GB1599033A - In situ structural wall construction - Google Patents
In situ structural wall construction Download PDFInfo
- Publication number
- GB1599033A GB1599033A GB1087077A GB1087077A GB1599033A GB 1599033 A GB1599033 A GB 1599033A GB 1087077 A GB1087077 A GB 1087077A GB 1087077 A GB1087077 A GB 1087077A GB 1599033 A GB1599033 A GB 1599033A
- Authority
- GB
- United Kingdom
- Prior art keywords
- foam
- wall
- frame
- cavity
- structural
- 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.)
- Expired
Links
- 238000011065 in-situ storage Methods 0.000 title claims description 10
- 238000010276 construction Methods 0.000 title description 9
- 238000000034 method Methods 0.000 claims description 50
- 239000006260 foam Substances 0.000 claims description 38
- 239000002184 metal Substances 0.000 claims description 13
- 230000001413 cellular effect Effects 0.000 claims description 11
- ODGAOXROABLFNM-UHFFFAOYSA-N polynoxylin Chemical compound O=C.NC(N)=O ODGAOXROABLFNM-UHFFFAOYSA-N 0.000 claims description 10
- 239000004033 plastic Substances 0.000 claims description 9
- 229920003023 plastic Polymers 0.000 claims description 9
- 230000029058 respiratory gaseous exchange Effects 0.000 claims description 9
- 229920001807 Urea-formaldehyde Polymers 0.000 claims description 7
- 239000011093 chipboard Substances 0.000 claims description 7
- 229910001209 Low-carbon steel Inorganic materials 0.000 claims description 6
- 239000000123 paper Substances 0.000 claims description 4
- 229920002635 polyurethane Polymers 0.000 claims description 4
- 239000004814 polyurethane Substances 0.000 claims description 4
- 239000004639 urea-formaldehyde foam Substances 0.000 claims description 4
- 229920005830 Polyurethane Foam Polymers 0.000 claims description 3
- 238000005253 cladding Methods 0.000 claims description 3
- 239000011496 polyurethane foam Substances 0.000 claims description 3
- 238000012986 modification Methods 0.000 claims description 2
- 230000004048 modification Effects 0.000 claims description 2
- 239000003973 paint Substances 0.000 claims description 2
- 238000005192 partition Methods 0.000 description 7
- 238000009413 insulation Methods 0.000 description 4
- 229920002522 Wood fibre Polymers 0.000 description 1
- 238000009435 building construction Methods 0.000 description 1
- 239000011491 glass wool Substances 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 239000011810 insulating material Substances 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 238000009423 ventilation Methods 0.000 description 1
Classifications
-
- 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
- E04B1/7604—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 fillings for cavity walls
-
- 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
- E04B2/84—Walls made by casting, pouring, or tamping in situ
- E04B2/86—Walls made by casting, pouring, or tamping in situ made in permanent forms
- E04B2/8647—Walls made by casting, pouring, or tamping in situ made in permanent forms with ties going through the forms
Landscapes
- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Physics & Mathematics (AREA)
- Electromagnetism (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Acoustics & Sound (AREA)
- Building Environments (AREA)
Description
(54) IMPROVEMENTS IN AND RELATING TO IN SITU
STRUCTURAL WALL CONSTRUCTION
(71) We, HERTFORDSI-IIRE COUNTY
COUNCIL, a Local Authority of County
Hall, Hertford, Hertfordshire, SG13 8DD, do hereby declare the invention for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement:
The present invention relates to m situ structural wall construction and provides a joint-free structural wall system suitable for external use and having good thermal insulation properties. The term " structural wall" is used in this Specification (including the Claims) to mean a load-bearing wall.
It is known to construct separating or partition walls for buildings by screwing plasterboard to the vertical sides of a stud frame and, optionally, to provide sound insulating material in the cavity thus formed. In particular so-called " Gyproc jumbo metal stud separating walls" have been used for a number of years in both industrial building systems and traditional building constructions. " Gyproc" is a
Registered Trade Mark. Said Gyproc walls have a metal stud frame in which galvanised, rolled, mild steel horizontal channels are braced by galvanised rolled, mild steel studs of channel section extending vertically at longitudinally spaced intervals along the channels.
One or more Gyproc wall boards (plasterboards) are screwed vertically to the outside of each side of the frame and, optionally, a glass-wool blanket is hung in the resultant cavity within the frame. These and other stud frame cavity walls facilitate simple and relatively inexpensive partition wall construction but are non-load bearing. It is an object of this invention to employ similar wall building techniques for structural (i.e. load-bearing) walls.
It is also known to fill cavities of structural cavity walls of buildings with rigid (i.e. substantially non-flexible cellular plastics foam, especially polyurethanes or ureaformaldehydes, in order to increase the thermal insulation provided by said walls.
