GB2480315A - Construction element with insulating layer - Google Patents

Construction element with insulating layer Download PDF

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Publication number
GB2480315A
GB2480315A GB201008046A GB201008046A GB2480315A GB 2480315 A GB2480315 A GB 2480315A GB 201008046 A GB201008046 A GB 201008046A GB 201008046 A GB201008046 A GB 201008046A GB 2480315 A GB2480315 A GB 2480315A
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United Kingdom
Prior art keywords
construction
construction element
cavity
cavity wall
masonry
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Application number
GB201008046A
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GB201008046D0 (en
Inventor
Paul John Darrington
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Individual
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Individual
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Publication date
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Priority to GB201008046A priority Critical patent/GB2480315A/en
Publication of GB201008046D0 publication Critical patent/GB201008046D0/en
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Withdrawn legal-status Critical Current

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    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C1/00—Building elements of block or other shape for the construction of parts of buildings
    • E04C1/40—Building elements of block or other shape for the construction of parts of buildings built-up from parts of different materials, e.g. composed of layers of different materials or stones with filling material or with insulating inserts
    • E04C1/41—Building elements of block or other shape for the construction of parts of buildings built-up from parts of different materials, e.g. composed of layers of different materials or stones with filling material or with insulating inserts composed of insulating material and load-bearing concrete, stone or stone-like material

Abstract

A construction element for use in an inner leaf of a cavity wall construction is a building block and comprises a masonry layer106having a cavity side face a parallel opposing face. An insulation layer107is secured to the cavity side face of the masonry layer106and presents a cavity-side surface. The insulation layer107is configured to withstand a compressive force from a load applied to the upper side of the construction element, so as to provide a component of lateral stability to the inner leaf of the cavity wall during construction thereof. The insulation layer107may be a polyurethane or polyisocyanurate foam and may have a foil facing. The masonry layer106may be concrete or foamed concrete such as aircrete. A method of constructing a cavity wall comprises the steps of receiving a plurality of construction elements and laying received construction elements to form an inner leaf having an interior side provided by the cavity-side surfaces of the construction elements. A thin joint laying technique may be used.

