EP3988731A1 - Construction de façade utilisant un montant thermique traversant les parois - Google Patents

Construction de façade utilisant un montant thermique traversant les parois Download PDF

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Publication number
EP3988731A1
EP3988731A1 EP21187146.2A EP21187146A EP3988731A1 EP 3988731 A1 EP3988731 A1 EP 3988731A1 EP 21187146 A EP21187146 A EP 21187146A EP 3988731 A1 EP3988731 A1 EP 3988731A1
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EP
European Patent Office
Prior art keywords
plate
wall
angle
edge
vertical
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP21187146.2A
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German (de)
English (en)
Inventor
Hugh Bowerman
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Laing Orourke PLC
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Laing Orourke PLC
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Filing date
Publication date
Application filed by Laing Orourke PLC filed Critical Laing Orourke PLC
Publication of EP3988731A1 publication Critical patent/EP3988731A1/fr
Pending legal-status Critical Current

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C3/00—Structural elongated elements designed for load-supporting
    • E04C3/02—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces
    • E04C3/04—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/56—Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members
    • E04B2/58—Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members with elongated members of metal
    • E04B2/60—Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members with elongated members of metal characterised by special cross-section of the elongated members
    • E04B2/62—Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members with elongated members of metal characterised by special cross-section of the elongated members the members being formed of two or more elements in side-by-side relationship
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/74—Removable non-load-bearing partitions; Partitions with a free upper edge
    • E04B2/7407—Removable non-load-bearing partitions; Partitions with a free upper edge assembled using frames with infill panels or coverings only; made-up of panels and a support structure incorporating posts
    • E04B2/7409—Removable non-load-bearing partitions; Partitions with a free upper edge assembled using frames with infill panels or coverings only; made-up of panels and a support structure incorporating posts special measures for sound or thermal insulation, including fire protection
    • E04B2/7412—Posts or frame members specially adapted for reduced sound or heat transmission
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/88—Curtain walls
    • E04B2/96—Curtain walls comprising panels attached to the structure through mullions or transoms
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C3/00—Structural elongated elements designed for load-supporting
    • E04C3/02—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces
    • E04C3/04—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal
    • E04C3/08—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal with apertured web, e.g. with a web consisting of bar-like components; Honeycomb girders
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C3/00—Structural elongated elements designed for load-supporting
    • E04C3/02—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces
    • E04C3/29—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces built-up from parts of different material, i.e. composite structures
    • E04C3/291—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces built-up from parts of different material, i.e. composite structures with apertured web
    • 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
    • E04B2001/7679—Means preventing cold bridging at the junction of an exterior wall with an interior wall or a floor
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C3/00—Structural elongated elements designed for load-supporting
    • E04C3/02—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces
    • E04C3/04—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal
    • E04C2003/0404—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects
    • E04C2003/0408—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects characterised by assembly or the cross-section
    • E04C2003/0413—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects characterised by assembly or the cross-section being built up from several parts
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C3/00—Structural elongated elements designed for load-supporting
    • E04C3/02—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces
    • E04C3/04—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal
    • E04C2003/0404—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects
    • E04C2003/0443—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects characterised by substantial shape of the cross-section
    • E04C2003/0465—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects characterised by substantial shape of the cross-section square- or rectangular-shaped
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C3/00—Structural elongated elements designed for load-supporting
    • E04C3/02—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces
    • E04C3/04—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal
    • E04C2003/0404—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects
    • E04C2003/0443—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects characterised by substantial shape of the cross-section
    • E04C2003/0473—U- or C-shaped

Definitions

  • the present disclosure relates to the construction of a wall, in particular, a wall for a building.
  • Buildings have an external envelope designed to keep weather and noise out whilst keeping heat in.
  • the vertical elements of this envelope are called the façade.
  • the façade In low rise buildings, the façade is often integral with the structure of the building (e.g., brickwork), but in multi-storey building the façade is usually a panelised system attached to the edge of the building frame.
  • a facade may be split into different layers through its thickness.
  • the two main layers are cladding, which gives the building its appearance and is the first line of defence against weather, and the wall structure that contains all the structure, insulation and membranes necessary to ensure the technical performance of the wall system.
