EP2494118B1 - Revêtement isolant - Google Patents

Revêtement isolant Download PDF

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Publication number
EP2494118B1
EP2494118B1 EP10812890.1A EP10812890A EP2494118B1 EP 2494118 B1 EP2494118 B1 EP 2494118B1 EP 10812890 A EP10812890 A EP 10812890A EP 2494118 B1 EP2494118 B1 EP 2494118B1
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EP
European Patent Office
Prior art keywords
battens
cladding
wall structure
support
insulation
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EP10812890.1A
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German (de)
English (en)
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EP2494118A2 (fr
Inventor
James Gleeson
Roger Pecnik
Steve Twin
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James Hardie Technology Ltd
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James Hardie Technology Ltd
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Priority claimed from AU2009905307A external-priority patent/AU2009905307A0/en
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    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
    • E04B1/762—Exterior insulation of exterior walls
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
    • E04B1/762—Exterior insulation of exterior walls
    • E04B1/765—Bottom edge finishing profile
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E04F13/0864—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements composed of superposed elements which overlap each other and of which the flat outer surface includes an acute angle with the surface to cover

Definitions

  • the present invention relates to improved undercladding insulation and cladding support systems and to wall structures using the same.
  • the inventions have been developed primarily for application in the external insulation of new building structures and for post construction modifications to improve the thermal efficiency of existing wall structures. However, it will be appreciated that the inventions may also be adapted for other uses such as internal walling structures.
  • the structural component of a new external wall is provided either by framing elements to which a structural sheathing component is usually secured for bracing, or some form of masonry wall.
  • One commonly used method for then applying external insulation is to first secure a series of vertical spaced battens to the block work or sheathing and then position batts of insulation material between the battens. Some form of building paper or other waterproof and optionally reflective membrane is then secured over the battens and insulation material. Finally, a further series of battens are then secured on top of the underlying battens and building paper in order to provide mounting and support for the external cladding.
  • Another method commonly used in Europe involves securing complex metal rail and brackets systems to the exterior of masonry walls. Insulation of various forms is applied to the exterior walls between and/or around the rails and brackets and cladding is then subsequently attached to the metal bracket system. This method is also costly and time consuming to install and the metal components result in significant thermal bridging which reduces the overall insulating efficiency of the finished system.
  • an externally insulated clad wall structure comprising:
  • the panel may include:
  • the panel is configured to be generally impervious to the through passage of liquid water applied from the direction of the front surface.
  • a separate liquid water and/or water vapour barrier may be applied to the front surface and/or the rear surface of the panel during installation.
  • the battens extend outwardly from the front surface to provide drainage passages therebetween.
  • the fastener retaining battens have sufficient fastener holding strength to support an external cladding without the need to provide through fixtures to an underlying structural wall element when securing the cladding.
  • the backing sheet is made from an expanded polystyrene foam which is preferably made to be inherently impervious to water.
  • the panel may be made impervious to water, at least in part, by inclusion of a water barrier film adhered to the front of the sheet to form the front surface.
  • the barrier is in the form of a layer of aluminium foil or foil faced sheeting, which also serves to simultaneously improve the insulating characteristics of the backing sheet and thereby the thermal rating of the panel.
  • the front surface of the water barrier membrane is preferably hydrophobic.
  • the water-resistant front surface has selective permeability characteristics, in the sense of being at least partially permeable by air and water vapour (i.e. "breathable"), while being substantially impermeable by water in liquid form.
  • the water-resistant front surface is both breathable and substantially hydrophobic.
  • the front surface complies with the locally applicable building code or standard that applies to building wrap specifications such as AS/NZS 4200.1:1994, ASTM E1677, BS3177, BS4016 and any other similar or related codes or standards.
  • the backing sheet may be made of a lightweight cementitious material, optionally treated, covered or coated to achieve the desired water resistance characteristics.
  • the fastener retaining battens are made of a durable nailable material capable of independently holding fasteners that are securing an external cladding material.
  • the battens are made from a lightweight nailable fibre cement.
  • the fibre cement batten composition includes density modifiers such as: inorganic hollow or foamed microparticles (see for example WO 01/68547 ); calcium silicate hydrate; entrained air and other suitable density reducing additives, or any combination thereof. Other details of suitable formulation components are set out in the description of preferred embodiments.
  • the battens are made of a durable nailable polymeric material.
  • other materials may also be suitable provided they have sufficient structural rigidity, fastener holding strength and durability characteristics.
  • the panel is configured to have sufficient strength characteristics to also act as a sheathing board in new wall construction. This may be achieved via properties inherent in the backing sheet insulation material, or via some form of reinforcing which may be provided by a layer of another material secured to the insulation material.
  • the panel may include:
  • the panel is configured to be impervious to liquid water applied from the direction of the front surface.
