements ~ or r~l~tin~ to r cf~l~ed s~ n~ M~teri~s TECE~NICAL FFF 7~,n This inventioIl relates to b~ in~ maten~ls, a~d to methods of impro~
their char~rt~7;$tics by applying a surface co~tin~. F~r co~l~,e~ipn~ e only, the present i7-~ention will be descibed with ~eference to bnil7n~;n~
materials such a9 panels used in c~ i7 F stru~t7~res such EIS wall, and roof panels, and in particul~r p~nel~ made ~om hydrocarbon l~ased fo~m.~ for which the invention may be pa7ticularly aprli~-Rhle. ~owe~er, it is to be ~nderstoot that it i9 not to be limited as such. Moreover, becau~e the invention may have other appli~ati~ ~s it is to be unde,~Lood that the p~ior art and pos~ible embotlim~n~s of t~e i~entio~ as discussed beIow are giveIl hy way of e~ample only.

BAC~G~?.O~ ART

Convel~tionally panels used in bllildings for ~ ;ne ~t~uctures are prot~ct~rl/f~ni~hed and/or reinforced by a surface layer of a Inaterial s~lch as paint, fibreglass polyester or epox~ resL~, pl~Qt~.~, concrete/cement and the like. P~int is the most ¢ommnn1y used material for finis~ine ~d weather proofing wood based matenals, plaster is tlsed on sof~cer gib-board type materials or with latb~ but is not ~e~erally ~uitable for e~terior sur~aces, ~rhile concrete/cement is common1y l~.sed for ~ni~ine extern~l surfaces of cladding materials $uch ~s ~ood, brick or hydrocarbon based foa~ panels. With concrete/cement finishes a ~uitable mater~al ~uch as a mesh may be attac~ed to the s~ ace to improve hQnf~in~ to the surface. Due to the ~eig~t and fragile n~ture of the ce~ent coating this mu~t gener~lly be applied once the panel has been irlstalled in position. The applic~tion ~pe~tion is thus ~ulnerable to 2 ~ 73~2 gS/10674 - PCI~NZ94100103 ~eather coIlditions and there is a requirement for s~ e~ on site labour, especially ~hen special finishes or curved s~rfaces such as at cor~ers or around pillars are required. This adds to the ¢ost and co~ction ~ime.
Furthermore, since the coating is applied afte~ the panel has been att~rhe.l to ~u~olL meInbers, the co~inE relies ~olely o~ ~hesirm tu the substrate and is thus susceptible to debonding.

i'ibre~l~ss polyeste~ or epo2~y resin fi~iqh~s pro~ride a ve~y tough light weight fle~ble fi~i~h and are ~ommonly ~ed vvith wood based matenals.
H-...ev~r due to the cost of the epo~y resi~ this n~etho~ is not generally econl mical for large ~lrface ~eas. Fur1;he~more~ polyester res~ tend to dissol~re l~lroc~r~on ba~ed fo ~m ms~eri~ kin~ them unsl~it~hle for tbis aprliratjon, Certain paints whic~ do not dissolve t~e foam, sucll as pla~ic (acrylic~
Paints maY be aDl~lied to the surface tn nrmn~lP s~ r~ ;n o~ AJ~
improvement in stre~gth and weather resi~tarlce to the foam panel, however the ~nount of protectir~n proYided is generally not ~ffi~ient for building panels. Although additional ~t~e~th may be p~ovided by applying a thick laye~ of paint with ~ rei~forcing mesh such as a f~bregla~s cloth e~he~e~ therein, if applied thickly such paints reqwre a considerable time to harden. Furthe.more, the cost of the pai~t makes the process expen~ive.

There is thu~ a need for a surface fin~sh for builbing materials/panels ~hic~ can be applied off site, ana ~ particular for a ~urface fini~h that is su~tab~e for fini.~hine hydrocarbon based foam panel materials or ~t~F~r,hin~ in~ to foPm mateIials, ~vhi~h is flexible ~d tough and ~hich ca~ ~et in thick applications.

21 7~842 wo ~s110674 Pcr~ 03 Matenals such as mi~ctures of acryllc modif~er P~IMA~ F~-2727 supplied by Rohm & Haas Ltd mi2ced with a Portland cement are known for their a~;lity to set in thick applicatio~s even u~der wate~, and are used for app~ tion~ such ~s repairing and S~-AlinE~ around foundations which may e~en be under water. These mixtures depend for thelr set~ng ability on the complementa~ setting characteristics of cement ~d acrylic, the ceme~t ta3~ing up moisture to set and the ac2ylic gi~ up moisture. They are therefore not depende~t on the atmospheric moisture/d~in~ for setting and can thus be applied thickly Since they have a high percent~ge of cement and/or ~and they provide a rela~ively low cost repair medium, and are tough and weatherproof. These mater~ls huw~v~;:r have not h~r~vrore beeIl used or co~ci~red for l~rge scale aprlir~inn as a surface tr~ t for b~ nF mateIials, o~ ~or use as adhesi~es ~vith foam ~atenals.

