GB2479023A - Construction panel and method of use - Google Patents

Construction panel and method of use Download PDF

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Publication number
GB2479023A
GB2479023A GB1018388A GB201018388A GB2479023A GB 2479023 A GB2479023 A GB 2479023A GB 1018388 A GB1018388 A GB 1018388A GB 201018388 A GB201018388 A GB 201018388A GB 2479023 A GB2479023 A GB 2479023A
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United Kingdom
Prior art keywords
layer
construction
construction panel
panel according
building
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Granted
Application number
GB1018388A
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GB2479023C (en
GB201018388D0 (en
GB2479023B (en
Inventor
Glenn Melvin
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Individual
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Individual
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Publication of GB201018388D0 publication Critical patent/GB201018388D0/en
Publication of GB2479023A publication Critical patent/GB2479023A/en
Application granted granted Critical
Publication of GB2479023B publication Critical patent/GB2479023B/en
Publication of GB2479023C publication Critical patent/GB2479023C/en
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Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
    • E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
    • E04C2/288—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and concrete, stone or stone-like material
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/04—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/40—Layered products comprising a layer of synthetic resin comprising polyurethanes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/02—Physical, chemical or physicochemical properties
    • 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
    • E04B1/78—Heat insulating elements
    • E04B1/80—Heat insulating elements slab-shaped
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
    • E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
    • E04C2/296—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and non-metallic or unspecified sheet-material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2419/00—Buildings or parts thereof

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Acoustics & Sound (AREA)
  • Electromagnetism (AREA)
  • Finishing Walls (AREA)

Abstract

A construction panel (2, figure 1 ) is provided for use on an external surface and/or part of a building or construction. The panel includes a first layer 4 formed, at least in part, from a material having one or more insulating properties, and at least a second layer 6 joined or applied to said first layer, said at least second layer formed from or includes a water resistant or water repellent material. The first layer is preferably polyurethane, expanded polystyrene or rockwool. The second layer is preferably a cement-type board or composed of magnesium or calcium silicate. There may be a third layer 20 applied on the outside surface 3. This may be an elastomeric coating, masonry paint, a textured coating or a decorative coating.