  • the unitary insulation panels may also include a layer of rigid reinforcing material such that the panel can also function as a structural sheathing panel.
  • the reinforcing layer can take any suitable form such as, but not limited to, a layer of structural timber or fibre cement material optionally adhered or otherwise fixed to the rear of the panel.
  • the front portion of the panel is configured to provide one or more primary water drainage regions in the front surface that extends in between raised fastener retaining regions. Secondary drainage and/or ventilation regions or channels may also be provided in the fastener retaining regions to link adjacent primary drainage regions.
  • the generally planar rear portion of the panel is made from a lightweight foamed polymeric material and the second portion is made from a similar material having a denser structure configured to have fastener retaining properties.
  • the panel is preferably impervious to water passage through the panel by virtue of the material properties of one or both regions.
  • the denser fastener retaining structure can extend the full area of the panel or just in selected regions that may extend within the panel body and/or extend outwardly therefrom.
  • Potentially suitable polymeric materials include, but are not limited to, polystyrene (Owens Corning, Dow Chemicals), polyurethane or polyisocyanurate (Johns Manville).
  • the panel is made from a light weight foamed cementitious material with at least the second front portion having a structure capable of retaining fasteners of predetermined parallel spacings for securing cladding thereto.
  • all forms of the panel are configured such that the fastener securing regions are readily visually identified from the front surface.
  • the method includes the steps of:
  • each support member includes a fixing flange for securing to the structural wall element and a support flange that is of sufficient depth to support the panel and integrally connected battens or integrally formed fastener retaining regions so as to prevent the battens or fastener retaining regions sagging under load from the cladding secured thereto.
  • the support member is in the form of one or more lengths of structural metal sections such as aluminium angle.
  • other forms and/or materials may be used such as custom bent zinc-alum sheet metal sections.
  • the support member may comprise a plurality of discrete brackets or a combination of brackets and lengths of metal section. If long lengths of metal section are used, means should also be provided to allow drainage of moisture from behind the cladding. This could be done, for example, by leaving gaps between adjacent lengths of metal section, or using lengths provided with drainage apertures in the support flange.
  • the assembly will also include a ventilated end cover strip, most usually in the form of a lightweight asymmetrical channel section made of aluminium, zinc-alum or plastic secured to the structural wall and sized to fully cover the lower edge of the cladding support panel assembly.
  • a ventilated end cover strip most usually in the form of a lightweight asymmetrical channel section made of aluminium, zinc-alum or plastic secured to the structural wall and sized to fully cover the lower edge of the cladding support panel assembly.
  • the method includes the step of applying an adhesive to the wall element or the insulating panel prior to tilting the panel into engagement with the wall element.
  • mechanical anchors may be applied through the fastener retaining regions or battens and insulation material to further secure the assembly to the underlying support structure and help prevent post installation sagging.
  • incompressible spacer elements can be included, ideally at or near the batten securing positions.
  • the spacers may take the form of tube like elements through which the mechanical anchors may be applied. The spacers may be added during installation or incorporated in to the panel structures.
  • reinforcements in the form of inextensible anchors are also important.
  • the method of securing the panels will depend in part on the thickness and weight of the insulation and the weight of the cladding to be applied, the environmental factors relevant to the region of installation, plus consideration of any relevant local building codes that may apply, particularly in respect of wind loadings.
  • the method may include the step of applying some form of water barrier to the underlying wall structure prior to applying the insulation panels and cladding. This may be by way of application of a suitable building wrap or rigid moisture barrier, or, in the case of masonry walls for example, by applying some form of water resistant coating.
  • a suitable building wrap or rigid moisture barrier or, in the case of masonry walls for example, by applying some form of water resistant coating.
  • the need for and type of barrier or treatment will be determined by the site conditions and local building codes that may apply.
  • the method also includes the subsequent steps of progressively securing cladding panels to the battens on the installed insulation panels.
  • the cladding is secured using impact fasteners into the battens.
  • An externally insulated clad wall structure may include a structural wall element to which has been secured, directly or indirectly, to one or more unitary insulation cladding support panels.
  • An externally insulated clad wall structure may include:
  • Each batten support member includes a fixing flange for securing to the structural wall element and a support flange that is of sufficient depth to support the end of the cladding support battens, which in use are located ideally forward of the insulation material.
  • the support member consists of a length of structural metal section, which may be aluminium angle or some other custom bent structural section made, for example, from zinc-alum.
  • the support member may comprise a plurality of discrete brackets or a combination of brackets and lengths of structural section. If lengths of structural section are used, means should also be provided to allow drainage of moisture from behind the cladding. This could be done, for example, by leaving gaps between adjacent lengths of section, or using angle provided with drainage apertures in the support flange.
