EP3789552A1

EP3789552A1 - Modular building facade

Info

Publication number: EP3789552A1
Application number: EP20194323.0A
Authority: EP
Inventors: Martin Sweeney
Original assignee: Mosco Group Holdings Ltd
Current assignee: Mosco Group Holdings Ltd
Priority date: 2019-09-03
Filing date: 2020-09-03
Publication date: 2021-03-10
Also published as: GB2586809A; GB201912642D0; GB202013852D0

Abstract

A modular building façade (1) comprises a plurality of façade elements (2) mounted together on a building structure (3) to form a façade (1) or wall of the building. Each façade element (2) has a metal chassis (5) having an inner wall (6) and an outer wall (7) spaced-apart from each other and substantially parallel. A thermal insulation layer (8) is mounted between the inner wall (6) and the outer wall (7). A number of mounting connectors (10) on the inner wall (6) project outwardly therefrom for attachment to the building structure (3) by means of associated mounting brackets (11) rigidly secured to the building structure (3) by mounting bolts. A plurality of wall ties (15) project outwardly from the outer wall (7) and support a decorative façade (16) such as a brick façade. Resilient edge seals (18, 19, 20) extend between side edges of adjacent façade elements (2) assembled together on the building structure (3) to form a wall (1) of the building, providing an airtight seal between adjacent façade elements (2).

Description

Introduction

This invention relates to building construction, and in particular to forming a façade or outer wall on a building structure.

Background

In constructing apartment blocks or office blocks, generally a skeletal building structure of reinforced concrete is formed and this building structure then has cladding attached to an exterior thereof to form a façade or wall on each side of the building structure. It is known to mount pre-cast concrete wall elements on the building structure, however, such wall elements are typically very heavy and rely on site cranes or special access to manoeuvre on site. Generally, the building structure also has to be reinforced to accommodate the weight of such pre-cast concrete wall elements. As a result, installation time is relatively slow and site installation programmes are longer. The combination of special access, increased site program, and strengthened building structure, mean there is a significant cost penalty.
The present invention is directed towards overcoming this problem.
Examples of wall systems are to be found in CN 109594731 A and US 2012/0216471 A1 .

Summary of the Invention

According to the invention, there is provided a prefabricated modular building façade comprising a plurality of façade elements for mounting together on a building structure to form a façade of the building, each façade element including:

a metal chassis having an inner wall and an outer wall spaced-apart from each other and substantially parallel to each other,
a thermal insulation layer mounted between the inner wall and the outer wall,
a number of mounting connectors on the inner wall which project outwardly therefrom for attachment to the building structure,
a plurality of wall ties projecting outwardly from the outer wall and supporting a decorative façade, and
edge seals for sealing between side edges of adjacent façade elements assembled together on the building structure to form a wall of the building.

In one embodiment of the invention, each mounting connector has a head for complementary vertical sliding interengagement with a mounting plate which, in use, is rigidly attached to the building structure such that it projects outwardly therefrom, the head of the mounting connector seating on a support bar suspended below the mounting plate by adjusting screws extending between the support bar and the mounting plate.
In another embodiment, the head of the mounting connector is T-shaped and is slidably engagable within a complementary T-shaped re-entrant slot in the mounting plate.
In another embodiment, the support bar is vertically adjustable on the mounting plate by means of the adjusting screws.
In another embodiment the decorative façade comprises an array of brick slips mounted on the front wall.
In another embodiment the decorative façade comprises a plurality of spaced-apart upright supports mounted at he front wall and one or more decorative cladding panels mounted on the upright supports.
In another embodiment the decorative cladding panels comprise a plurality of vertically spaced-apart rails mounted on the vertical supports and a plurality of cladding elements mounted on the rails.
In another embodiment each cladding element and the rails have complementary interengagable formations for mounting the cladding element on the rails.
In another embodiment the cladding elements are bricks, each brick having mounting channels in a top face and in a bottom face of the brick for complementary engagement with associated mounting flanges on the rails.
In another embodiment an elastic mortar is mounted between adjacent bricks in the decorative façade.
In another embodiment, edge connectors are provided for interconnecting side edges of the façade elements at a head, a side and a base of adjacent façade elements, when mounted together on the building structure.
In another embodiment, the edge connectors include an airtight seal.
In another embodiment, seal mounting elements are mounted along the side edges of the façade element.
In another embodiment, the seal mounting elements are metal extrusions having outwardly facing seal mounting channels.
In another embodiment, a fire cavity barrier is provided for mounting between inner faces of the façade elements and the building structure.
In another embodiment, the fire cavity barriers are supported by mounting brackets on the building structure.
In another embodiment the façade element has internal cable trays housing electrical wiring looms and integrated WiFi.
In another embodiment, a door assembly and/or a window assembly is mounted on the chassis between the inner wall and the outer wall.
In another embodiment, the decorative façade comprises a brick façade.
In another embodiment, the decorative façade comprises a stone façade.
In another embodiment, the decorative façade comprises a glass façade.