  • a stud assembly for passing through a cavity wall, said stud assembly comprising: a quadrilateral plate comprising perforations, said plate comprising two opposing faces and four edges; an internal angle for attaching to a first edge of the plate and also for attaching to an internal portion of a wall; an external angle for attaching to a second edge of the plate and also for attaching to an external portion of the cavity wall; wherein the first edge and the second edge correspond to opposite edges of the quadrilateral plate.
  • the quadrilateral plate is formed as a two-quadrilateral plate construction whereby each of the two quadrilateral plates comprise perforations and are positioned substantially parallel to one another and are separated by a gap, and the internal angle and external angle are an internal channel and external channel, respectively.
  • perforations causes the heat path to be simultaneously lengthened and narrowed resulting in significantly reducing the amount of heat that can be transferred through the perforated plate relative to a solid plate.
  • the stud assembly further comprising an end channel substantially perpendicular to the other two edges (e.g. the short edges if the plate is rectangular) of the plates so as to attach the internal angle to the external angle.
  • the perforations are elongate perforations.
  • a plurality of the elongate perforations each comprise a bulbous end.
  • the perforations form an interlocking pattern.
  • the interlocking pattern is a chevron interlocking pattern.
  • the stud assembly further comprising a flange protruding from at least one of the two faces of the plate at a perimeter of at least some of the perforations.
  • At least one of the external angle or internal angle comprises a joggle offset where the angle meets the outside edge or the inside edge, respectively.
  • the joggle offset is at least the thickness of one of the two plates.
  • at least one of the first edge or second edge comprise a joggle offset where the first edge or second edge meet the channel.
  • the stud assembly further comprising: a first beam connector for attaching a portion of the internal angle to an upper beam; and a second beam connector for attaching a different portion of the internal angle to a lower beam.
  • a wall protrusion bracket apparatus for transferring loads from a wall projection into a load-carrying structure of a building, the apparatus comprising: a vertical-beam assembly, of length x running from a lower load carrying structure to an upper load carrying structure and formed by two vertical-beam flange sections and a connecting plate, the first vertical-beam flange being to the internal face of a cavity wall; a moment-resisting attachment bracket for connecting the vertical-beam assembly to a wall projection, said attachment bracket comprising: a plate of length y fixedly attached to a second flange section of the vertical-beam; and at least one rod passing through the plate and the second flange section, said at least one rod is at least partially threaded.
  • the apparatus further comprises an insulation layer between the vertical beam assembly and the wall projection.
  • the vertical beam assembly further comprises two angle beams of length x - y fixedly attached to the vertical-beam at the second flange section of the I-beam so as to form a cage for the attachment of an external cladding system.
  • the apparatus further comprises a connection on at least one of the ends of the vertical beam.
  • each of the two angles are attached to the vertical beam by at least two brackets.
  • the apparatus further comprises an elongate plate between two or more brackets, the brackets attaching an angle beam to the vertical beam, said elongate plate for transferring vertical cladding loads from the angle beam to the vertical-beam.
  • the apparatus comprises a stiffener plate between the two flange sections positioned along an upper or lower edge such that the attached plate bracket abuts the vertical-beam on the opposite side of the second flange section.
  • the moment-resisting attachment bracket further comprising an insulating block attached to the attachment plate by the at least two rods such that the plate is sandwiched between the insulating block and the second flange section.
  • a space in the cage formed between the two angle beams and the second flange section comprises insulation.
  • a panel-based cavity wall system for use in a building comprising top and bottom beams; comprising: a stud assembly for extending between a top beam and a bottom beam; and a moment-resisting bracket apparatus for extending between the top and the bottom beam
  • the system further comprises at least two insulation batts in thermal contact with the stud assembly, one of the insulation batts positioned at an internal portion of a cavity wall and the another of the insulation batts positioned at an external portion of the cavity wall.
  • the system further comprises a spacer to separate the at least two insulation batts at either side of the cavity wall.
  • the system further comprises a structural column extending between the top beam and the bottom beam.
  • a wall system for use in a building, comprising: the stud assembly as described above; a concrete slab at an external portion of a wall, the concrete slab comprising a supporting steelwork configured to form a frame with the stud assembly; wherein the stud assembly is at least partially embedded within the concrete slab; and wherein the external angle/channel of the stud assembly comprises tabs and/or concrete-admitting holes so as to improve anchorage of the concrete slab.