Further, it is known to restore the structural stability of structural cavity walls in
which wall ties have corroded by filling
the cavities with high density rigid cellular
platics foams of, for example, 30 to 40
kg/m3 density. In both of these applica
tions, the rigid foam is formed in situ in
the cavity.
The Inventors have now found that an
unexpected degree or structural stability
can be imparted to stud frame cavity walls
by filling the cavities of said walls with an
in situ formed rigid cellular plastics foam
which can even be of relatively low density of, for example, 8 to 10 kgs/m3. In this
manner structural walls can now be con
structed in similar manner to partition walls
thereby facilitating relatively inexpensive
construction by relatively unskilled labour.
According to the present invention there
fore, there is provided a method of con
structing ie situ a structural wall (as here
inbefore defined) which comprises con
structing a stud frame, attaching wallboards
to the respective sides of the frame to
form a cavity wall, and filling the cavity
thus formed with a rigid cellular plastics
foam formed in situ. By "wallboard' as
used in this Specification we mean a rigid board suitable for use as, or as a leaf of, a partition wall.
The invention provides also a method
of constructing a building having structural
walls in which some at ]east of said walls are constructed by attaching waliboards to the respective sides of a stud frame to form a cavity wall, and filling the cavity thus formed with a rigid cellular plastics foam formed in situ.
The stud frame comprises horizontally spaced studs connected together usually by horizontally extending tracks. In this connection, it will be appreciated that the word "stud" is a term of art for vertical bracing members for use in a hollow partition framework. Preferably, the frame is constructed of lightweight metal members, especially of channel-shaped cross-section and suitably of galvanised rolled mild steel.
Presently preferred frames are formed of
Gyproc jumbo metal studs spaced at 600 mm intervals between vertically spaced horizontally extending Gyproc metal channels. Said studs are 146 mm width and the channels are 148 mm width with the studs cut to fit from web to web in the channels and twisted into position. The studs and channels are formed of 0.6 mm thick galvanised rolled mild steel.
The wallboards for,attachment to the stud frame can be any of those used in the construction of partition walls or suitable for such use and include plasterboard, especially Gyproc wallboard, and compressed wood fibre or particle board, especially chip-board. When the structural wall is to be an external wall, the wallboard on the external (relative to the building) side of the frame should be of external quality, i.e. waterproof and weather resistant. External quality chipboard is particularly suitable for said latter purpose.
If a breathering foam is employed, e.g. a urea-formaldehyde, the wallboard(s) on at least one side of the stud frame will be moisture permeable to allow the foam to breath. Usually, said side will be the exterior of an external wall.
The wall boards will be attached to the respective outersides of the frame in order to form therewith a cavity wall. Usually they will be attached by means of screws although other suitable means of attachment such as bolts could be employed. If desired two or more wallboards can be attached in superimposed relationship at a respective side of the frame in order to increase the rigidity of the cavity wall structure and/or increase the sound and/or thermal insulation thereof. Preferably, the wall board(s) at the respective sides of the frame have a thickness (combined in the case of two or more boards on one side) in the range 12 to 40 mm, especially 15 to 30 mm, and the total cavity wall thickness is in the range 150 to 250 mm, especially about 200 mm.
The cavity in the cavity wall formed from the stud frame and wallboards is filled with foam which is formed in situ.
The foam is a rigid cellular plastics foam, preferably of closed cell structure, and will be selected to have the rigidity and stability required for the required purpose. Suitable foams are polyurethanes and ureaaldehydes, especially urea-formaldehyde.
An example of polyurethane foam is that of a density of 32 to 40 kgs/m3 and available from Imperial Chemical Industries
Limited under the Trade Mark " Tyfoam ".
A presently particularly preferred foam is a urea-formaldehyde foam of density of 8 to 10 kgs/m3 and available from Cape Insulation Services Limited under the Trade
Mark "Ufoam Plus".
The foam imparts unexpectd load-bearing properties to the cavity wall construction and further seals the wallboards to the stud frame. Thus by use of the method of this invention, it is possible to construct structural and, especially, external walls in a joint-free manner at relatively low cost, relatively quickly and without the highly skilled labour usually required for the construction of structural walls by conventional building techniques. It is also posisble to use the cheaper breathing foams for this purpose, provided that the wallboards on at least one side of the stud frame are moisture vapour permeable or other arranegments are made to allow the foam to breath.The structural wall produced by the method of the invention is of particular use as an external wall for buildings having controlled air handling systems (i.e. combined heating and ventilation) because the walls readily can be made impermeable to air.
The outer side surfaces of the filled structural walls constructed in accordance with the invention can be covered in known manner with for example decorative finishes or, in the case of external surfaces, with cladding.