  • the assembly will also include a ventilated end cover strip, most usually in the form of a lightweight asymmetrical channel section or right angle section secured to the structural wall and sized to cover at least the outermost lower edge of the cladding support assembly.
  • the insulation material can be in any suitable material and come in a variety of different forms.
  • batts of fibre glass, foamed glass, hemp and other materials can be used. These batts can be optionally coated pre or post installation to improve durability, weather proofing and/or handlability by, for example, coating with a spray on resin material or similar.
  • spray on insulating foam such as those produced by Demilec (USA) LLC (Sealection TM 500 etc) or Icynene (Canada) or those installed by companies such as IsoSpray Foam roof insulation services in the United Kingdom can be applied directly to the substructure in situ.
  • incompressible spacers of the kind discussed above can be used.
  • the spacers can be pre-applied to the battens or the battens otherwise pre-configured to allow easy location and retention of the spacers during installation.
  • the spacers may be integrally formed as part of the battens or the battens configured to eliminate the need for spacers by, for example, having an I-beam or hollow square structure or the like that extends right back to the underlying structural wall.
  • adjustable wall to batten spacers or spacer fasteners are used to enable in situ repositioning of the battens as may be required when the underlying structural wall is not flat as will often be the case. In such instances it may also be necessary to pack between the insulation material and battens and/or provide additional means to secure the insulation material.
  • the fastener retaining battens are made of nailable fibre cement of the kind already described.
  • other suitable materials including timber, can be used.
  • this wall structure may also include additional moisture management features as discussed above.
  • Figure 1 there is shown three examples of prior art systems for applying external installation to clad wall structures.
  • Figure la shows a common wall structure comprising frame elements 1 to which a structural sheathing board 2 has been applied.
  • a series of insulation battens 3 are then applied to the sheathing at the stud spacings and some form of insulating material such as an insulation batt 4 is applied therebetween.
  • some form of water or water vapour proof membrane 5 is secured over the insulation batts and battens as shown.
  • a further series of cladding mounting battens 6 are then secured over the insulation battens 3 and finally the external cladding 7 is secured on top.
  • FIG. 1c An alternative prior art system is shown in Figure 1c .
  • a proprietary insulation panel 9 is secured to the underlying wall structure such as the frame and sheathing assembly, or structural block work wall. While these insulation panels 9 typically include some form of water barrier or reflective membrane, it is still necessary to accurately locate and secure in situ a series of most usually timber cladding battens 6 on top of the sheathing 9 prior to the external cladding 7 being applied.
  • a complex metal bracketing system is attached to the masonry walls and the cladding is then attached to these brackets with the insulation positioned between the brackets behind the cladding.
  • the thicker the insulation panel and the heavier the intended cladding the more difficult it becomes to secure the battens through to the underlying structure without the risk of downward movement of the battens via sag once loaded by the attached cladding.
  • FIG. 2 there is shown a first preferred embodiment of a unitary insulation and cladding support panel 10 according to the first aspect of the invention.
  • the panel 10 includes a rectangular substantially rigid lightweight backing sheet 11 made of a thermally insulating material which has a rear surface 12 for mounting to an external wall element and an opposing front face 13.
  • the backing sheet can be made of any suitable lightweight thermally insulating material and may also comprise some form of composite product made of multiple layers of different materials. In the preferred form, the backing sheet is made predominantly from expanded polystyrene foam. The thickness of the sheet will depend upon the proposed application and factors such as the degree of insulation required, the density of the foam board and the structural properties that the final panel is required to have.
  • the backing sheet is made of expanded polystyrene foam, for example DOW Chemical's STYROFOAM ® Tongue & Groove panel.
  • the backing sheet may, for example, be made of OSB, fibre cement or a metal skin, such as aluminium, bonded to a foam sheet.
  • a layer of foil or a metallised faced membrane 14 is securely adhered to the front face 13 of the backing sheet 11.
  • An example of one particularly suited material is Du PontTM Tyvek ® ThermawrapTM metallised spun-bonded polyethylene fabric.
  • a series of parallel spaced fastener retaining battens 15 are then pre-secured to the front surface of the panel formed, in this instance, by the outer facing front surface of the foil membrane 14.
  • the backing sheet could be formed with indentations in the front surface into which the battens are partially or fully located.
  • the battens 15 can be made of any suitable nailable material including timber or polymeric materials. However, in the preferred form, the battens are made from fibre cement.
  • the formulation and/or processing is selected to produce a cured layer of reinforced fibre cement that is nailable. In most cases these nailable products have a relatively low density.
  • the hydraulic binder used in the fibre cement is preferably Portland cement but can also be any hydraulic cementitious binder chosen from a group including, but not limited to: high alumina cement, ground granulated blast furnace slag cement, gypsum hemihydrate, gypsum dihydrate, and gypsum anhydrite, or any mixtures thereof.