  • the wall projection bracket apparatus As many of the vertical elements summarised above, e.g. the stud, the wall projection bracket apparatus, the end post, etc., are essentially prismatic, they are capable of being located by a robot and welded together by a robot. Therefore, the wall system is inherently suitable for automated manufacture.
  • the present invention described below may form at least part of a façade construction system that enables integrated panels with wall-through elements to be manufactured in a substantially automated manner.
  • the façade construction system may include provision for up to 60% glazing area, brackets for wall protrusion attachments/brackets and an ability to either be supported from the building frame or stack supported from the ground.
  • the system meets required standards in terms of fire safety, acoustic isolation, air tightness and thermal performance.
  • the present invention in some aspect, relates to at least part of a modular wall system for use on the outside face of a building.
  • the system enables a high level of automation in manufacture and can be rapidly installed on site.
  • the wall system comprises top and bottom horizontal beam elements tied together by vertical elements comprising any of the following: stud(s), end post(s), and/or balcony bracket(s).
  • a stud passes through the thickness of a wall from the external face of an internal cavity to the internal face of an external cavity.
  • the stud comprises a perforated plate.
  • the perforated plate is preferably a quadrilateral shape, e.g. rectangular.
  • a first edge (e.g. a first long edge) of the plate is attached to an internal portion of a cavity wall by way of an internal angle and a second edge (e.g. a second long edge) of the plate is attached to an external portion of the cavity wall by way of an external angle.
  • the first and second edge correspond to opposite edges of the plate, e.g. two opposing edges of a rectangular plate.
  • perforations of the perforated plate are elongate in shape and run parallel to the first edge (e.g. the first long edge) of the plate.
  • Alternate rows of perforations may be staggered by half a perforation pitch such that heat transfer from one long side to the other via he plate must "zigzag" around the perforations. This causes the heat path to be simultaneously lengthened and narrowed resulting in significantly reducing the amount of heat that can be transferred through the perforated plate relative to a solid plate.
  • the plate (sometimes referred to as a "web") is formed as a two-plate construction whereby each of the two plates comprise perforations and are substantially parallel to one another.
  • the two plates may be separated by a gap (the gap typically being between 10 mm and 100 mm, preferably between 25 mm and 50 mm).
  • each of the two plates at a first side are attached to an internal portion of the cavity wall by way of an internal angle (i.e. there are two internal angles), and each of the two plates at a second side are attached to an external portion of the cavity wall by way of external angle (i.e. there are two external angles).
  • the stud may alternative comprise an internal channel and/or an external channel, respectively.
  • an internal angle or external angle can be used, the remainder of the description refers to internal and external channels, along with a two-plate construction, for the sake of clarity and consistency. However, a person skilled in the art would understand a single plate construction is equally suitable.
  • Figure 1 shows a plan section through a short length of a wall system.
  • the stud assembly 1 runs across the wall section.
  • Insulation batts 2 may be placed on each side of the stud 1.
  • the wall system comprises spacing 3 between the insulation batts to enhances acoustic performance and helps keep moisture on the outside.
  • Spacers 4 may be employed to set and maintain the spacing 3.
  • the inner insulation 2 is covered by foil faced membrane 5.
  • a continuous fillet-strip 6 may be attached by screws 7 to the stud 1 so as to trap membrane 5 and hold it in place.
  • the fillet strip is any continuous spacer.
  • the fillet strip comprises a non-combustible material such as gypsum.
  • the fillet strip is made of wood, i.e. a batten.
  • a non-combustible board 8 is fixed to the fillet-strip 6, creating cavity 9. Board 8 forms the internal surface of the wall. Cavity 9 may be used to run and fit services, e.g. electrical wiring.
  • the foil-faced membrane 5 faces into cavity 9, and preferably, the membrane 5 is fixed and sealed at all edges to ensure the wall is airtight, i.e., air and vapour cannot cross into the insulation 2.
  • Membrane 5 has the properties of blocking the passage of water vapour and air.
  • the foil type of membrane 5 is further selected to be highly reflective. In combination with cavity 9, the foil-faced membrane contributes approximately 10% of the wall's thermal insulation.
  • Breather membrane 10 is trapped between a horizontal rail 11 and stud 1 wherever these items cross, helping to hold membrane 10 in position. Breather membrane 10 is further secured at all edges. Breather membrane 10 has the properties of preventing the passage of liquid water but allowing the passage of water vapour.