It is an object of the present invention to provide a m.ethod of treating a surface of a bl~ in~ material using a material such as all acrylic modifier/f;ller mi~ such as that described abovel 90 as to address ~e above problems or at least to provide the public with a usefill ~ni~e Ftlrther aspects and advantage~ of the present inve~tio~ will beco~e apparent f rom ~e ensuin~ description ~hich ~s given ~y way o~ example ol~ly.

I~SCLOSUR~: OF' THE Il~ION

In t~le broadest sen~e the present inventio~ provides protective coating for application to material comprismg cemen~, and/or sand ~r ~nother fi}ler ~nd ~n ac~rlic p~ly~e~

2 1 73~2 ~vo gS/10674 ~ 03 - ~he invention provides a met~od of forming a preformed buiIdi~g element characterised by applyin~ a protecti~e co~ting to a s~bst~te comprising cement and/or sa~d or another filler and an acrylic polymer in layers and progres~ively building up t~e co~tin~ until the desired co~tine th~cknes~ has beeIl re~ e~.

The substr~te can be a ~dro-carboll based foam.

The protectr~e cos~;n~ ca~ be provided with a rei~forcin~ materi~l.

The rc~ fOs ~ g material ~ be a flexible lat~.

The acrylic pol~mer can in~lude polymethyl acrylate.

The aclylic polymer can be a polyIner co~sis~ng of Cl-18 ~1 ac~ylates.

The acrylic polymer can be a polymer consi8ting of Cl-18 alkyl me~hac~lates.

The acrylic polymer can be of the structure;

Rz ~C - C~
,C-- -~ 1 R1 can consist of one or more of hydrogen, methyl, ethyl, butyl or other suitable aliphatic hydrogen chains.

R2 can consist of hydrogen ~nd~or methyl.

:Rl c~n be mainly compnsed of Inethyl ~roups wit~ ~2 being hydro~en.

~ ~ 73342 wo gS/10~74 ~ ~4/00103 The substrate can be pro~nded wit~ a longitudinal c~vity to facilitate bPn~;ne of the ~l~m~nt The ca~ty ca~ be V-shaped.

The ca~ity can be dish shaped.

The method can include the step of appl~g a protective co~ E on o~e surfiace alld a layer of building paper on the ~osi~ surface.

The filler material may iuclude glElS9 beadg, cel~amic bubble8, chalk, quartz, pe~lite marble, silica F~n~-~, ~atural stone or synt~tic filling ageIlt~.

The reinforcing mate~al may be poly~4~01ene, glas~, ~ylon~ meta c~l~o~, Olelin, or ~ m~ltari5~1~; Of ~ 1 or specific fo~ms.

With a matenal sllch as the material descnbed above, si~ce the materi~lis relatively i~eYrensive compared to epo~y resin~, it caII pronae a low cost alt~ ;ve tre~t~n~nt for b~ inE~ p~nels and the like. Furthe~nore, since it is relatively light iD weight, i~ fle~ihlP~ and does not di~olve foam t~ype materials, it can be ~ed for co~t;n.~ foam pa~el~ o~f site. The panels can then be fitted to ~ b~ inE structure without the need for fi~t~e~
sllrface treatment once in~talled. The iIl~tallatioll opera~on is thus not vulnerable to we~er condi~ons, a~d there is not the r~lu~re~ent for ~killed on site lab~ur. Also since ~ hment ~embers ~ h as n~ls p~ss through the pa~els there is not the t~n~Pn~y for debo~ E ofthe surfa~e coating. F~ermore, the p~n~l~ can ~e cut and shaped of~ site as ~equired. Dlle to the f~e~ble nature of the co~tin~ (which can be determined by mi~lre ratios) the panels c~n also be bent OIl inst~l~AtjQn aIld if ~rp corner~ are required, the rear of the paneI ~ay be relief cut WO gS/10674 PCI/NZg4/00103 to enable a sharp bend to be made such as for a corner portion. The foam ~oated mate~ial ~ay also be formed in a vanety of shapes for dirrt~ -t buildin~ applications. For example coated half cylindric~l shapes may be made for fitting oYer posts to provide a pilla~, or corner piece~ may be ~nade for fitt~ng between panels at corners.