Description

CONSTRUCTION ELEMENT
Field of the Invention
The present invention relates to a construction element, in particular to a construction element for use in a cavity wall structure.
Background to the Invention
Different types of wall construction techniques are known. A type of wall structure is known as a cavity wall. The cavity wall comprises two leaves that extend substantially parallel to one another and that are separated by a cavity.
The two leaves are connected by wall ties, which are typically of all metal fabrication, to spread lateral loads. The masonry leaves of a cavity wall may be brickwork, blockwork or similar; and different masonry materials may be used on either side of the cavity. External cavity walls typically bear the load of roof trusses, floor joists and internal walls.
Cavity walls are usable to inhibit the undesirable penetration of moisture from the exterior of the building, such as from rain or humidity, into the interior of a building. Masonry is an absorbent material and hence water exterior of the building is drawn into the outer leaf. The absorbed water collects on the inside of the porous outer leaf; however the cavity provides a barrier to the collected moisture reaching the inner leaf and provides a route for the drawn-in moisture to escape. The collected water runs down the inside of the outer leaf towards weep holes or vents that provide the cavity wall with drainage.
Cavity walls are also usable to prevent heat loss from the interior of a building through the exterior walls. The air in the cavity is an insulator and so provides increased thermal efficiency, reducing heat loss from the interior of the building. In addition, the cavity is able to receive insulation material therein, to enhance the thermal insulation and thermal capacity of the cavity wall. In combination, the air gap and the cavity wall insulation provide increased thermal performance. This provides a user of the building with increased energy performance and reduced energy costs. With partial fill insulation, a void is maintained between the insulation material and the outer leaf, to avoid bridging between the two leaves of the cavity wall so as to prevent moisture crossing from the outer leaf to the inner leaf.
The standard cavity wall is 300 mm wide; this width being made up of a 100 mm wide outer leaf, a 100 mm wide cavity and a 100 mm wide inner ieaf.
The National House-Building Council standards require a minimum 50 mm clear cavity between insulation within the cavity and the external leaf of the cavity wall.
Building industry regulations are increasingly demanding improved wall insulation thermal ratings.
An approach to meeting the thermal requirements of cavity walls is to increase the amount of insulation placed within the cavity. However, this will ultimately require the overall width of the cavity wall to be increased. For a given building plot for an individual building, the increase of the cavity wall width is accommodatable by decreasing the floor area of the interior of the building.
For a given building plot for a plurality of buildings, the increase of the cavity wall width is alternatively accommodatable by decreasing the number of buildings. Either way, it is envisaged that the increase in the width dimension of the cavity wall in order to accommodate a greater quantity of cavity wall insulation will result in a significant decrease in the profitability of a building plot.
A problem therefore exists in increasing the thermal performance of a cavity wall without increasing the overall width of the cavity wall.
Summary of the Invention
According to a first aspect there is provided a construction element for use in an inner leaf of a cavity wall construction, said construction element having an inner face, an outer face, and upper and lower sides and comprising: a masonry layer having an inner face and an outer face, and an insulation layer secured to said inner face of said masonry layer and presenting a cavity-side surface; said insulation layer configured to withstand a compressive force from a load applied to the upper side of said construction element, so as to provide a component of lateral stability to the inner leaf of the cavity wall during construction thereof.
In an example, the masonry layer comprises aircrete. In an example, the insulation layer comprises a foil-faced foam insulation panel.
According to a second aspect there is provided a method of constructing a cavity wall, said method comprising the steps of a) receiving a plurality of construction elements according to the first aspect; and b) laying construction elements received at step a) to form an inner leaf having an interior side provided by said cavity-side surfaces of said construction elements.
In an example, step a) comprises receiving a plurality of construction elements having a masonry layer comprising aircrete and step b) comprises laying received construction elements using a thin joint laying technique.
Brief Description of the Drawings
For a better understanding of the invention and to show how the same may be carried into effect, there will now be desciibed by way of example only, specific embodiments, methods and processes according to the present invention with reference to the accompanying drawings in which: Figure 1 shows a first example of a construction element according to the present invention in use within an inner leaf of a cavity wall construction; Figure 2 shows a construction element according to the first example in further detail; Figure 3 illustrates features of construction elements according to the first
example in use;
Figure 4 illustrates features of a cavity wall; Figure 5 shows a second example of a construction element according to the present invention; and Figure 6 illustrates features of an inner leaf of a cavity wall constructed using construction elements according to the second example.
Detailed Description
There will now be described by way of example a specific mode contemplated by the inventors. In the following description numerous specific details are set forth in order to provide a thorough understanding. It will be apparent however, to one skilled in the art, that the present invention may be practiced without limitation to these specific details. In other instances, well known methods and structures have not been described in detail so as not to
unnecessarily obscure the description.
Fiure1 A construction element 101 is shown in Figure 1. Construction element 101 is configured for use in, and is shown in use within, an inner leaf of a cavity wall.