  • the filler which can be a reactive or inert material, is preferably ground silica sand but can also be any material chosen from the group including, but not limited to: amorphous silica, diatomaceous earth, rice hull ash, silica fume, microsilica, hollow ceramic spheres, geothermal silica, blast furnace slag, granulated slag, steel slag, fly ash, mineral oxides, mineral hydroxides, clays, magnesite or dolomite, metal oxides and hydroxides, polymeric beads, or any mixtures thereof.
  • the fibre cement additives can be chosen from a group including, but not limited to: silica fume, hollow ceramic spheres (see for example WO 01/68547 ), cenospheres, geothermal silica, fire retardants, set accelerators, set retarders, thickeners, pigments, colorants, plasticisers, dispersants, foaming agents, flocculating agents, water-proofing agents, organic density modifiers, aluminum powder, kaolin, alumina trihydrate, mica, metakaolin, calcium carbonate, wollastonite, mineral oxides, mineral hydroxides, clays, magnesite or dolomite, metal oxides and hydroxides, pumice, scoria, tuff, shale, slate, perlite, vermiculite, polymeric beads, calcium silicate hydrate and polymeric resin emulsions, or any mixtures thereof.
  • Preferred polymeric resins are products such as, but not limited to, acrylic latexes, styrene-butadiene latexes, or mixtures thereof. These latexes can be emulsions or be in a redispersible powder form. In Portland cement-based materials, the latexes need to be stabilised to withstand the high-alkali environment.
  • the fibres used in the fibre cement are preferably cellulose wood pulp but can also be natural or synthetic organic or inorganic fibrous material chosen from the group including, but not limited to: ceramic fibre, glass fibre, glass ceramic fibre, natural fibres such as kenaf, hemp, flax and jute, carbon fibre, mineral wool, steel fibre, synthetic polymer fibres such as polyamides, polyesters, polypropylene, polymethylpentene, polyacrylonitrile, polyacrylamide, viscose, nylon, PVC, PVA, and rayon, or any mixtures thereof.
  • the fibres are more preferably fibrillated cellulose fibres, such as described in Australian Patent No. 515151 .
  • the fibre-reinforced cement is made from a plastic mixture or an aqueous slurry, with or without post pressing, by any one or more of a number of conventional processes such as the Hatschek sheet process; Mazza pipe process; Magnani process; injection molding; extrusion; hand lay-up; moulding; casting; filter pressing; Fourdrinier forming; spattering; multi-wire forming; gap blade forming; gap roll/blade forming; bel-roll forming; wellcrete and other processes.
  • Hatschek sheet process Mazza pipe process
  • Magnani process injection molding; extrusion; hand lay-up; moulding; casting; filter pressing; Fourdrinier forming; spattering; multi-wire forming; gap blade forming; gap roll/blade forming; bel-roll forming; wellcrete and other processes.
  • the battens are of sufficient thickness and have sufficient fastener holding strength to support an external cladding without the need to provide through fixtures to an underlying structural wall element.
  • the battens may also include a plurality of pre-drilled holes to receive fasteners for securing the battens through the backing sheets into the underlying wall structure when this is required.
  • the battens are preferably secured to the backing sheet using a high strength water resistant adhesive such as epoxy, polyurethane, rubber or acrylate.
  • the panels 10 will be sized to comply with relevant local building regulations and the battens 15 spaced according to batten spacing requirements in that particular region which usually relates to local wind loading.
  • one suitable sized panel has a length of 2700mm, a width of 600mm.
  • the foam backing sheet may be around 70mm thick and a single centrally disposed batten is provided that is at approximately 50-70mm wide and around 19mm thick. All of these dimensions may vary according to each application and in some cases additional battens may need to be added during installation to align with non-regular stud spacing attachments and the like.
  • the panel 10 comprises simply the insulating backing sheet 11 with the fastener retaining battens secured directly to the backing sheet front face 13.
  • the front face 13 of the panel will itself preferably be impervious to water.
  • the insulating panel is made from a foamed material, a closed cell structure may achieve this objective or it may be achieved purely by the forming method.
  • some form of waterproof coating could be applied to the front surface 13 to achieve the water barrier characteristics if required. It should be noted that additional moisture barriers may also be applied behind or on top of the panel during the installation process.
  • the backing sheets of Figures 2 and 3 have a planar front surface
  • the front surface could have profiled recesses in to which the battens are partially or fully located.
  • FIG. 4 there is shown a further embodiment of the invention where the panel 10 has fastener retaining regions 16 which are more integrally formed within the panel than the fastener retaining battens 15 of the previous two embodiments which are made separately and then pre-secured to the backing sheets 11.