Imitation f;nishes such as of brick, wood, weather board, rou~h cast concrete and the l;kP, may be fo~ed o~l the su~face of panel~ of a variet3r of ma~ials by appl~ring the matrix mate~al to a flat or pre-~h~pe-l surface, and theIl working the ~at~c matenal as required prior to set~ng.

Reinforcil~.g ~imil5~r to t~le f~ont ~o?~t1n~ or of other materials 811Ch as b~ ing paper ~ay also be adhered to the re~r su~face of the fo~
p~3n~lR. This would negate the require:~ent for on xite ins~llA~ion of ~uilding paper. The panels could al~o be used as an alternati~e to gi~
board lini~g ~nd could have ~he fiIlal p~t/w~llp~per applied in the facto~. Wil;h s~ hle reinforci~g, rooftiles ~r,d tbe like inco,~olating a fo~ type subtr~te may be pos~ible Panel$ could also be ~ade with a~ e~in r f;nish on one ~ide and interior finish on the ot~er side and f;tted to a b~ in~ stru~ure, for e~ample wi~h a simple "I" type connector bet~reen the panels to provide a joint, thus Pn~h~ c~ ine of a buildin~ to be done in a short time.

Panels suitable for complete sectioIl~ such ~s wall or fence panels may also be po~.~ihle. For example a thick fo~nl panel may be made with cavities to take roof support~ or fence supports, or to form moulds for pouring concrete :iu~Gl~ pillars That may provide for roof support.
This m~y be prepared and coated with t~e mat~ m~terial off site, ~nd WO95/106?4 1 ~/r~94100103 t~en ql~ickly ~ bled at the site, ~vithout the need for skilled on site la~our. Alte~nal;ively or in addition wit~ ~all panels, these may ~e made with extra reinforcement band~ laid into the matnx over the panel$ to give the reqwred strength for roof support. Suitable mate~ial clad with the matrix cl~tltljn~ ~ay also be formed ~nth ca~nties for enc~sin~ objects such as e~isting structural members (i.e. pillars), or fo~ settin~ in positio~ and then p~u~ng a mate~al such as concrete into the cav~ty to fo~n a st-ructural member.

FurtheL ."ore, a method of construction may be applied to the co~struction of comrlete s~;ructures made up using a subslr~Le m~t~.ri~l such as poly~ es,e ~rhich is then completely or p~rtially e~c~e l with the mat~x . Due to the ~ ti~r praperties and ease of forming of the ~ubst~ate, and the ~reller~t water resistaDt ~ ulJe~ lie~ of tl~e co~ is method of construction may be sllit~hle for tl~e m~n~7~ct~7re of articles suc~ ~g letter bo~es, p~llars, he~mS~ posts, aIld cnnt~iners.

Since the m~t~Y mZIt4~ 3 flesible and totlgh and adheres stron~ly to foam materi~ls, it may also be suitable as an alternative to metal cl~-l;nf~ used part~cularly for cool xtore panéls. The matrix material could be easily repaired if d~m~ged, a:nd moi~ture content of the fo~
substrate ~ould be easily ~hPl~k~ by simply inserting a probe through l;he ¢o~t.in~ rn~teria~ and subsequently repainn~ ~ith a ~uitable material.

The strong a~hesive properties of the matri~ material ~lso make it suitable as an adhesi~e for at~hing foam p~nPl~ to objects such as a supportin$ ~tructure. Panel~ could thus be boIlded in position rather than u~ing pins and the like thereby avoiding the need to punctllre the foaIn material and leave it vulnerable to moisture absorption and cont~min~ti~n.

~ 1 73842 WOgSJ10674 ~ l~.n~ 00l03 The tough fle2nble ~ture of the co~tin~ may al~o make it suitable for coating floor and ~leckinE mat~ri~ and for co~inE~ mate~ls for use in fenci;qg and as fence pnn~.l.c.

T~e e~cellent water proofing prope~ties of t~e ~at~i~; may make it lJrefe,~ble as a co~1;ne ~or extenor ~urfaces, comp~red to convelltional plaster co~tin~-C aIld the lil~e.

varie~r of l~pes of the abo~e described matr~ material may be used ~epe~ inE on ,~ ulent~ pro~ided they enable a tough fle~nble co~
of relati~ely low cost suitable for aprl;~tin~ to buildi~g material~, For e~a~nple the proportions and types of mat~ri~l.c u8ed in ~e flexible modifier P~IMAL~ F~-2727 ~nay be varied a~ requir~d or desired, and add~tives such as fire retarda~ts may be ~ e~l, or other filler~ u~ed.