  • the horizontal rail 11 is fixed to stud 1 by screws 12, e.g. pan head screws. Horizontal rail 11 may be perforated in order to maintain at least 50% continuity of the vertical cavity to the outside of the breather membrane.
  • Figure 2 shows the main components of the top half of a stud 1.
  • the perforated plate 17/18 is shown as a two-plate construction. Therefore, rather than internal angle for attaching one edge of the plate to internal portion of the cavity wall, and an external angle for attaching the opposite edge of the plate of the external portion of the cavity wall, the stud 1 comprises internal channel 13 for attaching the one edge of each of the two-plates to the internal portion of the wall and an external channel 14 for attaching the opposite edge of each of the two plates to the external portion of the wall.
  • the two plates 17/18 are attached to the formed channels 13, 14 by a connection means, e.g. by rivets 19.
  • the space formed between the two plates may comprise an insulating material 20.
  • the channels 13, 14 are connected to end channels 15 at the top and bottom by a connection means, e.g. rivets 16.
  • Internal channel 13 is located to the inside of a wall system, and it may be made of any metal having the appropriate strength and stiffness characteristics, e.g. ferritic steel.
  • External channel 14 is located to the outside of a wall system. This may be subject to wetting and drying and hence needs to be made from a metal that does not corrode in normal atmospheric conditions.
  • the end channels 15 cross from inside to outside of the cavity wall. To reduce the conduction of heat along the end channels, it is made of a non-corroding metal with a low heat of conduction, for example, austenitic stainless steel.
  • the perforated plate 17, 18 also crosses from inside to outside (when attached to the internal and external angles/channels).
  • Heat conduction is reduced by making the plate thin, keeping the heat path long and using a metal with low thermal conductivity. Since the plate is thin and crosses to the outside, it must be from a corrosion resistant material. Rivets 16, 19 must be from materials that are galvanically compatible with the other elements. Stainless steel is typically used for all components.
  • the internal and external angles/channels 13,14 and perforated plate(s) 17,18 are preferably made from ferritic stainless steel;
  • the end channel 15 and rivets 16,19 are preferably made from austenitic stainless steel.
  • the insulating material 20 is a preferably a mineral wool batt.
  • Figure 3 shows an elevation on a stud 1 fixed to an upper beam 21 and lower beam 22.
  • the thermal stud 1 may be attached directly to beams 21, 22, however since the stud is typically made from stainless steel and the beams 21, 22 are typically carbon steel, galvanic isolation is required.
  • Connectors 23, 24 achieve this isolation.
  • the upper beam 21 may move down relative to lower beam 22. In this scenario, it is necessary for one of the connectors to incorporate a sliding action. This would typically be upper connector 24.
  • Connectors 23, 24 can be located a fixed distance 25 from the end of the stud.
  • the maximum value of distance 25 is determined by the relative stiffness of the internal channel 13 and the transverse buckling resistance of perforated plates 17, 18.
  • the stud 1 is required to transfer forces (shown as references 26 and 27 in figure 3 ) to upper and lower beams 21, 22. Force 26 typically arises from the weight of any cladding system attached to the outside of the stud. Force 27 typically arises from wind pressure. Stud 1 is designed to be stiff so that forces are transferred with minimal deflection of the internal face attaching to internal channel 13.
  • Figure 4 shows a view of a wall frame.
  • Upper beam 21, lower beam 22 and end posts 28 are connected to form a frame. Studs 1 are inserted into the frame and fixed top and bottom as shown in figure 3 .
  • the end posts 28 may be structural where load carrying capacity is required. Where full height openings are required, e.g. to form doors out onto a balcony, then a moment-resisting bracket 29 is fitted into the frame. Where reduced height openings are required, e.g., to form windows, then studs 1 of a variety of lengths are combined in order to form an aperture assembly 30.
  • Typical maximum horizontal spacing of vertically oriented elements within a frame is 600mm.
  • Figure 5 shows an isometric view of a typical perpendicular (or substantially perpendicular) joint used to form an aperture opening from studs.
  • the optional insulation 20 has been omitted for clarity.
  • the connection may be made using welding 31 or an angle cleat 32 and fixing means (e.g. screw 33).