  • the panel 10 comprises a generally planar rear portion 17 having pre-determined thermal insulation properties with a rear surface 18 for mounting to a wall element and an opposing front region 19 that is spaced from the rear surface 18. Extending from this front region 19 is a second portion 20, which is represented by the darker material shown in the representations, and which terminates in a front surface 21.
  • the second portion 20 includes one or more fastener retaining regions 16 for retaining fasteners at predetermined parallel spacings for securing cladding thereto.
  • the panel 10 also preferably includes a plurality of water drainage channels 22 which extend in between the raised fastener retaining region 16. Region 16 has two functional requirements. The first is to act like a washer to distribute concentrated load on a fastener attaching panel 10 to the wall structure under wind or other loads, and the other to provide sufficient cladding fastener holding to resist wind load and other loads on the cladding.
  • the panel is constructed as a composite made from two bondable, flowable materials.
  • the rear portion of the panel 17 may be made from a very low density lightweight foamed polymeric material, whereas the second portion 20 adjacent the front face 21 is made from a higher density polymeric material so as to provide the requisite fastener retaining properties.
  • the panel may be made impervious to the through passage of water applied via the front face 21 by virtue of the material properties of the front and/or rear regions or again be achieved by some form of coating applied to the surface.
  • Figure 5 there is shown a variation on the embodiment of Figure 4 which is configured to simulate the physical structure achieved in Figures 2 and 3 , but made by the same technique and using similar materials to those discussed in respect of the embodiment of Figure 4 .
  • the panels of Figures 4 or 5 may be made from light weight foamed cementitious materials with the rear and front portions having different properties as discussed above.
  • the disclosures in WO 231287 and AU 2006230666 may, at least in part, be useful in describing how such an article could be constructed.
  • the panels may include further layers of different materials to vary the performance characteristics of the board.
  • FIG. 6 there is shown a preferred method for constructing an externally insulated clad wall structure using the unitary insulation cladding support panels 10 of the invention.
  • the panel 10 has a foam backing sheet 11 and a single centrally disposed fibre cement batten 15.
  • a masonry structural wall element 30 is erected in the usual manner.
  • the outer surface of the structural wall 30 may then be weather proofed in the desired or required manner by application of some form of moisture barrier such as a building wrap or, for masonry walls, optionally a moisture resistant coating.
  • this cover strip will usually be made of a relatively light gauge aluminium, zinc-alum sheet metal or plastic material and preferably configured in the manner of an asymmetrical channel.
  • This provides one long edge flange for securing to the underlying wall structure, a central flange that is wide enough to span between the structural wall and the rear side of the cladding, and an optional short front flange in the form of an upstanding lip that acts to capture the front most surfaces of the unitary panel including the battens or fastener retaining regions.
  • the central flange usually includes apertures 32 to allow egress of moisture that accumulates behind the cladding and enable ventilation of this region.
  • Support means in the form of lengths of structural support section (e.g. aluminium angle or custom bent zinc-alum section or similar) 33 and/or discrete brackets 34 are then secured to the front face of the wall element 30 at a position that defines the lowermost point 34 of the unitary insulation panel 10, which often means they are located above and possibly overlapping the cover strips 31.
  • the brackets 34 are positioned to align with and support the lowermost ends of the battens 15.
  • the supports are located to provide a minimum 100mm clearance from the ground.
  • the support section 33 and brackets 34 each have a relatively wide rear flange 35 for rigidly securing to the underlying structural element 30, and a support flange 36 of sufficient depth to support the full depth of the panel assembly including, most importantly, the battens or fastener support regions. In this manner any load applied to these regions as a result of the cladding weight and/or wind loads is transferred back to the main structure and the risk of sagging of the cladding and battens is substantially reduced.
  • the preferred support is in the form of a length of structural section 33, then means should ideally be provided to allow moisture drainage and ventilation from behind the cladding. This can be done, for example, by providing drainage apertures in the channel or using discontinuous lengths of angle with gaps therebetween.
  • adhesive 36 may be applied at predetermined locations on the structural wall element 30 as shown in Figure 6 .
  • One method involves applying 50mm patches of adhesive at 300mm centres.
  • the panel 10 is then positioned with the lowermost edge 37 resting on the installed angle and brackets such that the panel inclines outwardly from the wall as shown in Figure 7 .
  • the panel is simply tilted into engagement with the wall element as shown.
  • a plurality of suitable fasteners 38 are then optionally applied through the battens 15 to further secure the panel to the underlying structural wall element.
  • Examples of potentially suitable heavier duty fasteners include: Ramset TM fasteners such as Easydrive TM , Suredrive TM , Ramplug TM and Dynabolt TM as well as Hilti TM fasteners including Impact Anchors HPS-1, HT and the HRD series. As shown in the drawings, the fasteners may be applied through the battens, usually through pre-drilled holes. Potentially suitable fastener examples include 160mm x 10mm dia Ramset TM Ramplug and 140mm x 8mm dia Ramset TM Easydrive TM nylon anchor. It should be noted that use of adhesive is entirely optional, particularly when heavy duty anchors are being used.