In co~t~ne 1~e s~rface of the bnil~ matenal, ~ ional co~til~s of differe~t mate~ e may also be applied as req~ired or des~red. For example the ~urface may fi~st be coated ~;vith a thin p~ coat of a ~uitable material pnor to npplying t~e IT~a~ materi~l. Alternatively or in addition, further coats of other material may be applied oYer or ~etween layers of the m~trt~ material. ~or exa~ple ~aterial such as treated wood chip8, or spherical light weight ceramic or po~y~ly,el.e bubbles may be u~ed ss a filler to liFht~n the c~a1in~ material, or may be sprinkled o~ the surface between co~t~ne~ to provide ~lr~ onal bulk. The matnx materi~l may be applied by any suit~ble mean~ 3~or eY~mple it may be spre~d by hand, b~ush, or rolled ~ith a roller, sprayed ~Il, or applied by dipping the pa~el in the matrix m~teriAl 2'J~ ~3~4~
WO gS~10674 PC~ 94100103 ~ny suitable t~pe of. reinforcing m_te~ial may be applied to the surfa~e pro~rided this is able to bond with the material aIld has sufficient strength. For example a glass f;bre ~ater~al ~ay be most s1litable bo~ever other ~i~rous materials such as KE~ o~ carbon fibres or polyester fibres may be used. I'he rei~for :~ng nlnte~ iAl may be applied i~
any suitable fo~m such as a mat (unidirer~ h~l open weave ~esh) or as chopped ~trand. Chopped stra~d may provide a ~reater impact resistance for c~ applir~t;o~ due ~Q the abili~ of the fibre~ to align wit~ t~e lo~in~ direclion in the fle~hle mat;ri~ m~t~ In the case of ~hopped strand applicatio~, the rei~orcirlg material may be applied together with the matlix material. Worl~ing of the I~ei~ur~ ~to the matrix may be b~ any suitable method such as presS~lg, rolLi~g, br~ in~, surface pre~ure or vibration, or by the addition of farther mal~c ms~tc~ ion or ~acuum ~.oce~e~

Additio~al matri~ matenal may be applied o~er the ~r~t co~t. This material may be the same as that of the first coat or may be di~e ~.L.

V~ious ~pes of b~ mate~ial may ~e suitable for tre~ nt by the ~bove method. For example, pol~ e in~ nn in ~heet fo~n or profiled, light weight concrete panels, timber T'~Plq. asbestos, ce~ent fibre boards, co~posites of the above in~ludillg ~,ome ins~ tin~ or fire reta~ding m.aterial~.

In treating th~ rface of the b~ inE material, a fi~ft coat of either epo~y, polyurethane, or ac~lic, ~ixed ~nth a h~rdener may be applied.
In a ~er~ d embodiment an all ac~ylic rno~ifi~ of the type PRTl~
FP~2727 ~s supplied by ~ohm ~ Haas Ltd may be suitable. A possible mi~tllre ratio for this may be 100 part~ of P~IlUAr~ FM2727 modifier 2~ 73842 V~'O !~5/10674 - PCTJNZ94~00103 and 100 parts of Portla~d ~ement confo~ming to AST~ C-150. If required tr~ aid in pro~uction, additional ceme~t m~y be added along with other ing~edients such as #70 grade mesh sand, strengthening ~lbres, thickener, defoamer, coalescing agerlt, ~urfactants and dispersants, plasticisers, water, colora~ts, mica a~d white c~nPrlt as required or desired.

In t~e case of an alkali resistant glass mat ~el~ulce~ent for the abave mo~ified cement m~, this may vary in weight and densi~. For PY~m~lP
llS~m/m2 gives a moderately light weight l~fo~ me~t, ~vhilst 2 layer~
of 115~m/m2 or a layer of 2~0g~2 or even two layer~ of 2~0gm/m2 gives much stronger reinforce~ent. Fo~ general fn~n wall aprli alkali re~istant libre glass mat of 130~/m2 m~ be most suitable.

If a ~ec~-n~ coat m~triY is applied ~i-~ can be either a ,51'mil~r 2~1iX to the first coat mat~ ~lesr--ihed abo~e or can be made di~- e~tly to provide di~erent ~urface characteristics. For PY~rrlrle, the ~ec~rl~l m ~t~iY may comp~se 10~ parts of PR~MAT~) EM2727 fle~ble moAifip-r to 200 parts of Portland cempnt confonning to ASI~I C-150. If desi~ed this could also have co~bin~tion~ of the same additional ingredie~ts as the first coat matrix rle~r~h~d ~bove.