Description

Construction Panel and Method of Use Thereof The present invention relates to a construction panel and a method of use thereof.
Although the following description refers almost exclusively to a construction panel for use on an external surface or part of a building, it will be appreciated by persons skilled in the art that the panel could be used on either an internal or an external surface on any construction, surface or building.
On construction of a building, it is desirable to provide the external surface of the building with a waterproof or water resistant outer coating, thereby preventing water ingress into the walls of the building over time and/or during adverse weather conditions. Conventionally this outer coating has been achieved by applying render or paint to the external surface of the building. An example of a known render procedure is Rendalath®. However, a problem with the application of render and/or paint is that this can only be undertaken successfully when weather conditions are dry. This can cause delays in completion of building projects during periods of wet weather and can increase the cost of the building project. The render is normally applied to a support wire system that is attached to the external surface of the building, which increases the cost and the number of steps involved in the procedure. The process is therefore labour intensive and time consuming.
As an alternative to render or plaster, it is known to provide external surfaces of building with an external cladding, such as stone or metal cladding, which has a waterproof outer coating.
This type of cladding typically includes a plastic or metal material which may limit the aesthetic effect provided by the external appearance of the building and is also expensive to produce.
It is therefore an aim of the present invention to provide a construction panel that overcomes the abovementioned problems.
It is a further aim of the present invention to provide a method of use of a construction panel that overcomes the abovementioned problems.
According to a first aspect of the present invention there is provided a construction panel for use on an external surface and/or part of a building or construction, said panel including a first layer formed, at least in part, from a material having one or more insulating properties and at least a second layer joined or applied to said first layer, said at least second layer formed from or includes a water resistant or water repellent material.
Preferably the water resistant or water repellent material is a particulate material, such as particle board, and further preferably is a cement based particulate material, such as cement particle board.
Preferably the cement based particulate material is a silicate containing material.
According to one aspect of the present invention there is provided a construction panel for use on an external surface and/or part of a building or construction, said panel including a first layer formed, at least in part, from a material having one or more insulating properties and at least a second layer joined or applied thereto, said second layer formed from a silicate containing material.
The provision of the construction panel with the second silicate containing layer provides the panel with a certain degree of water resistance, thereby allowing the panel to be fitted to an external surface or part of a building or construct in any weather condition, such as in the rain, snow, high humidity conditions and/or the like. In addition, there is no requirement for application of a wet lining, such as render or plaster thereto.
The simplicity of the panel and method of assembly of the panel to a suitable surface provides an 80% saving in labour.
The present invention therefore provides a dry lining technique for use preferably on the outside of an external surface of a building or construction but also for use on an internal surface of a building or construction. The dry lining technique of the present invention differs from those used conventionally on internal surfaces, such as use of plasterboard panels, since plasterboard is formed from a single layer of gypsum or gypsum like material which absorbs moisture and/or water.
The panel of the present invention also has the advantage that it insulates the building or construct, thereby reducing heat loss from the building and/or keeping the building cool. This helps to reduce costs associated with the building, such as heating and/or air conditioning and also reduces carbon emissions. In addition, the panel of the present invention is strong, impact resistant and robust, thereby providing rigidity and impact protection to the surface of the building or construction.
The construction panel of the present invention can provide a direct replacement to render used on exterior facades of buildings or constructions.
In a preferred embodiment the at least second layer forms an outer surface of the construction panel and faces outwardly from an external surface or part of the building or construction in use.
Preferably the first layer forms an inner surface of the construction panel and is typically arranged to be located facing, adjacent to, abutting with and/or joined to an existing external surface or part of the building or construction in use.
In one embodiment at least a third layer is applied to the outer surface of the second layer. The at least third layer is preferably formed from or includes a waterproof or water resistant material. In this embodiment the second layer forms an intermediate layer of the final construction panel.
Preferably the at least third layer forms an elastomeric outer coating on the panel. The at least third layer can include any or any combination of masonry paint, a textured coating, a suitable decorative effect and/or the like.
Preferably the first, second and/or at least third layer can be provided in substantially overlapping relationship. One layer may be applied to substantially the entire surface of an adjacent layer or to a part thereof.
In one embodiment a mesh, support means or similar support material can be located in or between one or more of the layers of the panel. This can help provide the panel with increased impact resistance and strength.
In one embodiment the construction panel including the first and second layers is pre-fabricated and is then fitted to an external surface or part of a building or construction in use. The at least third layer can be applied to the outer surface of the second layer once the construction panel has been fitted. In one example, the at least third layer can be applied to the outer surface of the second layer prior to the construction panel being fitted to a building or construction.
Preferably the first and at least second layers are laminated together using a suitable lamination method or lamination means. Any known lamination method or means could be used.
In one embodiment the material of the first layer is or includes any or any combination of polyurethane, expanded polystyrene or rockwool.
Preferably the first layer has a thickness of between 20-200mm.
However, the thickness of the first layer is such so as to provide suitable insulation to the building or construction on which the panel is to be applied to in use.
In one embodiment the silicate containing material of the at least second layer is calcium silicate and/or magnesium silicate.