The following is a description, by way of example only and with reference to the accompanying drawing, of a method of constructing a structural wall in accordance with a preferred embodiment of the present invention. The single figure of the drawing is a perspective cut-away view of a structural wall constructed by the said method.
Referring to the drawing, a structural wall generally indicated at 1 has a stud frame formed of upright Gyproc jumbo metal studs 2 extending between horizontal tracks of Gyproc metal channel 3. The nature of the Gyproc frame members and their assembly into a stud frame has been described hereinbefore. A single sheet 4 of 18 mm thick external quality moisture vapour permeable chipboard is screwed onto the outside of one side of the frame.
On the outside of the other side of the frame there are attached a 12 mm vapour check plasterboard innerlining 5 and a 9.5 mm taper edge plasterboard outerlining 6.
In this manner a cavity wall is constructed using techniques which are conventional in the construction of non-load bearing separating or partition walls. A ureaformaldehyde foam composition ("Ufoam Plus") is pumped into the cavity between each pair of studs by means of access holes provided, for example, in the face boards to fill the cavity. After gelling, the foam provides in the cavity a rigid cellular foam having a density of 8 to 10 kg/m3 which imparts an unexpectedly high degree of structural stability to the fiinshed wall 1 enabling it to be used for load-bearing purposes.
When the wall 1 is to be used for external walling, as is intended, the chipboard 4 is covered with breathing paper 7 and cladding 8, e.g. vertical tiling as shown in the Figure. The plasterboard 6 is covered with a decorative finish, for example paint or wallpaper.
The wall will be located relative to adjacent walls and ceilings by securing the respective track 3 or stud 2 thereto in manner known per se.
The structure of wall 1 is particularly suitable for use in buildings having controlled air handling systems because the wall is air-impermeable. However, the chipboard 4 and breathing paper 7 are moisture permeable and thereby facilitate the use of the relatively cheap breathing foam, urea-formaldehyde. The vapour check plasterboard innerlining 5 prevents moisture vapour from the foam passing through the outerlining 6.
It will be appreciated that the invention is not restricted to the particular details described above but that numerous modifications and variations can be made without departing from the scope of the invention as defined in the following Claims.
WHAT WE CLAIM IS:- 1. A method of constructing in situ a structural wall (as hereinbefore defined) which comprises constructing a stud frame, attaching wallboards to the respective sides of the frame to form a cavity wall, and filling the cavity thus formed with a rigid cellular plastics foam formed in sftu.
2. A method of constructing a building having structural walls (as hereinbefore defined) in which some at least of said walls are constructed in stu ii by attaching wall- boards to the respective sides of a stud frame to form a cavity wall, and filling the cavity thus formed with a rigid cellular plastics foam formed in situ.
3. A method as claimed in Claim 1 or
Claim 2 wherein the frame is constructed for lightweight metal members.
4. A method as claimed in Claim 3 wherein the metal members are of channelshaped cross-section.
5. A method as claimed in Claim 3 or Claim 4 wherein the metal members are formed of galvanised rolled mild steel.
6. A method as claimed in any one of the preceding Claims wherein the wallboard(s) at the respective sides of the frame have a thickness in the range 12 to 40 mm.
7. A method as claimed in Claim 6 wherein the said wallboard(s) thickness is 15 to 30 mm.
8. A method as claimed in any one of the preceding Claims wherein the total cavity wall thickness is in the range 150 to 250 mm.
9. A method as claimed in Claim 8 wherein the total cavity wall thickness is about 200 mm.
10. A method as claimed in any one of the preceding Claims wherein the foam is of a closed cell structure.
11. A method as claimed in any one of the preceding Claims wherein the foam is a polyurethane.
12. A method as claimed in Claim 11 wherein the polyurethane foam has a density of 32 to 40 kgs/m3.
13. A method as claimed in any one of
Claims 1 to 10 wherein the foam is a ureaaldehyde.
14. A method as claimed in Claim 13 wherein the urea-aldehyde is a ureaformaldehyde.
15. A method as claimed in Claim 14 wherein the urea-formaldehyde foam has a density of 8 to 10 kg/m3.
16. A method as claimed in any one of the preceding Claims wherein the foam is a breathing foam and the wallboard(s) on at least one side of the stud frame is moisture vapour permeable to allow the foam to breath.
17. A method as claimed in Claim 16 wherein the exterior wallboard(s) of the structural wall are moisture-vapour permeable but the interior wallboards are impermeable to moisture vapour.
18. A method as claimed in Claim 1 and substantially as hereinbefore described with reference to the accompanying drawing.
19. A structural wall whenever constructed by a method as claimed in any one of Claims 1 and 2 to 17.
20. A building whenever constructed by a method as claimed in any one of Claims 2 to 17.
**WARNING** end of DESC field may overlap start of CLMS **.
Claims (20)
1. A method of constructing in situ a structural wall (as hereinbefore defined) which comprises constructing a stud frame, attaching wallboards to the respective sides of the frame to form a cavity wall, and filling the cavity thus formed with a rigid cellular plastics foam formed in sftu.
