GB2462912A

GB2462912A - Prefabricated timber building system

Info

Publication number: GB2462912A
Application number: GB0914677A
Authority: GB
Inventors: Gary Treanor
Original assignee: Kingspan Research and Developments Ltd
Current assignee: Kingspan Research and Developments Ltd
Priority date: 2008-08-29
Filing date: 2009-08-21
Publication date: 2010-03-03
Anticipated expiration: 2029-08-21
Also published as: IES20090651A2; GB2462912B; GB0914677D0; IE20090638A1; IE86329B1; WO2010023649A1

Abstract

The prefabricated timber building system comprises a support layer 2 comprising timber frame studs 5 with insulation 6 in between, an insulation foam board 3 overlying the support layer and a membrane 4 sandwiched between the support and insulation layers to provide a substantially airtight system. The foam board may have metallic foil material on one or both faces and may comprise a polyisocyanurate or phenolic material. The foam board may be fixed to the timber studs by battens 20 which are placed over the board and secured to the frame studs. An inner facing 30, preferably of plasterboard, may be secured to the battens. The system may include an outer facing 40, which may comprise orientated strand board, and an exterior membrane. The insulation between the studs is preferably a fibreglass material.

Description

INTELLECTUAL

. .... PROPERTY OFFICE Application No. GB09 14677.0 RTM Date:12 November 2009 The following terms are registered trademarks and should be read as such wherever they occur in this document: Tyvek Kooltherm Intellectual Property Office is an operating name of the Patent Office www.ipo.gov.uk "A timber frame building system"

Introduction

With increasing energy costs there is a need for improving the insulation of buildings.

This invention is directed towards providing an improved timber frame building system which will address this issue.

Statements of Invention

According to the invention there is provided a prefabricated timber frame building system comprising:-a support layer comprising a plurality of timber frame studs with insulation between the studs; an insulation foam board overlying the support layer; and S...

a membrane sandwiched between the support layer and the insulation layer to *...

*. provide a substantially air-tight system. * S. * . .

* The insulation foam board may have a facing on one or both faces thereof. The facing may be of a metallic foil material. * S. * *-I

*. .L3 *:*. In one embodiment the insulation foam is of a polyisocyanurate material.

In another embodiment the insulation foam is of a phenolic material.

The system preferably also comprises fixing means for fixing the insulation foam board to the timber studs.

The fixing means may comprise a plurality of battens placed over the insulation foam board and fixings for fixing the battens to the support layer studs.

In one embodiment the battens are spaced-apart to define together with a facing voids for services.

In one embodiment the insulation between the studs comprises a fiberglass material.

Brief Description of the Drawings

The invention will be more clearly understood from the following description thereof given by way of example only, in which:-Fig. I is an isometric, partially cut-away view of a timber frame building system of the invention; Fig. 2 is a side cross sectional view of the system of Fig. 1; I...

Fig. 3 is an exploded cross sectional view of a building frame system with one thickness of insulation; : Fig. 4 is a cross sectional view of the system of Fig. 3 assembled; *..2 *.. Fig. 5 is an exploded cross sectional view of a building frame system with another thickness of insulation; Fig. 6 is a cross sectional view of the system of Fig. 5 assembled; Fig. 7 is an isometric, partially cut-away view of part of a building constructed using the system of Figs. I to 6; Fig. 8 is another isometric view of the building part of Fig. 7; Fig. 9 is a cross sectional view of a sole plate and window sill detail of a building; Fig. 10 is an enlarged view of an alternative sole plate and rising wall detail of Fig. 9; Fig. 11 is an enlarged view of a detail of Fig. 9; Figs. 12 to 15 illustrate alternative soleplate fixing details; Fig. 16 is a partially exploded cross sectional view of a window head detail of a building; Fig. 17 is an assembled view similar to Fig. 16; Fig. 18 is a partially exploded cross sectional view of a wall to floor intersection detail of a building; Fig. 19 is an assembled view similar to Fig. 18; Fig. 20 is a partially exploded cross sectional view of a wall to truss eaves detail of a building; * ** * * * * S. Fig. 21 is an assembled view similar to Fig. 20; * *.

Fig. 22 is a partially exploded cross sectional view of a sloping rafter eaves detail of a * * building; Fig. 23 is an assembled view similar to Fig. 22; Fig. 24 is a partially exploded cross sectional view of another sloping rafter eaves detail of a building; Fig. 25 is an assembled view similar to Fig. 24;