Preferably the at least second layer has a thickness of between 3-10mm.
In one embodiment the first layer is substantially of a greater thickness than the at least second layer.
Preferably the construction panel has one or more tapered peripheral edges. The tapered edges typically have a narrowing taper towards the free edge of the panel.
Preferably all the edges of the construction panel have a narrowing taper towards the free edges thereof.
In one example, adhesive and/or tape is located over the edges of two adjoining construction panels in use to join the same together. The edges of the panel are formed so as to allow a substantially flat, planar surface to be formed between the two adjoining panel edges on application of the adhesive and/or tape.
In one example, scrim tape or a suitable fibrous joining tape is used. The tape is located over the edges, and preferably tapered edges, of two adjoining boards and adheres or joins the same together. The third layer can be applied over the scrim tape or joining tape and the second layer if required.
The construction panel can be provided with attachment means for attaching the same directly or indirectly to an object or surface in use, such as an interior or external surface, substrate or part of a building or construction in use. The attachment means can include any or any combination of one or more screws, nuts and bolts, fixing rails, inter-engaging edges, members, adhesive, specialist adhesive and/or the like.
The construction panel can be of any suitable size and/or shape.
In one example, the construction panel is substantially square or rectangular in shape.
One or more trims can be applied to the construction panel if required.
According to a second aspect of the present invention there is provided a method of using a construction panel, said panel including a first layer formed, at least in part, from a material having one or more insulating properties, and at least a second layer joined or applied to said first layer, said at least second layer formed from or includes a water resistant or water repellent material, said method including the step of attaching the construction panel to an external surface and/or part of a building or construction.
The construction panel is typically fitted or retrofitted to an existing external or internal surface or part of an existing building or construction. The surface of the building or construct to which the panel is to be fitted is prepared to ensure the surface is stable. For example, any debris and/or loose material on the existing surface is removed. The existing surface may be cleaned if required.
A rail system can be fixed to the existing surface of the building or construct using suitable fixing means. The rail system typically includes a plurality of rail member located at spaced apart intervals on the external surface. The construction panels can be fixed to or between the rail members in use.
The construction panels are typically located adjacent to each other in abutting relationship to form a substantially flat, planar surface. For example the panels can be aligned next to each other in an end to end and/or side to side configuration.
The panels can contact the existing surface of the building or construct and/or can be provided a spaced distance therefrom.
According to a further aspect of the present invention there is provided a building or construct having external construction panels associated therewith.
According to a yet further independent aspect of the present invention there is provided a dry lining method for an external surface of a building or construction.
According to a further aspect of the present invention there is provided an exterior construction panel.
An embodiment of the present invention will now be described with reference to the accompanying figures, wherein: Figure 1 shows a front perspective view of a construction panel according to the present invention; Figure 2 is a cross sectional view taken through the panel shown in figure 1; and Figure 3 is a simplified view of construction panels being applied to an external surface of a building.
Referring firstly to figures 1-2, there is illustrated a dry lining construction panel 2 for use as an external surface of an existing building or construction. The panel has an outer surface 3, an inner surface 5 and side walls or edges 8.
The construction panel 2 comprises a first inner insulating layer 4 formed from polyurethane. The second intermediate layer 6 is formed from calcium or magnesium silicate board. The second intermediate layer 6 provides the panel 2 with a certain degree of water resistance, thereby allowing the panel to be applied to an external surface or part of a building in any weather condition to provide a water resistance hyer to the building or surface. The board can be left on the external surface of the building until a suitable time when a further outer coating may be applied thereto.
First and second layers 4, 6 are laminated together by any suitable known lamination technique to form a pre-fabricated dual layer board. The first layer is typically thicker in dimensions than the second layer but the layers can be any suitable thickness as required. This dual layered board can then be transported to a suitable construction site for application to the surface of a building as and when required.
The panel 2 in the illustration is substantially square in shape and has narrowing tapered edges 8.
Although the following description refers to the construction panel being applied to an external surface of a building or construction, it will be readily understood that the panel could be applied to an internal surface of a building or construct if required. However, the significant advantages of the panel are realised when the panel is applied outside.
In use, the external surface of an existing building 10 is prepared by removing any loose material, such as render or plaster therefrom. A plurality of fixing rails 12 are fixed to the external surface 14 of building 10 using screws. The rails are located a spaced distance apart. This distance is such that a construction panel can be fitted between two adjacent rails.
Constructions panels 2, 2' are fitted side by side onto rails 12 using screws 16 so that the edges 8 thereof are in abutting relationship. Scrim tape 18 is then applied over the edges 8 of the two adjacent panels 2, 2' to join the same together and form a substantially flat, planar join.
Once the construction panels 2, 2' are fitted and joined together, a third outer layer 20 can be applied to the outer surface of layer 6 to provide a further water resistance coating and/or a suitable aesthetic finish to the construction panel. For example, the third layer can comprise masonry paint. It is not necessary to apply outer layer 20 immediately or at all to the surface of layer 6 to ensure some degree of water resistance is provided to the building.
The construction panel of the present invention provides a simpler means of providing a finishing surface to a building or construction which can be applied and used in any weather condition. In addition, the construction panel provides insulation to the external surface of the building or construction, thereby helping to save costs associated with heating and/or keeping the building or construct cool.

