GB2350626A

GB2350626A - Insulated cladding

Info

Publication number: GB2350626A
Application number: GB9912009A
Authority: GB
Inventors: Donald Macpherson Dallas
Original assignee: Individual
Current assignee: Individual
Priority date: 1999-05-25
Filing date: 1999-05-25
Publication date: 2000-12-06
Also published as: GB9912009D0

Abstract

A prefabricated composite insulated panel comprises an external sheet 10 (which may be corrugated), insulation 21 and inner sheet 11, an upright support member 13 surrounded by load bearing sleeve 14, and a bush 17 for the receipt of a fixing 18,19, which fixes the panel to a structural member.

Description

1 2350626 A CLADDING SYSTEM The invention relates to the insulated

built-up/composite metal cladding system as used in the external protection of roofs and walls. This invention will demonstrate a major improvement in the assembly and fixing of built up/composite metal cladding systems, suitable for roofs and walls in industrial, retail, and commercial buildings.

The UK construction industry is under continual pressure to raise productivity, reduce costs and improve quality. These factors and the ability to deliver what the client demands, at the right time, to the appropriate quality and at an affordable cost are the key drivers for change in the industry.

Insulated composite cladding systems have been utilised for some time. Two principle approaches currently exist: - 1. Prefabricated (composite) generally plastic insulant. 2. Site assembled (built up) - generally mineral insulant.

Deficiencies exist in both approaches and these are well documented. However, the major concerns are: - 1. Prefabricated (Composite panel) The composite panel is a pre-fabricated product, which is produced in a factory environment, and sent to site ready to be installed, the insulation is normally polyurethane. There are distinct advantages to this type of prefabrication, however:

0 Polyurethane age with time. Trials have shown that over ten years, thermal conductivity increases by approximately 50%, greatly reducing the efficacy of the product.

Severe fires have been reported in constructions containing foamed composite panels. The polyurethane insulant used in these systems is combustible, and gives off a toxic gas when burnt. There have been a number of serious fires in UK factories and retail buildings where the existence of polyurethane panels have been found to expedite the fire.

0 There are other problems associated with polyurethane panels such as durability, and being environmentally unfriendly. However these problems only highlight the reasons that make it worthwhile to investigate, innovate and improve the "builtUP 99 system.

2 2. The site assembled system (built-up system) The built-up system is delivered to site as individual components, these components are assembled on site. The components require a structure to which they can be assembled, this can be a steel portal frame, which is erected on site. This allows the components to be assembled into a built- up system. When used on a roof application they are assembled as described below, (A wall application will be similar).

Fixing the inner sheet (the liner), to the steel portal frame is viewed as "fragile" and raises serious "Health and Safety" issues during installation.

The layout of the insulation, normally a lightweight mineral wool of approximately 24kg\rn3 is fitted in all types of atmospheric conditions, this raises buildability and quality issues.

Fitting the spacer bar (this supports the top sheet and prevents the insulation from being compressed, which would reduce its insulating properties) involves drilling through the liner into the purlin, and raises both health and safety and quality issues.

The top sheet (the weather protection sheet) is laid in position and drilled onto the spacer bar, causing very hot metal cuttings to be spread about the finished roof, raising additional quality issues.

The finished product can be a good product providing all fixings are in place and all insulation is installed correctly. The major problems are the inefficient method of assembly, the lack of good quality vapour control, and the quality and safety issues that are raised in the assembly and installation process.

The objective of this invention is to provide an assembled composite panel to site, where it can be quickly fixed to standard structural members, using standard fixings and components at normal centres. The system offers rapid completion times of a quality-assembled product, which can be supplied in 1, 2, or 3 metre wide modules (wider if transportation to site was available) and requiring no further site work.

Accordingly this invention provides a built-up system that does not require a structure to become an assembly. The key to this invention is the design and the bringing of various components together using the clamping arrangement described as items 13 to 17 in the detailed description. The advantages of factory assembly, with tight quality control over the full assembly process, coupled with the installation of a factory fitted vapour control barrier, and the lightweight and fire properties of a mineral insulant or alternatives are encompassed. A finished product arriving on site, which can be quickly fixed to standard structural members using standard fixings and components at normal centres. The system offers rapid completion times of a quality-assembled product, which requires no further site work.