External cavity wall 102 comprises an inner leaf 103 and an outer leaf 104, which are spaced apart so as to define a cavity 105 therebetween. Inner leaf 103 has an exterior side 106 and an interior side 107. Similarly, outer leaf 104 has an exterior side 108 and an interior side 109. As shown, the respective interior sides 107, 109 of the inner and outer leaves 103, 104 of cavity wall 102 are cavity-side surfaces. An external cavity wall is often used in the building of housing. In such an application, a standard cavity wall construction would typically comprise a 100mm wide blockwork inner leaf, a 100mm cavity and a 100mm wide brickwork outer leaf. It is also common to partially fill the cavity of cavity wall with insulation so as to leave a clear cavity between the partial fill insulation and the outer leaf of the cavity wall.
Figure 2 Construction element 101 is shown in further detail in Figure 2.
Construction element 101 has an inner face 201, an outer face 202, an upper side 203, a lower side 204, a first end 205 and a second end 206. Construction element comprises a masonry layer 207 and an insulation layer 208. The masonry layer 207 has an inner face 209 and an outer face 210. These two layers 207, 208 are secured together, such that the construction element is provided as a single unit; however this Figure also shows the masonry and insulation layers 207, 208 of the construction element 101 individually for the purposes of clarity. The insulation layer 208 is secured to the inner face 209 of the masonry layer 207 and presents a cavity-side facing surface 211.
The construction element 101 has a width direction W extending between the inner and outer faces 201, 202; a depth direction D extending between the upper and lower sides 203, 204 and a length direction L extending between the first and second ends 205, 206. Across the width direction W, there is a width component of masonry layer 207 and a width component of insulation layer 208.
Thus, the upper and lower sides 203, 204 and the first and second ends 205, 206 each show a portion of masonry layer 207 and a portion of insulation layer 208; whilst the inner face 201 shows only insulation layer 208 and the outer face 202 shows only masonry layer 207. In this example, the conètruction element 101 has a substantially rectangular cross-section, and presents six substantially rectangular faces.
The construction element 101 has a compressive strength characteristic, to withstand a load applied in the direction indicated by arrow 212 between the upper side 203 and the lower side 204, which will hereinafter be termed the vertical compressive strength'.
Figure 3 Figure 3 shows a plurality of construction elements 101 in use. As shown, the construction elements 101 form the inner leaf 103 of cavity wall 102. In this example, the construction elements 101 are laid in rows in according to a repeating stretcher bond' pattern. In this example also, the wall structure of the inner leaf 103 has a single-element thickness.
Each construction element 101 is oriented such that the cavity-side surface 208 faces in the direction towards the outer leaf 104. As shown, with all of the construction elements 101 forming the inner leaf 103 of the cavity wall 102 having this orientation, the exterior side 106 of the inner leaf 103 shows only the masonry layer 207 and the interior side 107 of the inner leaf 103 shows only the insulation layer 208. It is to be understood that the inner leaf 103 has an interior side 107 that is provided by the cavity-side surfaces 208 of the construction elements 101 forming the inner leaf 103.
The construction element 101 is hence used in this illustrated application in place of traditional masonry to form the inner leaf of the cavity wall. However, as previously stated, the construction element 101 comprises an insulation layer.
The insulation layer 208 of the construction element 101 is configured to withstand a compressive force, indicated at 301, from a load applied to the upper side 203 of the construction element 101, so as to provide a component of lateral stability to the inner leaf of the cavity wall during construction thereof. Typically, the load on an external wall is applied by the roof structure and any floor and internal wall structures. The insulation layer 208 also provides an extra degree of insulation for the cavity wall.
The contribution of the structural properties of the insulation layer 208 to the stability of the inner leaf 103 of the cavity wall 102 during construction thereof allows the construction element 101 to be used as a direct substitute for a traditional masonry construction element with the advantage of providing additional insulation for the cavity wall 102.
Thus, in this example, and in keeping with common widths of components of a cavity wall, cavity wall 102 has an overall width 302 of 300 mm, with the inner leaf 103 having a width 303 of 100 mm, the outer leaf 104 having a width 304 of mm and the cavity 105 having a width 305 of 100 mm.
Thus, in this example, the construction element 101 has a width of 100 mm.
As examples, a construction element as described herein may have overall dimensions of: 440 mm length x 215 mm depth x 100 mm width; 220 mm length x 215 mm depth x 100 mm width; 620 mm length x 215 mm depth x 100 mm width; 310 mm length x 215 mm depth x 100 mm width. It is to be appreciated however that a construction element as described herein may be differently dimensioned as desired. The dimensions of a construction element as described herein may vary within and/or between applications.
In an example, the masonry layer 207 of the construction element 101 comprises aircrete. In another example, the masonry layer 207 of the construction element 101 comprises concrete. In this way, the masonry layer 207 component of the construction element 101 exhibits similar characteristics and performance of a traditional all-masonry equivalent construction element. It is to be appreciated that the masonry layer of the construction element may comprise any suitable material or combination of materials.
In an example, the insulation layer 208 of the construction element 101 comprises polyurethane. In another example, insulation layer 208 of the io construction element 101 comprises polyisocyanurate It is to be appreciated that the insulation layer of the construction element may comprise any suitable material or combination of materials. In an example, the insulation layer comprises foam insulation.
The ratio of the width of the masonry layer to the width of the insuatiofl layer of the overall construction element width may be any suitable ratio. In an example, the ratio of the width of the masonry layer to the width of the insulation layer of the overall construction element width is, or is approximately, 80:20. In an alternative example, the ratio of the width of the masonry layer to the width of the insulation layer of the overall construction element width is, or is approximately, 75:25. In a further example, the ratio of the width of the masonry layer to the width of the insulation layer of the overall construction element width is, or is approximately, 60:40.