I

Fig. 26 is a cross sectional view of air tight details in an attic truss of a building; Fig. 27 is a cross sectional view on the section line in Fig. 26; Fig. 28 is a cross sectional view of a gable detail with a flat ceiling; Fig. 29 is a cross sectional view of a gable detail with a vaulted ceiling; Fig. 30 is an exploded view of part of the detail of Fig. 29; Fig. 31 is a cross sectional view of a gable parapet detail to a flat ceiling; Fig. 32 is a cross sectional view of a gable parapet detail to a vaulted ceiling; Fig. 33 is a partially exploded cross sectional view of a wall to wall corner detail; Fig. 34 is an assembled view similar to Fig. 33; Fig. 35 is a partially exploded cross sectional view of a wall to wall mid detail; * .;Q Fig. 36 is an assembled view similar to Fig. 35; * ** ** S * ** Fig. 37 is a partially exploded cross sectional view of a wall to exterior wall detail; * ** Fig. 38 is an assembled view similar to Fig. 37; Fig. 39 is a partially exploded cross sectional view of an internal wall to external walls joint detail; Fig. 40 is an assembled view similar to Fig. 39; Fig. 41 is a partially exploded cross sectional view of an internal corner in an external wall detail; Fig. 42 is an assembled view similar to Fig. 41; Fig. 43 and 44 are cross sectional views of an external wall ope detail (plan); Figs. 45 and 46 are cross sectional views of a dormer wall detail; Figs. 47 and 48 are cross sectional views of a detail at an internal wall meeting an internal corner in an external wall; Figs. 49 and 50 are cross sectional views of a corner detail with a steel post; Figs. 51 and 52 are cross sectional views of a corner detail at an opening; Fig. 53 is a cross sectional view of a window part of a building; and Figs. 54 to 57 are perspective views illustrating the detail of the system in the region of an opening. * * *

: : ;Q: Detailed Description ***I

* *. Referring to the drawings there is illustrated a prefabricated timber frame building system 1 comprising a support layer 2, an insulation foam board 3 and a membrane 4 sandwiched between the support layer 2 and the insulation board 3. * * *.* I

The support layer 2 comprises a plurality of timber studs 5 with insulation which in this case is in the form of fiberglass 6 between the studs 5. The fiberglass is typically 100mm or 150mm thick.

The membrane 4 is of a material to provide vapour controllairtightness. The membrane 4 provides a continuous barrier against air leakage and water vapour transfer. One such membrane is Du Pont Tyvek SD2.

The insulation foam board 3 preferably has a facing, especially a metallic foil facing 10 on at least one and preferably both faces. The foam board 3 may for example be a suitable thickness such as 50 mm of Kooltherm or TW55 insulation board from Kingspan. The insulation has flat faces and may for example be of polyisocyanurate or phenolic foam. Phenolic foam board has enhanced compressive strength and fire resistance. The joints between adjacent boards are covered with a suitable jointing barrier tape.

The system is substantially air tight and ensures that cold external air does not infiltrate into the building interior.

The foam board 3 overlies the studs 5 to reduce thermal losses through the studs 5.The flat face of the board 3 that engages with the membrane 4 ensures that the membrane 4 is held tightly in place, on fixing. The foil facing on the board face that engages with the membrane 4 also enhances air tightness and insulation.

Fixing means for fixing the insulation board 3and membrane 4 is in this case provided by battens such as 35 mm x 44 mm timber battens which are aligned with and are fixed by nails or the like to the studs 5 through the insulation board 3. The nails are preferably hot fix nails to avoid damage to the membrane 4. Because the nails travel through a number of layers the insulation * * and air tightness properties are not compromised by the holes made by the fixings. *..*

* The battens 20 are spaced-apart and provide a void 21 for services such as electrical wiring and or water pipes behind a facing 30 such as plaster board. The facing 30 may have sockets 32 and the like. * ** * S *

*5S 25 ** S S. e.: The timber building frame system may have any desired outer facing such as a board 40 which may be an oriented strand board (OSB). There is also preferably an outer breather membrane 41.

Brickwork 50 may, for example, be provided on the external side of the building.

The timber frame building system has excellent insulation properties. For an 89 mm stud frame (175 mm) system using Kooltherm insulation board from Kingspan a U value of 0.18 W/m2K has been achieved. For a 140 mm stud frame (225 mm) a U value of 0.15 M/m2K has been achieved. The tests were carried out according to BS EN ISO 6946. The product also passed a condensation risk analysis according to BS 5250.

The system also has good fire resistant properties. With a facing of one layer of 12.5 mm thickness of plasterboard the fire resistance was in excess of 30 minutes. With a facing of two layers of 12.5 mm thickness of plasterboard the fire resistance was in excess of 60 minutes. The fire test was carried out in accordance with the reasons of BS 476 part 21: 1987.

Referring to Figs. 7 and 8 part of a building incorporating the system of Figs. ito 6 is illustrated.

Element 50 indicates finished ground level. There is foundation 51 on which inner and outer leaves 52, 53 of a blockwork rising wall are built. A floor damp proof membrane 54 is mounted on the inner leaf 52 and a sole plate 55 with angle brackets 56 on top of the damp proof membrane to support the support layer 2 of the timber frame. Anchor straps 57 are fixed to the studs 5 and built into an external brick or block cladding 50. Wall ties 59 are provided. To accommodate fixings for radiator brackets and the like the vertical service battens 20 may be cut-away to accommodate horizontal supports or noggins 45.

Figs. 9 to 11 illustrate a sole plate and window sill detail of a typical building. Referring particularly to Fig. 11 it will be noted that the barrier membrane 4 is tracked to the face of the batten 20 to ensure maintenance of the barrier at the joint.

* Various alternative soleplate fixing details are illustrated in Figs. 12 to 15.