Claims (22)

  1. Claims 1. A construction panel for use on an external surface and/or part of a building or construction, said panel including a first layer formed, at least in part, from a material having one or more insulating properties, and at least a second layer joined or applied to said first layer, said at least second layer formed from or includes a water resistant or water repellent material.
  2. 2. A construction panel according to claim I wherein the water resistant or water repellent material is a particulate material or particle board.
  3. 3. A construction panel according to claim I wherein the water resistant or water repellent material is a cement based particulate material or cement particle board.
  4. 4. A construction panel according to claim 3 wherein the cement based particulate material is a silicate containing material.
  5. 5. A construction panel according to claim 5 wherein the silicate containing material is calcium or magnesium silicate board.
  6. 6. A construction panel according to claim I wherein the first ayer is or includes any or any combination of polyurethane, expanded polystyrene or rockwool.
  7. 7. A construction panel according to claim 1 where the first layer has a thickness of between 20-200mm.
  8. 8. A construction panel according to claim I wherein the at least second layer has a thickness of between 3-10mm.
  9. 9. A construction panel according to claim I wherein the first layer has a substantially greater thickness than the at least second layer.
  10. 10. A construction panel according to claim I wherein the at least second layer forms an outer surface of the construction panel and faces outwardly from an external surface or part of the building or construction in use, the first layer forms an inner surface of the construction panel and faces inwardly, abuts with or is joined to the external surface or part of the building or construction in use.
  11. 11. A construction panel according to claim I wherein a third layer is applied to the outer surface of the second layer, the second layer therefore forming an intermediate layer in the final construction panel.
  12. 12. A construction panel according to claim 11 wherein the third layer is formed from or includes a waterproof or water resistant material.
  13. 13. A construction panel according to claim 11 wherein the third layer includes any or any combination of an elastomeric coating, masonry paint, textured coating or decorative coating.
  14. 14. A construction panel according to any preceding claim wherein the first, second and/or at least third layers are provided in substantially overlapping relationship.
  15. 15. A construction panel according to claim I wherein a mesh or support material is located in or between two or more layers of the panel.
  16. 16. A construction panel according to claim I wherein the first and at least second layers are pre-fabricated via lamination means.
  17. 17. A construction panel according to claim I wherein said panel has one or more tapered peripheral edges.
  18. 18. A construction panel according to claim I wherein said panel includes one or more trims.
  19. 19. A construction panel according to claim I wherein attachment means are provided to allow attachment of the panel to a surface or object in use.
  20. 20. A method of using a construction panel, said panel including a first layer formed, at least in part, from a material having one or more insulating properties, and at least a second layer joined or applied to said first layer, said at least second layer formed from or includes a water resistant or water repellent material, said method including the step of attaching the construction panel to an external surface and/or part of a building or construction.
  21. 21. A method according to claim 21 wherein adhesive and/or tape is located over the edges of two adjoining construction panels to join the same together.