  • incompressible spacers may be inserted into the panel at regions at or near where the fasteners will be used.
  • rigid length adjustable fasteners may be used which engage with the battens to enable the position of the battens (and hence the panel) to be adjusted relative to the supporting wall.
  • each row supported at its base by appropriate support means of the kind discussed above.
  • joints between adjacent panels can be sealed with flashing tape 39 and additional battens 40 added at corner positions as required.
  • Corner trim 41 may also be used as shown in Figure 10 .
  • the cladding 42 can then be applied in the usual manner by securing, preferably with impact fasteners, through to the integrally provided fastener retaining regions or battens provided on the panels 10.
  • sheathing boards can first be applied to the frame elements after which non structural insulating panels are applied in a very similar manner to the masonry application, but ensuring that the panels do connect back to the frame elements where required.
  • structural versions of the insulating panel are to be used, there is no need to first apply sheathing boards as the insulation panels themselves will provide this structural function. The above comments regarding weatherproofing once again apply.
  • the systems according to the fifth aspect of the invention do not use prefabricated unitary insulation panels with integral cladding support systems. Instead they use a wide variety of existing and new insulation materials and batten systems, along with the novel batten support elements used in the system described above in relation to Figures 6 to 10 .
  • One form not specifically illustrated, relates to the use of specially designed or proprietary insulation panels in combination with highly durable nailable fibre cement battens that are secured to the underlying wall structure by use of adhesive or mechanical fasteners that extend through the battens and insulation panels along with base support means such as the support brackets or angles as described above.
  • the method of installation is similar to that described for the unitary panels except that the battens 15 are not integral with the insulation panel 9 (see Fig. 1c ), but need to be manually installed after the panels have been positioned. This may necessitate an additional step of needing to secure the insulation panels to the underlying structural wall prior to the batten being installed. This can be done by any means compliant with local area requirements and which may include the use of fasteners and/or adhesive. However, all the comments relating to support means, optional additional water barriers, the possible need to use incompressible spacers or fasteners and various finishing means like the protective end cover strip 31 and corner trim 39, are all applicable to this aspect of the invention.
  • incompressible spacers in the form of straight cut or stepped hollow tubes 45 are pre-assembled to the rear of the cladding support battens 46.
  • the spacers can be made of any material and any suitable form. If straight ended tub, they may be adhered to the battens. If a stepped end is provided, it may be possible to have a push fit into predrilled counter bored holes in the rear of the battens.
  • other forms of spacer and other means of aligning and/or connecting the spacers to the battens may be used.
  • rigid length adjustable fasteners of the kind previously described may also be used which operate to both fasten and space the battens to/from the wall.
  • the optional channel shaped cover strips 31 can be connected to the wall.
  • Batten support elements such as support brackets 34 are then secured to the wall at spacings that correspond with the intended location of the lower most edges of the cladding support battens 46.
  • the battens with pre-assembled spacers, can be positioned so the lower edges rest on the support brackets and are then secured to the wall structure using anchors that pass through the spacer tubes 45.
  • Insulation material 47 such as batts made from fibre glass, hemp or others suitable materials can then be positioned between the installed battens.
  • optional additional moisture control layers can be installed as required and then the cladding 42 can be secured to the battens in the usual manner as shown.
  • battens and spacers are extremely flexible.
  • a huge range of different insulation materials can be used such as those produced by Demilec (USA) LLC (Sealection TM 500 etc) or Icynene (Canada) or those installed by companies such as IsoSpray Foam roof insulation services in the United Kingdom.
  • spray on materials such as foam or recycled paper products etc can also be used.
  • the spacers or equivalent fasteners will only be needed if the proposed insulation material offers inadequate compression resistance or there is a need to be able to adjust or control the final position of the battens relative to the underlying structure to achieve an acceptably flat surface to which cladding can be applied. Furthermore, it may not be necessary to pre-assemble the spacers. For example, it may be possible to insert the spacers into gaps formed in the insulation after it has been applied to the underlying structure before the battens are attached.
  • a simple angle shape end cover 50 as shown in Figures 12 and 13 which are commonly available in Europe in a wide variety of sizes. These covers have an upstanding front flange 51 and a horizontal cover flange 52 in which are provided ventilation apertures 53. As shown in Figure 12 , these covers are installed by securing to the front face of the cladding support battens 15. Accordingly, the support brackets 33 or 34 are usually the first components secured to the prepared structural wall element 30. In most cases the ventilated end cover 50 will then be secured to the battens 15 (or equivalent fastener retaining regions 16 in other forms of panels) after the insulation and battens have been secured to the wall 30.