Brief Description of the Drawings

The invention will be more clearly understood by the following description of some embodiments thereof, given by way of example only, with reference to the accompanying drawings, in which:

Fig. 1 is a perspective view of a modular building façade element according to the invention, shown mounted on a building structure;
Fig. 2 is another perspective view of the modular façade element shown in Fig. 1;
Fig. 3 is an elevational view showing a wall of a building formed by a number of the modular façade elements, arranged side by side on the building structure;
Fig. 4 is an enlarged elevational view of portion of the wall shown in Fig. 3;
Fig. 5 is a sectional view taken along the line V-V of Fig. 4;
Fig. 6 is a sectional view taken along the line VI-VI of Fig. 4;
Fig. 7 is a detail sectional view taken along the line VII-VII of Fig. 5;
Fig. 8 is a detail sectional view taken along the line VIII-VIII of Fig. 5;
Fig. 9 is a detail sectional view taken along the line IX-IX of Fig. 5;
Fig. 10 is an enlarged detail sectional plan view showing two interconnected façade elements on the building structure;
Fig. 11 is a view similar to Fig. 10 showing another portion of the façade;
Fig. 12 is a view similar to Fig. 10 showing a further portion of the façade;
Fig. 13 is an enlarged detail sectional plan view showing a corner connection between two adjacent façade elements;
Fig. 14 is a sectional elevational view showing portion of the modular building façade according to the invention;
Fig. 15 is a sectional elevational view of another portion of the modular building façade;
Fig. 16 is another sectional elevational view of portion of the modular building façade according to the invention;
Fig. 17 is a detail, partially cut-away perspective view of a modular building façade element according to another embodiment of the invention; and
Fig. 18 to Fig. 30 are perspective views showing a number of assembly steps in the construction of the modular building façade element of Fig. 17.