  • Apertures are typically lined with boards 34. Boards may be affixed to the internal and external channels 13, 14 by a fixing (e.g. screws 35).
  • the boards 34 are typically used for fixing to window and door frames.
  • the boards 34 reinforce the stud 1 at locations of concentrated forces. Additionally, boards 34 provide a backing to internal and external membranes required to control vapour and moisture.
  • Figure 6 shows a part section through a vertical stud where it connects to a horizontal stud.
  • External channels 14 butt up to each other to enable welding 31. It is necessary that fixings (e.g. rivets 16, 19) do not protrude beyond joining line 36 else they may interfere with the coming together of the external channels 14.
  • Joining line 36 is coincidental with the external face of the wall and the external channel 14.
  • the external channel 14 may comprise a joggle offset 37. As shown in figure 6 , it will be apparent that the offset of the joggle 37 is a function of the height of the rivet head 19 such that the rivet head (or any other fixing) does not protrude beyond the joining line 36.
  • any gap associated with joining line 36 is reduced to a minimum.
  • the outer surface of the perforated plate(s) 17, 18 is/are set to be flush with joining line 36 by a counter joggle offset 38.
  • the offset dimension of counter joggle offset 38 is the offset of joggle offset 37 minus the thickness of the perforated plate 17,18.
  • Figure 6 shows a thermal stud with a two-plate 17,18 construction jointed to external channel 14 using fixings (e.g. rivets 19). There are other ways of jointing the perforated plates 17,18 to the internal and external channels 13, 14.
  • FIG. 7 shows an alternative construction of the stud 1 which is also within the scope of the present invention.
  • the external and/or internal channels 13,14 are formed without a joggle offset 37.
  • the Perforated plate 17, 18 is shown jointed to the internal/external channel using a laser weld 39.
  • the perforated plate 17, 18 is shown jointed using a resistance weld 40. Note that where a flush finish weld is used, there is no need for counter joggle offset 38 in the perforated plate(s). This requires that the thickness of the perforated plate is sufficiently small that the gap created during fit-up along joining line 36 can be welded over.
  • thermal stud 1 A key feature of thermal stud 1 is the perforated plate(s) 17,18. A short length of plate is shown in more detail in figure 8 .
  • the perforated plate(s) 17, 18 is/are necessarily made from thin metal to minimise the amount of heat transmitted from inside to outside (top to bottom as drawn in figure 8 ). Such metal will be prone to out-of-plane buckling under the application of in-plane compression or shear stress, as would arise from forces 26 and 27 shown in figure 3 .
  • the perforated plate(s) can be stiffened considerably by forming the thin metal out of the plane.
  • Another method to reduce heat flow from an inside portion of a wall to an outside portion of the wall across the plate(s) is to increase the length of the flow path and reduce the flow path width. In some aspects, this is achieved by elongate perforations 41. By staggering the perforations, i.e. the arranging the perforations such that they form an interlocking pattern, the heat flow path 42 (shown as a dotted line) is increased significantly in length. The longer the perforations 41 and the closer their centreline spacing 43, the longer and narrower the heat flow path 42 will be.
  • perforation length 45 is increased and spacing 43 is reduced, there is reduced resistance to out-of-plane buckling. This is exacerbated by a reduction in a formed depth 44 ( fig 8 , section B) resulting from less material being available for forming as spacing 43 reduces.
  • the formed depth 44 may also be described as a flange protruding from at least one face of the plate(s) at a perimeter of at least some of the perforations.
  • one or more of the following features can be included in the forming of the perforated plate to improve performance:
  • the bulbous ends 48 may form a lightly interlocking pattern such that a straight-line buckle about the plane long axis is resisted. It should be noted that there are various ways of providing an interlocking pattern, chevrons being another option.; when forces are applied to the plate, the result is to induce in-plane bending stresses within the plate. Sharp changes in stress direction, e.g., as happens at the ends of the perforation 41, results in increased stresses due to stress concentration. Bulbous end 48 increases the radius at these critical points, reducing the peak magnitude of the stresses that may arise due to wind pressure forces 27 (as shown in figure 3 .
  • the wall provides further measures to prevent buckling of the perforated plate.