  • the assembly 55 has two parts. The first is a simple right angled corner flashing 56 made from thin coated sheet steel material or similar with fairly wide flanges 57. The second part is an appropriately configured L shape of either batten material 58 or corner trim 59 secured to the external corner region of the flashing using, for example, screws as shown.
  • FIGS 15 and 16 The different ways in which this corner flashing assembly can be used are shown in Figures 15 and 16 .
  • an L shape of batten material 58 is pre-secured to the flashing 56.
  • This assembly 55 is then secured directly over the insulation 11 and fastened through to the structural wall 30 using fasteners along centre lines 60 which may need to be vertically offset where required.
  • the corner trim 41 is then secured to the batten material 58 as shown.
  • the corner trim 41 is pre-secured to the flashing 56, the wide flanges 57 of the flashing enabling the assembly to span across to corner battens 15 that are fastened back to the structural wall 30.
  • fibre cement is the preferred material for the battens
  • the invention is also clearly suitable for use with timber battens as significant advantages are conferred over the prior art simply by use of the batten support means.
  • the unitary insulation and cladding support panel according to the first and second aspects of the invention and the method of constructing an externally clad insulated wall using those panels provides significant advantages over the prior art.
  • the amount of skilled on site labour required is significantly reduced, as there is no need for the separate step of accurately and securely applying battens on top of a previously applied multi-layer insulating structure prior to securing the cladding.
  • Benefits also accrue from the embodiments of the fifth aspect of the invention which combines the use of any suitable insulation material with any suitable kind of fastener holding battens that are structurally supported at their lower ends by support elements connected to the underlying structural masonry or framed wall system.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Physics & Mathematics (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Acoustics & Sound (AREA)
  • Electromagnetism (AREA)
  • Building Environments (AREA)
  • Finishing Walls (AREA)
  • Working Measures On Existing Buildindgs (AREA)

Claims (16)

  1. Structure de mur revêtu à isolation externe comportant :
    un élément (30) de mur structural ;
    une pluralité de lattes (15) de soutien de revêtement situées à une certaine distance de l'élément (30) de mur structural ;
    une couche de matériau (11) d'isolation positionnée entre l'élément (30) de mur structural et la pluralité de lattes (15) de soutien de revêtement ;
    au moins un élément (42) de revêtement étant fixé à au moins une latte (15) de soutien de revêtement, caractérisé en ce qu'au moins une latte (15) de soutien de revêtement est soutenue par un organe (33, 34) de soutien qui est fixé au niveau ou à proximité de la base de l'élément (30) de mur structural ; et
    en ce qu'au moins un organe (33, 34) de soutien de latte comprend un flasque (35) de fixation destiné à se fixer à l'élément (30) de mur structural et un flasque (36) de soutien qui est d'une profondeur suffisante pour soutenir l'extrémité d'au moins une latte (15) de soutien de revêtement.
  2. Structure de mur revêtu à isolation externe selon la revendication 1, l'organe (33) de soutien comportant une longueur de profilé métallique structural.
  3. Structure de mur revêtu à isolation externe selon la revendication 1 ou la revendication 2, l'organe (34) de soutien comportant une pluralité de supports discrets.
  4. Structure de mur revêtu à isolation externe selon l'une quelconque des revendications 1 à 3 incluses, l'organe (33, 34) de soutien étant configuré pour permettre l'évacuation de l'humidité à partir de l'arrière du revêtement.
  5. Structure de mur revêtu à isolation externe selon l'une quelconque des revendications 1 à 4 incluses, comportant en outre une bande ajourée (31, 50) de couverture d'extrémité, dimensionnée et située de façon à recouvrir au moins le bord inférieur extérieur extrême de la structure de mur revêtu à isolation externe.
  6. Structure de mur revêtu à isolation externe selon l'une quelconque des revendications 1 à 5 incluses, les lattes (15) de soutien de revêtement étant constituées d'un fibrociment léger clouable.
  7. Structure de mur revêtu à isolation externe selon l'une quelconque des revendications 1 à 5 incluses, les lattes (15) de soutien de revêtement étant constituées d'un matériau polymérique durable clouable.
  8. Structure de mur revêtu à isolation externe selon l'une quelconque des revendications 1 à 7 incluses, le matériau (11) d'isolation comportant un panneau d'isolation préformé sensiblement rigide ou semi-rigide.
  9. Structure de mur revêtu à isolation externe selon la revendication 8, le panneau (11) d'isolation étant constitué d'une mousse de polystyrène expansé.
  10. Structure de mur revêtu à isolation externe selon la revendication 8, le panneau (11) d'isolation étant constitué d'un matériau polymérique approprié.
