GB2520539A

GB2520539A - Improved insulation panels and method of insulating buildings

Info

Publication number: GB2520539A
Application number: GB1320725.3A
Authority: GB
Inventors: Terence George O'hara
Original assignee: Individual
Current assignee: Individual
Priority date: 2013-11-25
Filing date: 2013-11-25
Publication date: 2015-05-27
Also published as: GB201320725D0

Abstract

A prefabricated insulation panel comprises at least two portions of insulation panel 7 embedded in at least one layer of render. At least one portion of a reinforcing material is embedded in the render. The portions of insulating panel may be formed from expanded polystyrene and may be acoustically insulating. The render may be a plaster material and the reinforcing material may be a mesh cloth, fibres, paper or cardboard. The render may be applied using a multifunction bridge and the panel may be cut to size by a CNC controlled saw. A method of producing a prefabricated insulation panel is also claimed.

Description

1 Improved insulation panels and method of insulating buildings 3 The present invention relates to the field of insulation of buildings and 4 constructions. Particularly, but not exclusively, applications of this invention relate to the external thermal insulation of existing buildings or retrofit external 6 insulation. It is also envisaged that the present invention can be applied to 7 insulation of new buildings, buildings interiors and other types of insulation other 8 than thermal, such as acoustic insulation, for example.

Background to the invention

12 There is nowadays an increasing trend in reducing energy consumption in all 13 aspects of life due to environmental and economic concerns. Homes and 14 businesses heating is an enormous part of the energy bill of a nation, especially is in countries with cold or very cold winters, such as Scotland and other Nordic 16 countries. Thermal insulation of buildings and other types of constructions are 17 essential to reduce the heating expenses of any household, company or any 18 organisation.

Most buildings suffer from excessive heat loss through their walls either 21 because their walls are of solid construction, or they lack a cavity wall insulation 22 system, and they cannot have such systems retrofitted or the fitting of an 23 external wall insulation system is costly and complex.

Current retrofit insulation systems are made up of various materials, such as 26 insulations boards, cementitious or non cementitious layers, reinforcing layers, 27 further cementitious or non cementitious layers, and a decorative or colour coat.

28 These systems are multilayer systems applied in-situ, i.e. at the place where the 29 building to be insulated is located, and require skilled workers to apply them with installation times measured in weeks rather than days.

32 Some elements of multilayered external insulation systems require that they be 33 installed in dry weather to avoid the constituent materials being damaged by 34 water and to allow moist porous layers to dry before applying subsequent 1 layers. The consequence of this is that these systems cannot be installed during 2 certain periods of the year or during unpredictable or unsuitable weather 3 conditions, such as rain or snow. The cementitious or non cementitious layers 4 also require that the ambient temperature is above a certain value so that they can aggregate correctly. These weather constraints add to the cost and time to 6 complete the installation process.

8 Additionally, these systems need scaffolding around the building so that the 9 workers can apply them safely and efficiently. The scaffolding installation adds to the cost of the overall insulation project and can disturb the building 11 occupants' ingress and egress.

13 It is desirable that the thermal insulation of existing buildings, that at the time of 14 construction were not properly insulated, would be less expensive and complex.

In order to deploy a suitable insulating barrier to the exterior of an existing 16 building or construction there have been several methods developed over the 17 years, which address several aspects of importance, such as time, material and 18 labour requirements.

One known method is described in patent publication DE 195 44713 Al, in 21 which a method for the external insulation of existing buildings is described. In 22 this method the exterior dimensions of a building are scanned with 23 optoelectronic means. The dimensions are stored in an electronic media and 24 transferred to the processing unit of a computer numeric control unit of a panel cutting device. The individual insulation panels are then cut according to the 26 building dimensions, taking into account the gaps for windows, doors, etc. The 27 cut panels are then decorated, rendered or painted before installation. Once the 28 panels have dried they are numbered in order of installation and transported to 29 site and installed, wherein the operator attaches the panels onto the building exterior wall, according to a predefined schedule. The panels are attached by 31 using a suitable adhesive, mortar or anchors, etc. and then a topcoat is applied 32 to cover the panels and joints between the panels and the topcoat is left to dry.

1 This method exemplifies that it is desirable to minimise the time spent on-site at 2 the point of installation, due to the limited days where the weather allows for the 3 installation and drying of the topcoat. It also exemplifies how the labour and 4 time intensive process of cutting the panels on-site is avoided. However, it is still desirable to reduce the time spent during the installation of the panels, so 6 that the labour costs are reduced further and there is more time left for drying of 7 the topcoat in favourable weather conditions. This would result in an increased 8 demand for retrofit insulation, a reduced energy expense and better external 9 insulations without points of water moisture ingress and thermal bridging.

ii It is among the objectives of the present invention to solve or at least partially 12 mitigate some of the disadvantages encountered in the prior art, in particular to 13 further reduce the time and costs involved in the installation of insulation 14 systems on a building and more particularly the appearance of points of moisture ingress and thermal bridging in retrofit external insulation of buildings.

17 Summary of the invention

19 According to a first aspect of the invention there is provided a prefabricated insulation panel comprising at least two portions of insulation panel substantially 21 coplanarly placed in close proximity to each other, further comprising at least 22 one layer of render placed on a common surface of the at least two portions of 23 insulation panel, wherein the at least two portions of insulation panel are at least 24 partially embedded in the at least one layer of render, and further comprises at least one portion of a reinforcing material at least partially embedded in or on at 26 least one of the at least one layer of render.