A construction element as described herein may be manufactured by any suitable technique or combination of techniques. In an example, an insulation layer is bonded to a masonry layer. An adhesive may be used, of any suitable type, and any suitable adhesive application process may be used.
It is to be appreciated that the vertical compressive strength of a construction element as described herein is dependent upon the individual compressive strength values of the masonry layer and the insulation layer and the ratio of these component layers of the construction element. Thus, the -.8-vertical compressive strength of a construction element as described herein is, in effect, a combined value.
In an example, the construction element 101 has a. vertical compressive strength in the range, or approximately in the range, of 2-7.5 N/mm2. In an example, the masonry layer of the construction element 101 has a vertical compressive strength in the range, or approximately in the range, of 2.5-10 N/mm2. In an example, the insulation layel of the construction element 101 has a vertical compressive strength in the range, o approximately in the range, of 1- 3N/mm2. As a simple illustrative exampIe, a construction element as described herein and having a width of 100 mm comprises 70% (70 mm wide) masonry layer having a compressive strength of 7 N/mm2 and 30% (30 mm wide) insulation layer having a compressive strength of 1.3 N/mm2, the vertical compressive strength of the construction element then being 5.29 N/mm2.
It is envisaged that a construction element as described herein is manufacturable to provide sufficient lateral stability to allow construction of up to 8 unsupported courses of an inner leaf of a cavity wall, and to provide sufficient lateral stability in the completed cavity wall for a house having up to three storeys.
Figure 4 As illustrated in Figure 4, a cavity wall having an inner leaf formed from construction elements as described herein is treatable in the same way as a traditionally built cavity wall.
Thus, the cavity wall 102 may be provided with insulation. In this example, cavity wall 102 has partial fill insulation 401, with a clear cavity, indicated at 402, provided between the partial fill insulation 401 and the outer leaf 104. The insulation may comprise any suitable material or combination of materials and can be any traditionally used type of partial insulation, for example rigid foam board or mineral wool. Further, in this example, the exterior side 106 of the inner leaf 103 is lined with plasterboard 403.
The use of the construction elements 101 as described herein to form the inner leaf 103 of the cavity wall 102, advantageously increases the U-value of the cavity wall 102 without increasing the width of the inner leaf 103 or the overall width of the cavity wall 102. Thus, a construction element as described herein, to form a partial-masonry inner leaf of a cavity wall having an aU-masonry outer leaf, beneficially provides for a cavity wall of a standard thickness to have an increased overall heat transfer coefficient (U-value), compared to a cavity wall of that same thickness having all-masonry inner and outer leaves. This feature is particularly useful in applications in which a relatively extremely low U-value must be achieved.
Figure 5 A construction element 501 is shown in Figure 5. Construction element 501 is similar to construction element 101 but also differs from construction element 101. In this example, construction element 501 has a masonry layer 207 but has a three-ply insulation layer 502. In this example, the insulation layer 502 comprises a foil-backed foam insulation panel, having a first foil layer 503 and a second foil layer 504 with a foam layer 505 disposed therebetween. The insulation layer 502 presents a cavity-side surface 506.
The foil layers may be aluminium layers. Low emissivity foil facings are known that are resistant to the passage of water vapour and that significantly increase the thermal resistance of the cavity by acting as radiant barriers and reflecting heat. As an overall effect, the foil layers of the insulation panel improve the thermal performance of the cavity wall. This, in turn serves to reduce energy usage costs of the final build.
Fjgure6 Figure 6 shows a cavity wall inner leaf 601 formed from a plurality of construction elements 501; with side 602 provided by the cavity-side surfaces 506 of the construction elements 501.
A method of constructing a cavity wall thus comprises the steps of receiving a plurality of construction elements as described herein and Laying received construction elements to form an inner leaf having an interior side provided by the cavity-side surfaces of the construction elements.
The received plurality of construction elements as described herein may be laid to form an inner leaf in accordance with any suitable technique. For example, traditional mortar joint material may be used. However, in examples in which the masonry layer of the construction element type is aircrete, then the construction elements may be laid according to thin joint construction. This technique utilises a thin joint mortar, which is more adhesive-like than traditional mortar. Thin joint construction enables construction elements to be laid with a thinner joint than that required by use of traditional mortar joint material, typically with a width in the range 2-3mm. The use of thin joint mortar is usually applied using an applicator, and this provides for an accurate and consistent depth of mortar. It has been found that the thin joint laying methodology increases the ease and speed of construction without the requirement for specialized skills.
Thus, a method of constructing a cavity wall may comprise the steps of receiving a plurality of construction elements as described herein and laying received construction elements using a thin joint laying technique to form an inner leaf having an interior side provided by the cavity-side surfaces of the constiuction elements.
In addition, in examples in which the masonry layer of the construction element type is aircrete, it is possible to bond the insulation layer to the aircrete masonry layer using the thin joint adhesive.
As described above, the present invention provides a construction element that provides considerable advantages for an operative performing the build and that provides considerable advantages for the end user of the building. It is to be understood that a construction element as described herein, comprising a masonry layer and an insulation layer, enables cavity walls to be constructed that achieve significantly higher thermal values than a traditional cavity wall constructed with all-masonry construction elements for both leaves. It is to be appreciated however that a construction element as described herein may be used in alternative applications to that described herein.