  • FIG 9 is a scrap view on the outside of a wall panel local to an aperture corner. Studs 1 are shown in their in-use state with rigid mineral wool batts 49 fitted tightly between studs. Calculation and testing have shown that there is enough strength and stiffness in the batts to stop the perforated plate buckling outwards, noting that the out-of-plane dimension of a buckle (which is elastic) is considerably greater than any clearance between batt 49 and stud 1. The buckle is thus prevented from fully forming, enhancing the strength of the thermal stud.
  • a mineral wool batt (ref, 20 in figure 2 ) is provided inside the thermal stud to inhibit an inward buckle.
  • the stabilising benefit of the mineral wool batt is replaced by that of a board 34.
  • the length of stud 1 needs to vary to enable the fabrication of aperture assemblies. Variation needs to be continuous, i.e., any length between a practical minimum and maximum. Since the plate is based on perforations of fixed length and pitch, a means of varying the length is required. Figure 10 shows how this is achieved. Holes 50 in perforated plate(s) 17, 18 (perforations omitted for clarity) and holes 51 in internal channel 13 are based on a 50mm pitch (although other sized pitches can be used), though typically only every other hole is required giving centre of rivets 19 at 100mm pitch (although other sized pitches can be used). Holes 50, 51 are positioned relative to the longitudinal centre of the internal and/or external channels 13, 14.
  • Holes 52 are set relative to the end of internal and/or external channels 13, 14.
  • the distance 53 between the last plate rivet 19 and the end channel rivet 16 will vary within a range of 25mm (although other distances can be employed).
  • the total range variation that can be accommodated is 50mm.
  • a welding robot will be set up to make one type of weld.
  • the dominant material is structurally thick carbon steel, hence a carbon steel welding metal will be used.
  • the electrode diameter will be optimised for structural sized welds. Welding thin stainless steel to structural steel is not be feasible without changing the welding wire. This adds considerable equipment costs and slows down the throughput of the automated cell.
  • Figure 11 shows one solution to the above issues by use of the top connector block 24.
  • the connector block 24 is shown located on internal channel 13.
  • the connector block is a carbon steel connector block.
  • the internal channel is a stainless steel internal channel.
  • an isolation membrane 54 is located between block 24 and internal channel 13, ensuring electrical separation.
  • a stainless steel screw 55 can be fitted through a slot 56 about centreline 57.
  • An isolating sleeve washer 58 under the head of screw 55 can be used in order to maintain isolation.
  • a weld 59 is made. It will be apparent that this weld is between materials of similar composition (e.g. carbon steel) and similar thicknesses, enabling the same welding set up to be used to attach the stud to the frame as is used weld up the frame itself.
  • FIG 11 is shown with slotted holes permitting movement at the joint. It will be apparent that if no movement is desired, then slotted holes 56 can be replaced by round holes. Typically movement is allowed at the top but not at the bottom.
  • the torque applied to screw 55 will determine the compression across the isolation membrane and hence amount of force required to slide the connection.
  • This force is optimally set to be greater than the maximum anticipated live load applied to the lower beam 22, but less than the force that will cause stud 1 to buckle.
  • thermal stud 1 will be able to transfer live loads up it's length, thereby causing the live load to be shared between upper beam 21 and lower beam 22.
  • This has the benefit of reducing deflections due to live loads and eliminates the risk of noise generation (e.g. creaks and squeaks) from the sliding joint as live loads are encountered.
  • Figure 4 shows two additional vertical elements that work alongside studs 1, upper beam 21 and lower beam 22 to form the façade panel ⁇ these are end posts 28 and wall protrusion brackets 29.
  • end post 28 varies according to their function. If a façade panel is stacked such that its weight is taken down to ground level via the panel, then end post 28 will be a structural member.
  • Figures 12a shows a typical arrangement. Posts 28 are attached by welds 60 to upper and lower beams 21, 22 thus forming a picture frame around the panel. Vertical loads are transferred along beams 21, 22 into end post 28. End posts are sized to take the cumulative load of any panels above. For stacked panels, post 28 would typically be a square hollow section.
  • Figure 12b shows a section through the end post 28 of figure 12a , but this time with a stud 1, insulation 2, 62 and top hat rail 11 added in.
  • a stud 1 To the right hand of the thermal stud the wall is as shown in figure 1 .
  • the insulation 62 To the left hand of the stud, the insulation 62 has been modified to fully fill the gap.