Additional layers of the above matrix m~xes a~d re;~orcing may be applied in association with a reinforcing ~aterial such as alkali resistant glass of wo~ren mesh open constrll~tion fo~ (u~idirectio~al alkall resista~t reinforcin~ mesh of open weave) having ~rying weights from lOOgm/m2 to 600~ or mo~e dependin~ ~ reinforc~~ent reql~irements.

2 i 738~2 ~10674 ~ T~z94Jo0103 Surface finishes may be carried out in the factor~r or on ~ite. I~picalfinishes m~y include, te~ctures, drag tgpe scratcbing fir~ishes, trowel smooth ~ni.~h~s, fo,~ed or profiled fini-c~e~ to obtai~ either ve~y smooth or predetermi~led f;ni~hinE shapes and pattern~, coloured ~lnishes, painted f~l~ishes, spoIlged or speci~l effect ~niS~eS. An e~ca~ple of a spe~ial ef~ect f~ish may be achieved wil~h a mi~et~e of lO0 p~rts of saI-d type ~50 ~nesh, 30 parts of Portland cement to ASIM C-1500, lO parts of p~TMAT~ F~2727 mo~i~er, and water as required. To this could be added a range of, or all of, t~e c~n ~inntions of additional i~gre~ient~ ~s included in the m~trix coat ~i~re~ desc~ibed abo~e.

Vanou~ mefllo~c may be u6ed for j~n~n~e~ the panel~ o~ site once installed, a~d for treatirlg the edges of t~e r~ To ensure again~t a~y seepage into ~he panels up through the bottom ed~e6 additioslal b~clc ~rap~i~g of ~he panel~ may be carned otlt by ~ing a layer of the matn~
material with reinfor~ a~ req~ired.

The edges of the panels to be joined may be simply butt joirlted toge~her, or jo~ed using edge 6trip~ with or ~ithout a h~ckinF rod and 9A~I~, and a reinfo~cin~ fabric such a~ rips of alkr li ~istaIlt glags mat may be cut to an ~}~pr~ iate width ~nd ~t~rhed ~oss the jo~t wi1 h a cos~tinf~ of the ~bove matr~x mat~rsl, or some other ~he-~jve or pla~ter. Alte~atively the edges ~nay be ton~ue and groo~ed, slotted, ~hip-l~pped, or straight or bevelled or tapered to take a jointinE strip suc~ as a plastic or aluInini~m 'rI" or "T" jointin~ st~ip. Joints may also be covered with h~ten~ such as w~th Tudor ~rpe b~ in~2.

wo9S~10674 2 1 7 :~ 8 4 2 ~ iY4/OOI113 ~RIE~ nESCRIPlIO~ OF l~IE n~AWINGS

Fu~ther aspects of the present invention will beco~e apFarent from the ensuing descript~on ~hich is given by way of example only and with reference to the drawings accompanying the provisional speci~ç-ation in which:

Fi~nre 1: i~ a schematic plan ~iew of foam panel illu~trating a b~ ine material accordi~g to the p~esent inveIltion and its Tnet~o~ of tr~Pn~ ~nd re 2: ic a ~chematlc plan view of corner piece for a ~wlding illustrating another building matenal according to the prese~t i~ ;nn, and F`~ure 3: is a perspecti~e view of ~refor~ed coTner b~ elements of the prese~ in~Pn~ d F'igure 4: i~ a sectional vie~ of a corner construction ill accorda~ce with the present invenh'on, and Fig~-re 5: i~ a side perspective view of a t~pical wall con~t~uction usinlz lhe building elements of the pre~ent iTlv~ntio2~ and Fi~ure ~: is ~n end vie~v of a eyebrow b~ ing Pl~smer~t of the present invention, and Figllre 6a: illustrates a fixing detail in~ si~re of the eyebrow el~m~nt of Fi~re 6, ~nd F;~re 7: illustrates a number of alternative shapes for buildi~g elemPnt~ of the present invention.