Detailed Description of the Preferred Embodiments

Referring to the drawings, there is illustrated a prefabricated modular building façade according to the invention, indicated generally by the reference numeral 1. The modular building façade 1 comprises a plurality of façade elements 2 mounted together on a building structure 3 to form a façade 1 or wall of the building.
Referring in particular to Fig. 2 and Fig. 10, each façade element 2 has a metal chassis 5 having an inner wall 6 and an outer wall 7 spaced-apart from each other and substantially parallel. A thermal insulation layer 8 is mounted between the inner wall 6 and the outer wall 7.
A number of mounting connectors 10 on the inner wall 6 project outwardly therefrom for attachment to the building structure 3 by means of associated mounting brackets 11 rigidly secured to the building structure 3 by mounting bolts 12.
A plurality of wall ties 15 project outwardly from the outer wall 7 and support a decorative façade 16. A brick façade 16 is shown in Fig. 1 and Fig. 2, however, any other suitable decorative façade could be provided, for example, a stone façade, a glass façade or an aluminium or copper façade, for example. In an alternative arrangement, if desired the decorative façade 16 could be formed by brick slips bonded to the outer wall 7, either directly or indirectly - such as to a panel mounted on the front wall 7, to imitate a brick or stone wall for example.
Resilient edge seals 18, 19, 20 extend between side edges of adjacent façade elements 2 assembled together on the building structure 3 to form a wall 1 of the building, providing an airtight seal between adjacent façade elements 2. Metal extrusions 22, 23 are mounted along the side edges of each façade element 2 and have outwardly facing seal mounting channels 24, 25 for reception of each end of the seals 18, 19.
The outer wall 7 is mounted on the inner wall 6 by means of cranked support elements 28 having an outer flange 29 for attachment by bolts 30 to an inner face of the outer wall 7 and an inner flange 31, which is perpendicular to the outer flange 29, attached by bolts 32 to a forwardly projecting web 33 on the inner wall 6.
Each mounting connector 10 has a T-shaped head 35 for complementary vertical sliding interengagement with an associated mounting plate 36 of the mounting bracket 11. The mounting plate 36 in use is rigidly attached to the building structure 3 such that it projects horizontally outwardly from the building structure 3, as shown in Fig. 2 and Fig. 10.
The head 35 of the mounting connector 10 seats on a support bar 37 (Fig. 2) suspended below the mounting plate 36 by adjusting screws 38 extending between the support bar 37 and the mounting plate 36. The head 35 of the mounting connector 10 is slidably engagable within a complementary T-shaped re-entrant slot 40 in the mounting plate 36.
It will be noted that the support bar 37 is vertically adjustable on the mounting plate 36 by means of the adjusting screws 38 and thus accurate height adjustment and levelling of each façade element 2 on the building structure 3 can be achieved easily, when mounting each façade element 2 on the building structure 3.
Connector plates 39 are mounted at top corners of each façade element 2 to interengage with bottom corners of another façade element 2 which in use is mounted directly above the façade element 2. The connector plates 39 are mounted in outwardly open side channels 40 at each side of the inner wall 6. Each plate 39 is fixed in the channel. A through hole adjscent a top of the plate 39 allows lifting gear to be attached to the plates 39 for lifting the façade element into position on the building during construction.
Referring in particular to Fig. 1 to Fig. 4, a door assembly 44 and/or a window assembly 45 may be integrally formed with any of the façade elements 2 as required.
Fig. 12 shows a façade element 2 with an arrangement for mounting glazing panels 50 on the façade element 2 in a double-glazed arrangement.
Fig. 13 shows an arrangement for forming a corner connection between two adjacent façade elements 2 at a corner of the building structure 3.
Referring in particular to Fig. 14, fire cavity barriers 55 are mounted between the building structure 3 and an inside face of the façade elements 2. The fire cavity barriers 55 are supported by associated mounting bracket assemblies 56 attached to the building structure 3.
In use, each façade element 2 is manufactured off-site in a manufacturing facility. A set of façade elements 2 to construct the outer walls of the building structure 3 is prepared and transported to a building site when required for fitting to the building structure 3. Each façade element 2 is lifted from the transport vehicle and positioned and connected in-situ to the pre-installed mounting brackets 11 on the building structure 3. Conveniently, scaffolding is not required. The façade elements 2 can be fitted using mini-cranes. When fitted, an immediate seal is created between the façade elements 2, allowing the internal fit-out phase of the construction to commence immediately.
It will be appreciated that any suitable decorative façade can be used for the façade elements 2. Also, as the façade elements 2 are of relatively light weight, there is no structural strengthening required to the building structure 3, and the façade elements 2 are easily handled and manoeuvred into place on the building structure 3.
Referring now to Fig. 17 to Fig. 30 there is shown another modular building façade element, indicated generally by the reference numeral 60, according to another embodiment of the invention. Parts similar to those described previously are assigned the same reference numerals. In this case, a plurality of spaced-apart metal upright supports 61 are mounted on the metal chassis 5 at the front wall 7. A number of vertically spaced-apart rails 62 are mounted on the upright supports 61. Bricks 63 are mounted on the rails 62. Each brick 63 has a mounting channel 64 in a top face of the brick 63 and a mounting channel 65 in a bottom face of the brick 63 for complementary interengagement with associated mounting flanges 66 on the rails 62.The bricks are assembled on the rails 62 to form, in this case, a brick façade 2 An elastic mortar 67 is inserted between the bricks 63 to weather seal the brick façade 2. Fig. 18 to Fig, 30 show sequential steps in the formation of the building façade element 60. Fig. 18 shows the rectangular metal chassis 5 which in this case includes window mounting openings 70, 71. In Fig. 19 and Fig. 20 inner wall 6 panels are mounted on the metal chassis 5. Insulation retaining profiles 73 and brackets 74 are mounted on the chassis 5 (Fig. 21 and Fig. 22) to retain thermal insulation panels 75 on the chassis 5 (Fig. 23). Panels 77 forming the outer wall 7 (Fig. 24) are mounted outside the insulation panels 75.
The upright supports 61 are then mounted on the chassis 5 (Fig. 25) and rails 62 are mounted spaced-apart on the upright supports 61. Bricks 63 are then assembled in a wall matrix on the rails 62, snap engaging with the rails 62 (Fig. 27 and Fig. 28). The elastic mortar 67 is inserted (Fig.29) into the joints between bricks 63 to seal the wall and glazing panels 78, 79 are installed in the openings 70, 71. Fig 30 shows a rear view of the fully assembled modular building façade element 60.
It will be appreciated that the invention provides a building façade system comprising façade elements that are completely manufactured off-site in a controlled manufacturing process under factory conditions and then when required transported to a site and immediately hung directly onto complementary spaced-apart mounting brackets on a building skeleton to form a fully finished wall of the building. The mounting brackets on the building structure may be cast in-situ or bolted to the building structure.
Advantageously the decorative façade or face of the façade element may have any desired finish such as brick, stone, aluminium rainscreen or the like for example. Conveniently, the decorative façade 16 may be provided by brick slips bonded to the outer wall 7. The brick slips may be of any suitable material such as clay, stone, ceramic or a plastics material to achieve a desired decorative finish.
Further, the façade elements are relatively lightweight and therefore specialist heavy lifting equipment is not required to lift each façade element into place on the building structure.
Each façade element may optionally include windows and/or doors, plenham boxes, balconies etc. as required. The façade elements include thermal insulation to NZEB & BCAR standards, incorporating fire-proof mineral wool insulation and fire cavity barriers.
Preferably each façade element is provided with internal cable trays housing electrical wiring looms and integrated WiFi. In addition, sensors may be fitted to the façade elements to monitor the performance of the building façade elements in use, to record moisture, air pressure in the void and heat build-up for example. Conveniently the sensors can be connected to a remote building management system to manage automatic opening vents and smoke management systems from an external remote 24 hour monitoring service. The building façade of the invention may also have smart wall capability to incorporate energy storing batteries within the insulation cavity.
The terms "comprise" and "include", and any variations thereof required for grammatical reasons, are to be considered as interchangeable and accorded the widest possible interpretation.
The invention is not limited to the embodiments hereinbefore described which may be varied in both construction and detail within the scope of the appended claims.