  22. 22. A method according to claim 21 wherein the tape is scrim tape or fibrous tape.AMENDMENTS TO THE CLAIMS HAVE BEEN FILED AS FOLLOWS1. \ construction panel for use on an external surface and/or part of a building or construction, said panel including a First layer formed, at least in part, from a material having one or mote insulating properties, and at least a second layer joined or applied to said first layer, said at least second layer formed from or includes a water resistant or vater repellent material, and wherein mesh support means arc located in or between one or more layers of the panel.2. A construction panel according to claim 1 wherein the \vater resistant or water repellent material is a particulate material or particle board.3. A construction panel according to claim 1 wherein the water resistant or water repellent material is a cement based particulate material or cement particle board.4. A construction panel according to claim 3 wherein the * cement based particulate material is a silicate containing *.** * inatei:ial. *. SI * * ** 5. A construction panel according to claim 5 wherein the silicate containing material is calcium or magnesium : ** silicate board. P. 50 * S * .6. A construction panel according to claim I wherein the first layer is or includes any or any combination of l)Iyurctlate, expanded polystyrene or rockwool.7. A construction panel according to claim 1 where the first layer has a thickness of between 20-200mm.\ construction panel according to claim 1 wherein the at least second layer has a thickness of between 3-10mm.9. A construction panel according to claim I wherein the first layer has a substantially greater thickness than the at least second layer.1 (J. A construction panel according to claim 1 wherein the at least second layer forms an outer surface of the construction panel and faces outwardly from an external surface or part of the building or construction in use, the first layer forms an inner surface of the construction panel and faces inwardly, abuts with or is joined to the external surface or part of the building or construction in use.1 1. r\ construction panel according to claim 1 wherein a third layer is applied to the outer surface of the second layer, the second layer therefore forming an intermediate layer in the final construction panel.* : 12. r\ construction panel according to claim 11 wherein * the third layer is formed from or includes a waterproof or -, \vater resistant material. * * , * I13. A construction panel according to claim 11 wherein the third layer includes any or any combination of an elaston-icric coating, masonry paint, textured coating or decorative coating.I 4. A construction panel according to any preceding claim wherein the first, second and/or at least third layers arc pro\nidcd in substantially overlapping relationship.15. A construction panel according to claim 1 wherein the first and at least second layers are pre-fabricated via lamination means.1 6. A construction panel according to claim 1 wherein said panel has one or more tapered peripheral edges.17. A construction panel according to claim I wherein said panel includes one or more trims.1 8. A construction panel according to claim 1 wherein attachment means are provided to allow attachment of the panel to a surface or object in use.19. A method of using a construction panel, said panel including a first layer formed, at least in part, from a material having one or more insulating properties, and at least a second layer joined or applied to said first layer, said at least second layer formed from or includes a water resistant or water repellent material, and wherein mesh I.....* support means are located in or between one or more * S....* layers of the panel, said method including the step of attaching the construction panel to an external surface and/or part of a building or construction.20. A method according to claim 19 wherein adhesive * *. . . : * * and/or tape is located over the edges of two adjoining construction panels to join the same together.21. A method according to claim 20 wherein the tape is scrim tape or fibrous tape.
GB201018388A 2010-06-14 2010-11-01 Construction panel and method of use thereof Expired - Fee Related GB2479023C (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GBGB1009880.4A GB201009880D0 (en) 2010-06-14 2010-06-14 Construction panel and method of use thereof

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GB201018388D0 GB201018388D0 (en) 2010-12-15
GB2479023A true GB2479023A (en) 2011-09-28
GB2479023B GB2479023B (en) 2012-04-11
GB2479023C GB2479023C (en) 2014-08-20

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Publication number Priority date Publication date Assignee Title
EP2851482A1 (en) 2013-09-19 2015-03-25 Redco NV Pre-fabricated construction panels
EP2851193A1 (en) 2013-09-19 2015-03-25 Redco NV Pre-fabricated construction panels
EP3034713A1 (en) 2014-12-16 2016-06-22 Siniat International SAS Pre-fabricated construction panels

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GB201009880D0 (en) 2010-07-21

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