WO g5/1067~1 PC:l'Jl`lZ94/00103 BEST ~IOD~, FO~ CA~YING OUT THE ~*T~ON

Ha.ving regard to ~igure 1, there LS shown a schematic section~l vie~ of a p~nel generally indicated by arrow 1 comprising a polystyrene foam substrate 2 coated with fibre glass rei~forced coa~nE gener~ indicate~l by arrow 3. The co~t~ne 3 co~ ts of a first layer 4 of a rn~fAl ~1 a layer of alkali resistant ~ s fibre mat 5, a ~ecoll~ layer 6 of a m~t~i~ material, a spIinkl~n~ of ~a~d a~d nptionally a ~;ni-~hin~ coat of pai~t 7. The fil'fit layer 4 matrix material ifi made u~ing a ~L~u~ of a~ tely 100 part~ by weight of ac~ c flP~7hle modifier p~lMAT~ F~ 727 2~d 180 parts by weight of cement. The second layer 6 m~tris m~t~ri~l is of cirnil~r compo~ition to that of the Srst layer 4 m~ material with ~ddit~nal sand. A re~ surface 8 of the sub~trate ~ iB cGve~ad with a layer of building paper 9 which is adhered to the substrate 2 with a co~t. nE of t~e mat~x material of ~imil:~r co~posstion to that of the layer 4. l~he panel 1 i~ ~tt~heA to a suppo~ting structure 10 by mea~6 of nails 11. The head~ of the nails are covered over with a material ~;mi7~r to that of t~e r.~ iY ~te~al of the ~e~on.l layer 6, 'rhe panel 1 showIl in th~ embodime~ is pro~ded with the fibre glass reinforced co~in~ 3 off site. Since the reinforced coating 3 is li~ht in weight a~d flexible, the pallel 1 can thell be easily tran~ e~ to the site and fitted into position on the supporting ~t~ucture 10, ~vithout t~e possihility of ~m~Ee to the su~face ~s ~vould be the case with a cement coated foam panels.

In t~eatin~ the surface of the foam substrate 2, the m~ r mater~l 4 is fi~t applied by ~olling, ~pray~ng or ot~erwise a mi~re of the ~atrix onto the substrate ~. ~he fibre glass mat S is 'chen laid over the layer of matrix 4 and pressed in with rollers ~o that t~e matrilc ~aterial ~3 ~i 7S84~
Wo ssrlo~74 PcrA~4~ 0~

permeates bett1veen the fibres of the mat 5. A co~ting of a se~Qn~ mat~c material 6 is then applied by sprayin~ and s~n~ ~ith #70 ~rade sand, and the panel ~Ilowed to d~ and ~ubseque~tly painted as reqllired.
D~ing may be by air d~ying but other methods 8Ut:~ as -Qnap he~ Rith i~a-red radiatio~ dehu~idif~i~g or ove~ cur~ng may be ~sed. A
~ini.chir~ coat of paint i~ then ~prayed on the pa~el rea~y for tral~Qport to the site for inFt~ tion After n:3ilin~ the panel in pOQit~on on ~ite t~e nail head~ are covt;~ed over with a thin layer of a c;mils~r ~ iY ms~t~

F~gure 2 _how~ another em~o~lima~lt of the ~r;Bent invention in ~e form of a corner fitting 20 for a building. ~n this figure com~o~pn~ ~imil~r to tho~e of the first embo~l;m~r~t ~re in~;c~t-~l witl~ t~e s~me numeral a~d descriptio~ omitted. The cor~er ~tting 20 i~ u~ed at co~ers of , ~.d differs fiom the panel of l~ re 1 i~ that a notch has been cut in the rear of the panêl afl;er ~ ¢ture so that the panel ¢an be bent tllough gO. Due to the flp~ible nature of t~e fibre glass reinforced ¢~ti~ 3, tbis does not crack on ben~ hlinE c,~ .~t:d corIIer sections to be fo~med by simply not~i~g ~he foam and be~rlinE, ei~her on site or a~
p~e-formed f~ctory corIler piece~.

Wit~ respect to E'igures 3 and 4, the co~er el~m~t illu~trated is provided with a lon~itt~d;tl~l V~h~rl cut~out 13 in the subst~ate m~tGrl~l 2 which en~ble~ sections of the elPmP~t to be folded at r~ght ~ngles and f;xed to corner st~ucture ~lPmpnt~ 14 as indicated. The cut-out 13 can be dish-~haped ~hich is mo~e swtable for~~ to cu~ved st~uctures.

E`igure 5 of the dr~wings illustrates ti~Lurd of the co~ner el~merltc Of Fig~re 3 to a corner st~ructure ~as show~ in Figure 4) alld adjoining pa~el .elemP~ts 1 fi~ed ~o wall structure members ~ 5.

~ ~ 73842 WO 95/10674 PCr~NZ94100103 Fi4~ures 6 and 6a show ~n eyebrow element 1~ ~d its method of ~ture to a ~ame s~cture 17.

Figure 7 shows alternative ~ros~-section of the building elements i~ the farm of "mouldings", for trimming and fin;~h;n~ g the elements of the present inventinn Al~ of the elementq descnbed can be r~ile~, qtapled and/or glued in place.