Claims

A prefabricated modular building façade comprising a plurality of façade elements for mounting together on a building structure to form a façade of the building, each façade element including:
a metal chassis having an inner wall and an outer wall spaced-apart from each other and substantially parallel to each other,

a thermal insulation layer mounted between the inner wall and the outer wall,

a number of mounting connectors on the inner wall which project outwardly therefrom for attachment to the building structure,

a decorative façade mounted at the front wall,

edge seals for sealing between side edges of adjacent façade elements assembled together on the building structure to form a wall of the building,

each mounting connector having a head for complementary vertical sliding interengagement with a mounting plate which, in use, is rigidly attached to the building structure such that it projects outwardly therefrom, the head of the mounting connector seating on a support bar suspended below the mounting plate by adjusting screws extending between the support bar and the mounting plate.
The prefabricated modular building façade as claimed in claim 1, wherein the head of the mounting connector is T-shaped and is slidably engagable within a complementary T-shaped re-entrant slot in the mounting plate.
The prefabricated modular building façade as claimed in claim 1 or claim 2, wherein the support bar is vertically adjustable on the mounting plate by means of the adjusting screws.
The prefabricated modular building façade as claimed in any one of the preceding claims wherein the decorative façade comprises an array of brick slips mounted on the front wall.
The prefabricated modular building façade as claimed in any one of the preceding claims wherein the decorative façade comprises a plurality of spaced-apart upright supports mounted at he front wall and one or more decorative cladding panels mounted on the upright supports.
The prefabricated modular building façade as claimed in claim 5 wherein the decorative cladding panels comprise a plurality of vertically spaced-apart rails mounted on the vertical supports and a plurality of cladding elements mounted on the rails.
The prefabricated modular building façade as claimed in claim 6 wherein each cladding element and the rails have complementary interengagable formations for mounting the cladding element on the rails.
The prefabricated modular building façade as claimed in claim 6 or claim 7 wherein the cladding elements are bricks, each brick having mounting channels in a top face and in a bottom face of the brick for complementary engagement with associated mounting flanges on the rails.
The prefabricated modular building façade as claimed in claim 8 wherein an elastic mortar is mounted between adjacent bricks in the decorative façade.
The prefabricated modular building façade as claimed in any one of the preceding claims, wherein edge connectors are provided for interconnecting side edges of the façade elements at a head, a side and a base of adjacent façade elements, when mounted together on the building structure.
The prefabricated modular building façade as claimed in claim 10, wherein the edge connectors include an airtight seal.
The prefabricated modular building façade as claimed in claim 11, wherein seal mounting elements are mounted along the side edges of the façade element.
The prefabricated modular building façade as claimed in claim 12, wherein the seal mounting elements are metal extrusions having outwardly facing seal mounting channels.
The prefabricated modular building façade as claimed in any one of the preceding claims, wherein a fire cavity barrier is provided for mounting between inner faces of the facade elements and the building structure.
The prefabricated modular building façade as claimed in any one of the preceding claims wherein the façade element has internal cable trays housing electrical wiring looms and integrated WiFi.