  • the selection of end post 28 should be such that the outside face of end post 28 results in dimension 61 being greater than 40% of the combined thickness of insulation 2.
  • a typical combination would be substantially 260mm of mineral wool insulation and substantially 100mm square hollow section posts, although other sizes can also be used.
  • end posts 28 would typically be aligned with and fixed to structural columns in the building. In such circumstances the size of post 28 may be reduced as there is no cumulative load to take down to ground.
  • Figure 13 shows a section through a façade panel at the location of an optional wall protrusion bracket apparatus 29 shown in figure 4 .
  • FIG. 13a shows the wall protrusion bracket spanning vertically between lower structural floor 63 and upper structural floor 64.
  • the lower and upper structural floors can be any horizontal load-carrying structures of a building.
  • the wall protrusion bracket apparatus comprises a vertical beam 65 with connection 72 at the top and connection 73 at the bottom.
  • the bottom of vertical beam 65 has moment resisting attachment bracket 66 fixed to it. Loads from balcony 67 are transferred through moment resisting attachment bracket 66 and into vertical beam 65.
  • the vertical beam may be any type of beam, e.g. a box beam or an I-beam.
  • the vertical beam has a dimension from the bottom to the top of "x ".
  • Cage 68 is attached to beam 65 in order to provide a fixing location for optional horizontal rails 11.
  • Figure 13b shows how the vertical forces 69 are transferred to the structural floors 63, 64. These vertical forces are transferred from a wall projection onto the structural floor.
  • the wall projection can be any wall projections, e.g. a balcony, a mezzanine floor, a bay window, etc.
  • Forces 69 multiplied by eccentricity 71 develop a moment at moment resisting attachment bracket 66. This moment is applied to one end of beam 65.
  • Horizontal forces of magnitude moment / length 70 are transferred via connections 72, 73 into floors 63, 64.
  • Vertical forces 69 are also transferred via connections 72, 73.
  • Connection 73 is vertically fixed, connection 72 has some compliance. This is necessary to limit the amount of load transferred from floor 63 down beam 65 and into floor 64. This compliance also caters for the change in height between floor 63 and floor 64 when for example concrete creeps and shrinks and the structure shortens under load.
  • Figure 14 shows a typical moment-resisting bracket 29 in isometric view.
  • plate 80 At the bottom of beam 65 is attached plate 80.
  • the attached plate has a dimension from the bottom to the top of "y”.
  • stiffener 78 connection 73, threaded studs 79 and insulating blocks 74 this forms the moment resisting attachment bracket 66.
  • the threaded studs 79 take the tensile component of the moment applied to the moment resisting bracket 29.
  • the cage 68 is formed by two angle beams, each of length "z", whereby "z” is the difference between dimension "x" and dimension "y” (i.e. the lengths of the vertical beam 65 and the attached plate 80, respectively.
  • Vertical angle 81 is connected to vertical beam 65 by brackets 75.
  • the brackets have a slip joint type connection to the vertical angle. In this manner dimension 77 can be set accurately relative to the panel datum.
  • the cage angles lie in the same plane as the external angle/channel forming the thermal stud, such that rail or board systems may be run over and substantially contact both the cage and the thermal stud.
  • brackets 75 have a cross-section limited to that required to carry horizontal loads. Vertical cladding loads are transferred from angle 81 via diagonal 76 to beam 65 and thence to connectors 72, 73.
  • Figure 15 shows a sectional plan view through the mid height of balcony bracket 29.
  • Datum distance 77 is shown relative to datum 82 which lies on upper and lower beams 21, 22.
  • the wall protrusion bracket apparatus 29 fits within the same inside to outside dimensions as the stud 1.
  • insulation 83 may be provided to fill any voids in vertical beam 65.
  • the space within cage 68 may comprise insulation 84.
  • Brackets 75 cross through the main thermal insulation. In order to reduce heat loss, brackets 75 are preferably made from a low conducting metal such as stainless steel.
  • the inner vertical face of the thermal studs has a vertical fillet strip fixed to it. Boards are fixed to the outside of this strip, forming a cavity. Cables and pipes are run in this cavity. A reflective foil vapour barrier is located between the thermal stud and the fillet strip. This acts to boost the thermal performance of the wall.