I believe the advantages of my l~ention to be ag follo~, howe~er it ~hould be appreci~ that all such advantages may not be xp~ on all e~bod;.ne~s af the i~v~t;on~ and the foll~ li~t is th~ u-~ given by way of e2cample oIlly ~ being ~ ive of pot~n~l advant~ge~ of t;lle pre~ent in~entiotn E'urthermore, it is not int~nde~l that tbe ad~ tage~ of the present i~ventio~ be restnc~ed tu tbose of the list which follow~.

l 'rhe matr~x ~ate~ial treatment ~n~hle~ paIlel~ such a~ ~oam ~ype panels for b~ es to be made llp of~ite and then ~talled withaut ~he need for further f;~i~hin~ or ~th 0~ m~n;n~l fini~hin~
Panels can thel~fGlé be made in a continuous productioll pr~ces$
with reduced ~1vastage. Problems relfl~;ne to delays due to ~eather coT~;t;srl~ ~nd the like are thus ~voided, ~ le~ o~ site labour is not required, and rapid co~struction is p~fi~ible ~n~hlin~ reductio~ in construction co~ts.
2. ~i~her quality can al~o be en~ured ~rou~h facto~y quality control.
For example accuratel~.¢ur~ed surfaces and flat surface~ can be easily produced. Also confo~rLity of production conditions can be ensured ~o the products can be manll~Pçt~.red under optimum condit1ons, with mate~ials mee~ing requ~ed ~ t~nrl~rdEi.

2 ~ 7 :S8~2 W0 !~5/10674 ~ r~4/00lw 3. Wastage of ~atenals c~ be avoided since :mate~ials can be ~ade to the required size and shape in the facto~y 80 that minirn:~l cllttine ~nd ~ormin~ is required on site.

4. Lo~v cost light ~ei~ht poly~ly~el~e foam panels can be used in a wide r~nge of applica~ions since the matrix ~aterial does not te~d to dissolve pol~xLyrene foams.

A~pects of the y~ese~t i~vention have been ~PC~ihe~ by way of e~ample only and it should be appre~ t~ ~at mo~i~c~1~olle and ~ m~ly be made thereto without de~ L~ ~OI~l the scope t~ereof as ~efinP~ in the ~ppex~ded cl~ms.

Claims

CLAIMS:

1. A method of forming a preformed building element characterised by:
applying a protective coating to a substrate comprising cement and an acrylic polymer in layers and progressively building up the coating until the desired coating thickness has been reached.

2. The method of claim 1 wherein the substrate is a hydro-carbon based foam.

3. The method of claim 1 or claim 2 wherein the protective coating is provided with a reinforcing material.

4. The method of claim 1 wherein the reinforcing material is a flexible lath.

5. The method of claim 1 or claim 4 wherein the acrylic polymer includes polymethyl acrylate.

6. The method as claimed in claims 1 to 5 wherein the acrylic polymer is a polymer consisting of C1-18 alkyl acrylates.

7. The method of claims 1 to 6 wherein the acrylic polymer is a polymer consisting of C1-18 alkyl methacrylates.

8. The method of claims 1 to 7 wherein the acrylic polymer is of the structure;

9. The method of claim 8 wherein R1 consists of one or more of hydrogen, methyl, ethyl, butyl or other suitable aliphatic hydrogen chains.

10. The method of claims 7 or 8 wherein R2 consists of hydrogen and/or methyl.

11. The method claimed in any one of claims 8 to 10 wherein R1 is mainly comprised of methyl groups with R2 being hydrogen.

12. The method claimed in any one of claims 1 to 11 wherein the substrate is provided with a longitudinal cavity to facilitate bending of the element.

13. The method claimed in claim 12 wherein the cavity is V-shaped.

14. The method of claim 13 wherein the cavity is dish shaped.

15. The method of claimed in any one of claims 1 to 14 including a protective coating on one surface and a layer of building paper on the opposite surface.

16. A preformed building element comprising a substrate and a protective coating on the surface thereof, said protective coating including major portions of cement and an acrylic polymer.

17. A preformed element as claimed in claim 16 wherein the substrate is a hydro-carbon based foam.

18. A preformed element as claimed in claim 16 or claim 17 wherein the protective coating is provided with a reinforcing material.

19. A preformed element as claimed in claim 16 wherein the reinforcing material is a flexible lath.

20. A preformed element as claimed in claim 16 to 19 wherein the acrylic polymer includes polymethyl acrylate.

21. A preformed element as claimed in claims 16 to 20 wherein the acrylic polymer is a polymer consisting of C1-18 alkyl acrylates.