2. A method of constructing a building having structural walls (as hereinbefore defined) in which some at least of said walls are constructed in stu ii by attaching wall- boards to the respective sides of a stud frame to form a cavity wall, and filling the cavity thus formed with a rigid cellular plastics foam formed in situ.
3. A method as claimed in Claim 1 or
Claim 2 wherein the frame is constructed for lightweight metal members.
4. A method as claimed in Claim 3 wherein the metal members are of channelshaped cross-section.
5. A method as claimed in Claim 3 or Claim 4 wherein the metal members are formed of galvanised rolled mild steel.
6. A method as claimed in any one of the preceding Claims wherein the wallboard(s) at the respective sides of the frame have a thickness in the range 12 to 40 mm.
7. A method as claimed in Claim 6 wherein the said wallboard(s) thickness is 15 to 30 mm.
8. A method as claimed in any one of the preceding Claims wherein the total cavity wall thickness is in the range 150 to 250 mm.
9. A method as claimed in Claim 8 wherein the total cavity wall thickness is about 200 mm.
10. A method as claimed in any one of the preceding Claims wherein the foam is of a closed cell structure.
11. A method as claimed in any one of the preceding Claims wherein the foam is a polyurethane.
12. A method as claimed in Claim 11 wherein the polyurethane foam has a density of 32 to 40 kgs/m3.
13. A method as claimed in any one of
Claims 1 to 10 wherein the foam is a ureaaldehyde.
14. A method as claimed in Claim 13 wherein the urea-aldehyde is a ureaformaldehyde.
15. A method as claimed in Claim 14 wherein the urea-formaldehyde foam has a density of 8 to 10 kg/m3.
16. A method as claimed in any one of the preceding Claims wherein the foam is a breathing foam and the wallboard(s) on at least one side of the stud frame is moisture vapour permeable to allow the foam to breath.
17. A method as claimed in Claim 16 wherein the exterior wallboard(s) of the structural wall are moisture-vapour permeable but the interior wallboards are impermeable to moisture vapour.
18. A method as claimed in Claim 1 and substantially as hereinbefore described with reference to the accompanying drawing.
19. A structural wall whenever constructed by a method as claimed in any one of Claims 1 and 2 to 17.
20. A building whenever constructed by a method as claimed in any one of Claims 2 to 17.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB1087077A GB1599033A (en) | 1978-03-15 | 1978-03-15 | In situ structural wall construction |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB1087077A GB1599033A (en) | 1978-03-15 | 1978-03-15 | In situ structural wall construction |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| GB1599033A true GB1599033A (en) | 1981-09-30 |
Family
ID=9975838
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB1087077A Expired GB1599033A (en) | 1978-03-15 | 1978-03-15 | In situ structural wall construction |
Country Status (1)
| Country | Link |
|---|---|
| GB (1) | GB1599033A (en) |
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB2136042A (en) * | 1983-03-08 | 1984-09-12 | Mctay Construction Limited | Wall repair system |
| US5906081A (en) * | 1995-05-04 | 1999-05-25 | Ma-Rakennus J. Mantyla Ky | Wall construction and method of manufacturing a wall construction |
| NL1008951C2 (en) * | 1998-04-21 | 1999-10-22 | Jan Hendrik De Wit | Internal wall construction with plaster filled cavity for internal walls of dwellings uses thin outer plasterboard panels attached to upper and lower support profiles |
| WO2002064914A1 (en) * | 2001-02-12 | 2002-08-22 | Seismic Rehab, Llc | Reinforced wall structures and methods |
-
1978
- 1978-03-15 GB GB1087077A patent/GB1599033A/en not_active Expired
Cited By (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB2136042A (en) * | 1983-03-08 | 1984-09-12 | Mctay Construction Limited | Wall repair system |
| US5906081A (en) * | 1995-05-04 | 1999-05-25 | Ma-Rakennus J. Mantyla Ky | Wall construction and method of manufacturing a wall construction |
| NL1008951C2 (en) * | 1998-04-21 | 1999-10-22 | Jan Hendrik De Wit | Internal wall construction with plaster filled cavity for internal walls of dwellings uses thin outer plasterboard panels attached to upper and lower support profiles |
| WO2002064914A1 (en) * | 2001-02-12 | 2002-08-22 | Seismic Rehab, Llc | Reinforced wall structures and methods |
| US6662516B2 (en) | 2001-02-12 | 2003-12-16 | Seismic Rehab, Llc | Reinforced wall structures and methods |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| PS | Patent sealed | ||
| PCNP | Patent ceased through non-payment of renewal fee |