  • the end posts may be one of a number of elements. With top and bottom beams they form 'picture frame' around the panel. Where the panel is used as an external wall of a 3d volumetric module the end post is a machined fabrication welded to the horizontal beams with preparations to connect to the rest of the module. If façade panels are stacked, the end post is a more simple section. In both cases they carry the loads from an assembly of volumetric modules or a stack of façade panels down to the foundation. If loads are transferred to the building structure at each level, then the end column can be a light weight structural section, a thermal stud or a balcony bracket.
  • the balcony brackets are a means of attaching cantilever balconies to the edge of a perimeter wall without having to install back beams. They are a significant enabler in permitting the modularisation of an external wall. They comprise of a vertical beam rigidly fixed to the lower beam and compliantly attached to the upper beam. The vertical beam has a machined plate at the bottom to which a balcony attaches.
  • the thermal stud may also be used as the through wall element of an external wall having a cast concrete outer cladding.
  • the thermal stud and a supporting steelwork are assembled into a frame and placed such that concrete may be poured to cover part or all of the outer angle or channel section.
  • the outer angle or channel has at least one protruding element formed or attached in order to enhance the anchorage into the concrete.
  • the concrete may include reinforcing steel.
  • a concrete slab 91 has a frame of thermal studs 92 at least partially embedded within it.
  • concrete 1 comprises reinforcing steel 93.
  • Perforated plates 94 are also embedded directly into concrete 91, in which case the plate edge may be deformed so as to provide improved anchorage 95 into the concrete.
  • the external channel/angle is formed in a manner so as to create tabs 96 and concrete admitting holes 97.
  • All of the vertical elements e.g. the stud, the wall projection bracket apparatus, the end post, etc., are essentially prismatic and designed to be capable of being located by a robot and welded together by a robot. Therefore, the wall system is inherently suitable for automated manufacture.
  • any reference to 'an' item refers to one or more of those items.
  • the term 'comprising' is used herein to mean including the elements identified, but that such elements do not comprise an exclusive list and an apparatus may contain additional elements. Furthermore, the elements are themselves not impliedly closed.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Thermal Sciences (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Building Environments (AREA)
EP21187146.2A 2020-07-23 2021-07-22 Construction de façade utilisant un montant thermique traversant les parois Pending EP3988731A1 (fr)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB2011449.2A GB2583314B (en) 2020-07-23 2020-07-23 Façade construction using through wall thermal stud

Publications (1)

Publication Number Publication Date
EP3988731A1 true EP3988731A1 (fr) 2022-04-27

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Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR1162523A (fr) * 1955-03-11 1958-09-15 Perfectionnement aux poutrelles métalliques composites pour planchers en béton armé
US5605024A (en) * 1994-02-07 1997-02-25 Sucato; Edward Stud assembly
US20130232911A1 (en) * 2010-04-08 2013-09-12 Dizenio Inc. Cold Formed Joist

Family Cites Families (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB476867A (en) * 1936-05-16 1937-12-16 Albert Henderson Improvements in or relating to metal structural members
GB544126A (en) * 1939-03-28 1942-03-30 Great Lakes Steel Corp Improvements in or relating to structural members
DE10130866A1 (de) * 2001-06-22 2003-01-02 Schoeck Entwicklungsgmbh Bauelement zur Wärmedämmung
GB2428697A (en) * 2005-07-23 2007-02-07 Mark Harris Pre-fabricated metal beam
GB2453716B (en) * 2007-09-24 2009-11-18 Brc Ltd Thermal break arrangements for construction elements
KR101676951B1 (ko) * 2015-03-30 2016-11-16 목포대학교산학협력단 철골구조 발코니용 열교차단장치와 이를 이용한 발코니 시공방법
US9752323B2 (en) * 2015-07-29 2017-09-05 Sacks Industrial Corporation Light-weight metal stud and method of manufacture

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR1162523A (fr) * 1955-03-11 1958-09-15 Perfectionnement aux poutrelles métalliques composites pour planchers en béton armé
US5605024A (en) * 1994-02-07 1997-02-25 Sucato; Edward Stud assembly
US20130232911A1 (en) * 2010-04-08 2013-09-12 Dizenio Inc. Cold Formed Joist

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GB202011449D0 (en) 2020-09-09
GB2583314A (en) 2020-10-21

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