22. A preformed element as claimed in claims 16 to 21 wherein the acrylic polymer is a polymer consisting of C1-18 alkyl methacrylates.

23. A preformed element as claimed in claims 16 to 22 wherein the acrylic polymer is of the structure;

24. A preformed element as claimed in claim 23 wherein R1 consists of one or more of hydrogen, methyl, ethyl, butyl, or other suitable aliphatic hydrogen chains.

25. A preformed element as claimed in claims 22 or 23 wherein R2 consists of hydrogen and/or methyl.

26. A preformed element as claimed in any one of claims 23 to 25 wherein R1 is mainly comprised of methyl groups with R2 being hydrogen.

27. A preformed element as claimed in any one of claims 16 to 26 wherein the substrate is provided with a longitudinal cavity to facilitate bending of the element.

28. A preformed element as claimed in claim 27 wherein the cavity is V-shaped.

29. A preformed element as claimed in claim 28 wherein the cavity is dish shaped.

30. A preformed element as claimed in any one of claims 16 to 29 including a protective coating on one surface and a layer of building paper on the opposite surface.

31. A method of forming a preformed building element characterised by:
applying a protective coating to a substrate comprising sand and/or a filler material and an acrylic polymer in layers and progressively building up the coating until the desired coating thickness has been reached.

32. The method of claim 31 wherein the substrate is a hydro-carbon based foam.

33. The method of claim 31 or claim 32 wherein the protective coating is provided with a reinforcing material.

34. The method of claim 31 wherein the reinforcing material is a flexible lath.

35. The method of claim 31 or claim 34 wherein the acrylic polymer includes polymethyl acrylate.

36. The method as claimed in claims 31 to 35 wherein the acrylic polymer is a polymer consisting of C1-18 alkyl acrylates.

37. The method of claims 31 to 36 wherein the acrylic polymer is a polymer consisting of C1-18 alkyl methacrylates.

38. The method of claims 31 to 37 wherein the acrylic polymer is of the O-structure;

39. The method of claim 38 wherein R1 consists of one or more of hydrogen, methyl, ethyl, butyl or other suitable aliphatic hydrogen chains.

40. The method of claims 37 or 38 wherein R2 consists of hydrogen and/or methyl.

41. The method claimed in any one of claims 38 to 40 wherein R1 is mainly comprised of methyl groups with R2 being hydrogen.

42. The method claimed in any one of claims 31 to 41 wherein the substrate is provided with a longitudinal cavity to facilitate bending of the element.

43. The method claimed in claim 42 wherein the cavity is V-shaped.

44. The method of claim 43 wherein the cavity is dish shaped.

45. The method of claimed in any one of claims 31 to 44 including a protective coating on one surface and a layer of building paper on the opposite surface.

46. A preformed building element comprising a substrate and a protective coating on the surface thereof, said protective coating including major portions of sand and/or a filler material and an acrylic polymer.

47. A preformed element as claimed in claim 46 wherein the substrate is a hydro-carbon based foam.

48. A preformed element as claimed in claim 46 or claim 47 wherein the protective coating is provided with a reinforcing material.

49. A preformed element as claimed in claim 46 wherein the reinforcing material is a flexible lath.

50. A preformed element as claimed in claim 46 to 49 wherein the acrylic polymer includes polymethyl acrylate.

51. A preformed element as claimed in claims 46 to 50 wherein the acrylic polymer is a polymer consisting of C1-18 alkyl acrylates.

52. A preformed element as claimed in claims 46 to 51 wherein the acrylic polymer is a polymer consisting of C1-18 alkyl methacrylates.

53. A preformed element as claimed in claims 46 to 52 wherein the acrylic polymer is of the structure;

54. A preformed element as claimed in claim 58 wherein R1 consists of one or more of hydrogen, methyl, ethyl, butyl or other suitable aliphatic hydrogen chains.

55. A preformed element as claimed in claims 52 or 53 wherein R2 consists of hydrogen and/or methyl.

56. A preformed element as claimed in any one of claims 53 to 55 wherein R1 is mainly comprising of methyl groups with R2 being hydrogen.

57. A preformed element as claimed in any one of claims 46 to 56 wherein the substrate is provided with a longitudinal cavity to facilitate bending of the element.

58. A preformed element as claimed in claim 57 wherein the cavity is V-shaped.

59. A preformed element as claimed in claim 58 wherein the cavity is dish shaped.

60. A preformed element as claimed in any one of claims 46 to 59 including a protective coating on one surface and a layer of building paper on the opposite surface.