Claims (15)

  1. Claims 1. A construction element for use in an inner leaf of a cavity wall construction, said construction element having an inner face, an outer face, and upper and lower sides and comprising: a masonry layer having an inner face and an outer face, and an insulation layer secured to said inner face of said masonry layer and presenting a cavity-side surface; said insulation layer configured to withstand a compressive force from a load applied to the upper side of said construction element, so as to provide a component of lateral stability to the inner leaf of the cavity wall during construction thereof.
  2. 2. A construction element as claimed in claim 1, wherein said masonry layer comprises aircrete.
  3. 3. A construction element as claimed in claim 1, wherein said masonry layer comprises concrete.
  4. 4. A construction element as claimed in any of claims I to 3, wherein said insulation layer comprises foam insulation.
  5. 5. A construction element as claimed in claim 4, wherein said insulation layer comprises a foil-faced foam insulation panel.
  6. 6. A construction element as claimed in any of claims I to 5, wherein said insulation layer comprises polyurethane.
  7. 7. A construction element as claimed in any of claims 1 to 6, wherein said insulation layer comprises polyisocyanurate.
  8. 8. A construction element as claimed in any of claims 1 to 7, wherein said insulation layer is bonded to said masonry layer.
  9. 9. A construction element as claimed in any of claims I to 8, having a width dimension of, or approximately, 100 mm.
  10. 10. A method of constructing a cavity wall, said method comprising the steps of: a) receiving a plurality of construction elements according to any of claims 1 to 9; and b) laying construction elements received at step a) to form an inner leaf having an interior side provided by said cavity-side surfaces of said construction elements.
  11. 11. A method according to claim 10, wherein step a) comprises receiving a plurality of construction elements according to claim 2 and step b) comprises laying received construction elements using a thin joint laying technique.
  12. 12. A construction element substantially as described herein with reference to, and as shown in, the accompanying drawings.
  13. 13. A method of manufacture of a construction element substantially as described herein with reference to, and as shown in, the accompanying drawings.
  14. 14. A method of constructing an inner leaf of a cavity wall comprising a plurality of construction elements substantially as described herein with reference to, and as shown in, the accompanying drawings.
  15. 15. An inner leaf of a cavity wall comprising a plurality of construction elements substantially as described herein with reference to, and as shown in, the accompanying drawings.
GB201008046A 2010-05-14 2010-05-14 Construction element with insulating layer Withdrawn GB2480315A (en)

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Application Number Priority Date Filing Date Title
GB201008046A GB2480315A (en) 2010-05-14 2010-05-14 Construction element with insulating layer

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Application Number Priority Date Filing Date Title
GB201008046A GB2480315A (en) 2010-05-14 2010-05-14 Construction element with insulating layer

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GB2480315A true GB2480315A (en) 2011-11-16

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR3034794A1 (en) * 2015-04-13 2016-10-14 Maher Drira INSULATING MASONRY ELEMENT FOR THE CONSTRUCTION OF WALLS

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2088923A (en) * 1980-12-09 1982-06-16 Barnes Leon Pearson Insulated constructional block
GB2272462A (en) * 1992-11-13 1994-05-18 Boral Edenhall Concrete Produc Masonry block
GB2291079A (en) * 1994-06-23 1996-01-17 Forticrete Ltd Insulated building blocks
US20020148181A1 (en) * 1996-02-08 2002-10-17 Friesner Charles E. Structural member
BE1015331A3 (en) * 2003-01-28 2005-02-01 Douterloigne Jan Albert Brick for thermally insulated walls, comprises construction and insulating elements connected together

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2088923A (en) * 1980-12-09 1982-06-16 Barnes Leon Pearson Insulated constructional block
GB2272462A (en) * 1992-11-13 1994-05-18 Boral Edenhall Concrete Produc Masonry block
GB2291079A (en) * 1994-06-23 1996-01-17 Forticrete Ltd Insulated building blocks
US20020148181A1 (en) * 1996-02-08 2002-10-17 Friesner Charles E. Structural member
BE1015331A3 (en) * 2003-01-28 2005-02-01 Douterloigne Jan Albert Brick for thermally insulated walls, comprises construction and insulating elements connected together

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR3034794A1 (en) * 2015-04-13 2016-10-14 Maher Drira INSULATING MASONRY ELEMENT FOR THE CONSTRUCTION OF WALLS

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Publication number Publication date
GB201008046D0 (en) 2010-06-30

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