  11. Structure de mur revêtu à isolation externe selon l'une quelconque des revendications 1 à 10 incluses, les lattes (15) de soutien de revêtement étant pré-assemblées sur le matériau (11) d'isolation ou incorporées autrement à celui-ci pour donner un panneau monobloc (10) d'isolation et de soutien de revêtement.
  12. Structure de mur revêtu à isolation externe selon l'une quelconque des revendications 1 à 11 incluses, le matériau (11) d'isolation étant traité pour améliorer la durabilité et/ou la résistance aux intempéries.
  13. Structure de mur revêtu à isolation externe selon l'une quelconque des revendications 1 à 12 incluses, comportant en outre une forme quelconque de moyen (45) d'entretoise incompressible pour s'assurer que les lattes sont fixées et maintenues à une distance prédéterminée de l'élément (30) sous-jacent de mur structural.
  14. Structure de mur revêtu à isolation externe selon la revendication 13, le moyen (45) d'entretoise étant mis en place en utilisant un élément (38) d'assemblage approprié qui interagit avec la latte et la maintient à une distance fixe de l'élément sous-jacent de mur structural.
  15. Structure de mur revêtu à isolation externe selon la revendication 13 ou la revendication 14, l'entretoise (45) ou les éléments (38) d'assemblage d'entretoise étant réglables pour permettre un réglage in situ de l'écartement des lattes (15) par rapport au mur structural (30) sous-jacent afin d'assurer une surface de fixation généralement plane pour les éléments (42) de revêtement.
  16. Structure de mur revêtu à isolation externe selon l'une quelconque des revendications 1 à 15 incluses, la couche de matériau (11) d'isolation et les lattes (15) de soutien de revêtement associées étant installées en une série de rangées horizontales l'une au-dessus de l'autre, les lattes (15) de chaque rangée étant soutenues au niveau de leur bord inférieur par un organe (33, 34) de soutien fixé directement à la structure (30) de mur.
EP10812890.1A 2009-10-29 2010-10-29 Revêtement isolant Active EP2494118B1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
AU2009905307A AU2009905307A0 (en) 2009-10-29 Undercladding insulation and cladding support systems and wall structures using the same
PCT/IB2010/003256 WO2011051818A2 (fr) 2009-10-29 2010-10-29 Systèmes de support de revêtement et d'isolement sous un revêtement et structures de paroi les utilisant

Publications (2)

Publication Number Publication Date
EP2494118A2 EP2494118A2 (fr) 2012-09-05
EP2494118B1 true EP2494118B1 (fr) 2016-02-17

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
NL2009420C2 (nl) * 2012-09-05 2014-03-10 Isobouw Systems Bv Werkwijze voor het aanbrengen van een droge bekleding tegen een constructieve vlakke ondergrond, isolatiepaneel voor toepassing bij een dergelijke werkwijze, en werkwijze voor het vervaardigen van een dergelijk isolatiepaneel.
US11035127B2 (en) 2015-12-23 2021-06-15 James Hardie Technology Limited Building cladding compositions, systems, and methods for preparing and assembling same

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2227765A (en) 1988-12-24 1990-08-08 Ernest William Fitton Decorative cladding
US20020083662A1 (en) 2000-12-29 2002-07-04 Cobblestone Construction Finishes, Inc. Ventilated wall drainage system and apparatus therefore

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Publication number Priority date Publication date Assignee Title
AU515151B1 (en) 1980-07-21 1981-03-19 James Hardie Research Pty Limited Fibre-reinforced cementitious articles
SE8301302L (sv) * 1982-03-11 1983-09-12 Isopag Ag Vermesperr for inre och yttre beklednad
SE454786B (sv) * 1984-02-10 1988-05-30 Leif Ekstrom Anordning for forankring av tva element med mellanrum vid varandra
US5946870A (en) * 1998-04-14 1999-09-07 Vinyl Corporation Panel support construction accessory
US6572697B2 (en) 2000-03-14 2003-06-03 James Hardie Research Pty Limited Fiber cement building materials with low density additives
EP1330580B1 (fr) 2000-10-10 2010-11-24 James Hardie Technology Limited Materiau de construction composite
US8297018B2 (en) * 2002-07-16 2012-10-30 James Hardie Technology Limited Packaging prefinished fiber cement products
AU2006230666B2 (en) 2005-10-19 2008-03-13 James Hardie Technology Limited A laminated building material
DE202006012370U1 (de) * 2006-05-09 2007-09-20 Böhm, Martin E. System zur Anbringung von Dämmmaterialien an Bauwerken

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2227765A (en) 1988-12-24 1990-08-08 Ernest William Fitton Decorative cladding
US20020083662A1 (en) 2000-12-29 2002-07-04 Cobblestone Construction Finishes, Inc. Ventilated wall drainage system and apparatus therefore

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WO2011051818A3 (fr) 2011-08-04
WO2011051818A2 (fr) 2011-05-05

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