3 A preferred embodiment of the invention will now be described by way of example with reference to the accompanying drawings in which: - Drawing 113 shows figure 1 in perspective a general arrangement of the assembled components.

Drawing 2/3 shows figure 2 an alternative fixing method of the assembled components.

Drawing 3/3 shows figure 2 turned at 180 degrees to enable a view of a 1 metre module and to view items 20 and 26, and details 23, 24, 25.

Referring to drawings number 1 and 3. The Factory assembled built-up system comprises of an external cladding sheet (10), with provision for a seal (24), and a snaphook side lap (25). Insulating material (21). An internal cladding sheet (11), with provision for a seal (23), and a spacer bar (12), designed to minimise localised insulation compression, all in the form of a sandwich or composite panel. They are secured together to become a factory assembled built-up composite system by means of a clamping device which is made up of the following non-standard items. An upright support bar (13), which is fitted through the internal cladding sheet 11. A compression and load-bearing sleeve (14), which is fitted over 13. A thermal break (15), designed to fit 13 and 14. A transportation sleeve (16), and a transportation support bar (26). The ends of the assembly can be fitted with end filler pieces (22), The sides of the assembly can be fitted with side tape (20). This creates a vapour control layer and is used for restricting water vapour flow into the construction. A standard fixing (18), and washer (19), is used to secure the assembly and to fix the assembly to standard structural members at site. When the assembly arrives on site the transportation sleeve is removed and the standard fixing is drilled into the structural members at site.

Drawing numbers 2 and 3, refers to an alternative method of using all the same components with the exception of item (16), which is replaced by an interference bush item (17), and item 13 is modified to become iteml3A. All components are assembled in the same method as described above with the exception of item 17, which is fixed into item 13A. The standard fixing (18) and washer (19), are now only required to fix the assembly to the structural members at site.

4

Claims

1. Accordingly this invention provides a built-up system that does not require a structure to become an assembly. The key to this invention is the design and the bringing of various components together using the clamping arrangement described as items 13 to 17 in the detailed description. The advantages of factory assembly, with tight quality control over the full assembly process, coupled with the installation of a factory fitted vapour control barrier, and the lightweight and fire proper-ties of a mineral insulant or alternatives are encompassed. A finished product arriving on site, which can be quickly fixed to standard structural members using standard fixings and components at normal centres. The system offers rapid completion times of a quality-assembled product, which requires no further site work.

2. A built-up metal cladding system as claimed in claim I wherein a special support bar 13 or 13A or similar is incorporated to assist in the pre-assembly.

3. A built-up metal cladding system as claimed in I or 2 wherein a compression and load-bearing sleeve 14 or similar is provided to support and assist in the preassembly and assembly.

4. A built-up metal cladding system as claimed in I to 3 wherein a thermal break 15 or similar is incorporated to reduce thermal transfer

5. A built-up metal cladding system as claimed in I to 4 wherein a transportation sleeve 16 or an interference bush 17 or similar is incorporated to assist in the preassembly of the system

6. A built-up metal cladding system as claimed in I to 5 wherein standard fixings are used to assist in the pre-assembly of the system.

7. A built-up metal cladding system as claimed in 1 to 6 wherein a standard internal cladding sheet or a specially designed internal cladding sheet I I or similar is incorporated to assist in the assembly of the system

8. A built-up metal cladding system as claimed in 1 to 7 wherein the side laps can incorporate side tape 20 or similar to assist in producing a vapour control layer and is used for restricting water vapour flow into the construction.

9. A built-up metal cladding system as claimed in I to 8 wherein the end laps can be sealed using a plastic or mineral filler piece 22 or similar to assist in producing a vapour control layer and is used for restricting water vapour flow into the construction.

10. A built-up metal cladding system as claimed in 1 to 9 wherein the assembled modules can be manufactured in variable widths limited only by available modes of transport to site.