* Referring to Figs. 16 and 17 there is illustrated a window head detail of a building. It will be noted that the internal vapour barrier layer 4 is lapped over the window rail to maintain the * * barrier at the joint.

Figs. 18 and 19 illustrate a wall to floor intersection of a building. It will be noted that in the case of the upper portion of the wall the barrier membrane 4 is lapped under the lowermost batten 20 and may be sealed to the floor on site. In the case of the lower portion of the wall the barrier membrane 4 is oversized to allow it to be turned over a floor panel on site. The upper and lower barrier membranes 4 are sealed at the joint therebetween, for example using mastic or the like.

Referring to Figs. 20 and 21 there is illustrated a wall to truss eaves detail of a building. It will be noted that the barrier membrane 4 is lapped over the uppermost batten 20 and may be sealed to a ceiling barrier 46, on site.

Referring to Figs. 22 and 23 there is illustrated a sloping rafter eaves detail of a building. It will be noted that the barrier membrane is lapped over the uppermost batten 20 and is sealed to a ceiling barrier membrane 47 on site.

Figs. 24 and 25 illustrate a stud wall with sloping rafter eaves detail with insulated plasterboard to ceiling. It will be noted that the barrier membrane 4 is again lapped over the uppermost batten and sealed to a ceiling barrier membrane 47 on site.

Figs. 26 and 27 illustrate air tight details in an attic truss of a building.

Fig. 28 illustrates a gable detail with a flat ceiling.

Figs. 29 and 30 illustrate a gable detail with a vaulted ceiling.

*:::: Referring to Fig. 31 there is illustrated a gable parapet detail to a flat ceiling. * ,*

Fig. 32 illustrates a gable parapet detail to a vaulted ceiling. * ** * * * * **

Figs. 33 and 34 illustrate a wall to wall corner detail.

Figs. 35 and 36 illustrate a wall to wall mid detail.

Referring to Figs. 37 and 38 there is illustrated a wall to exterior wall detail.

Figs. 39 and 40 illustrate a joint detail between an internal wall and external walls.

Figs. 41 and 42 illustrate joint detail between an internal corner and an external wall.

Figs. 43 and 44 illustrate an external wall open detail.

Figs. 45 and 46 illustrate a dormer wall detail.

Figs. 47 and 48 illustrate a detail at an internal wall meeting an internal corner in an external wall.

Figs. 49 and 50 illustrate a corner detail with a steel post.

Figs. 51 and 52 illustrate a corner detail at an opening.

Referring to Figs. 53 to 57 around an opening such as for a window 60 the internal barrier is lapped over the window rail at 61 and sealed, for example with mastic, to the underside of the window. Figs. 54 to 57 illustrate the cutting of the internal barrier layer 4 at a window or door opening and folding out into the opening 62. A suitable barrier tape is used to ensure that a continuous barrier is maintained. Fig. 57 shows sections 65 of barrier membrane being fitted to cills, head and jamb, in are continuous piece. All corners on all windows are taped with several layers of barrier tape.

The invention is not limited to the embodiments hereinbefore described which may be varied in detail. * * * Is I. * * I. * S. * e S S5S * I. S * *5 S.

Claims

-10 -Claims 1. A prefabricated timber frame building system comprising:-a support layer comprising a plurality of timber frame studs with insulation between the studs; an insulation foam board overlying the support layer; and a membrane sandwiched between the support layer and the insulation layer to provide a substantially air-tight system.
2. A timber frame building system as claimed in claim 1 wherein the insulation foam board has a facing on one or both faces thereof.
3. A timber frame building system as claimed in claim 2 wherein the facing is of a metallic foil material.
4. A timber building system as claimed in any of claims 1 to 3 wherein the insulation foam is of a polyisocyanurate material.
5. A timber frame building system as claimed in any of claims Ito 3 wherein the insulation foam is ofaphenolic material. s. * d *

*
6. A timber frame building system as claimed in any of claims 1 to 5 comprising fixing means for fixing the insulation foam board to the timber studs. * *. * S S **S S

*..
7. A timber frame building system as claimed in claim 6 wherein the fixing means comprises a plurality of battens placed over the insulation foam board.
8. A timber frame building system as claimed in claim 7 wherein the fixing means comprises fixings for fixing the battens to the support layer studs.

-11 -
9. A timber frame building system as claimed in claim 7 or 8 wherein the battens are spaced-apart to define voids for services.
10. A timber frame building system as claimed in claim 9 comprising an inner facing fixed to the support battens.
11. A timber frame building system as claimed in claim 10 wherein the inner facing is of plaster board material.
12. A timber frame building system as claimed in any of claims ito 11 comprising an outer facing for the support layer.
13. A timber frame building system as claimed in claim 12 wherein the outer facing comprises an oriented strand board material.
14. A timber frame building system as claimed in claim 12 or 13 comprising an exterior breather membrane external of the outer facing.
15. A timber frame building system as claimed in any of claims 1 to 14 wherein the insulation between the studs comprises a fiberglass material.
16. A timber frame building system substantially as hereinbefore described with reference to : the accompanying drawings. * U. * S S... * S. * S S * S. * *. * * S S.. S S. *S SS S.