28 A prefabricated insulation panel according to the first aspect of invention has 29 the advantage that it is easier and faster to install on a building than at least two portions of insulation panel individually. This is a benefit when trying to retrofit 31 external thermal insulation on an existing building as it is desirable to execute 32 the installation in the shortest time possible. This is also an advantage for 33 internal insulation systems. Other types of insulation projects might benefit from 34 this advantage, such as acoustic insulation.

2 Another advantage of a prefabricated insulation panel according to the first 3 aspect of the invention is that the at least one layer of render can be dried off in 4 an enclosed environment, in which the drying conditions can be adjusted to avoid cracks and crevices being produced while drying, especially important in 6 the areas between the at least two portions of insulation panel. This implies that 7 a better insulation can be achieved with the use of the prefabricated insulation 8 panels of the invention, where fewer points of moisture ingress or cold spots 9 might be produced than when using conventional portions of insulation panels installed in situ. The at least one portion of reinforcement material also provides 11 resistance against the formation of cracks and crevices within the layer of 12 render and it provides to the prefabricated insulation panel more resistance 13 against tensions arising during drying, handling, installation and service life.

Preferably the at least two portions of insulation panels may comprise three or 16 more portions of insulation panel. In this way, the advantage of a quick and 17 easy installation will be more pronounced and more time can be saved in 18 installing the prefabricated insulation panels. Supersized prefabricated 19 insulation panels can be produced by including several portions of insulation panel in a prefabricated insulation panel.

22 Preferably the at least two potions of insulation panels may be commercially 23 available or standard insulation panels. This is especially beneficial to lower the 24 cost and simplify the production of the prefabricated insulation panels of the present invention.

27 More advantageously the at least two portions of insulation panel may be 28 portions of expanded polystyrene (EPS) insulation panels. It will be understood 29 that other types of insulating materials may be used without departing from the scope of the invention. It will be also understood that other types of insulation 31 panels may be used, like for instance, glass fibre acoustic insulation panels.

1 The at least two portions of insulation panel may have flat edges or matching 2 profiled edges, such as tongue and groove edges, half lap edges or splined 3 edges.

If the portions of insulation panels have matching profiled edges, then stronger 6 prefabricated insulation panels may be produced.

8 Preferably the at least one layer of render may cover all of a common surface of 9 the at least two portions of insulation panel. This option produces a stronger prefabricated insulation panel.

12 Alternatively the at least one layer of render may cover part of a common 13 surface of the at least two portions of insulation panel. Optionally the at least 14 one layer of render may cover only the junctions between/among the at least two portions of insulation panel. These last options produce savings in render 16 material.

18 Preferably the prefabricated insulation panel comprises a layer of render on 19 either common surface of the at least two portions of insulation panel.

21 By applying a layer of render to each side of the prefabricated insulation panel, 22 this will exhibit an enhanced strength against tensions, deformation forces and 23 rupture.

Preferably the at least one layer of render may comprise a plaster material. It 26 will be understood that other render materials might be used without departing 27 from the scope of the present invention.

29 Preferably the at least one portion of reinforcing material is a single portion of reinforcing material extending through a whole or part of the at least one layer 31 of render and partially embedded on or in it. More preferably the prefabricated 32 insulation panel comprises two portions of reinforcing material each at least 33 partially embedded in or on a layer of render at least partially embedded on 34 either common surface of the at least two portions of insulation panel.

2 Optionally the prefabricated insulation panel may comprise a plurality of 3 portions of reinforcing material embedded in or on throughout all or part of the 4 at least on layer of render.

6 Optionally the prefabricated insulation panel may comprise a plurality of 7 portions of reinforcing material covering only the junctions between/among the 8 two or more portions of insulation panel.

By covering only the junctions between the two or more portions of insulation 11 panel, a saving in reinforcing material can be obtained.

13 Preferably the reinforcing material may be mesh cloth. It will be appreciated that 14 other reinforcing materials other than mesh cloth might be used, for instance, fibres, paper, cardboard, etc without departing from the scope of the invention.

17 According to a second aspect of the invention there is provided a method of 18 producing a prefabricated insulation panel comprising the steps of providing at 19 least one portion of reinforcing material, providing at least one layer of render, at least partially embedding the at least one portion of reinforcing material on or 21 in the at least one layer of render, providing at least two portions of insulation 22 panel, placing the at least two portions of insulation panel at least partially 23 embedded on the at least one layer of render and in close proximity to and 24 substantially coplanar with at least one of the at least two portions of insulation panel, and drying the at least one layer of render in an enclosed space.

27 Preferably the method may comprise providing at least one portion of 28 reinforcing material at least partially embedded in or on each of the at least one 29 layer of render. Optionally the method may comprise providing one portion of reinforcing material at least partially embedded in or on each of the at least one 31 layer of render. Alternatively, the method may comprise providing a plurality of 32 portions of reinforcing material at least partially embedded in or on each of the 33 at least one layer of render.

1 Preferably the method may comprise providing a layer of render at both sides of 2 the at least two portions of insulation panel.

4 Preferably the method may comprise providing three or more portions of insulation panels. In this way the prefabricated insulation panels produced will 6 insulate a building through a faster installation. Supersized prefabricated 7 insulation panels may be produced in this way.

9 Optionally the method may be carried out in a diagonal or vertical configuration.

ii Preferably the method may be carried out in a substantially vertical 12 configuration and the step of providing the at least one layer of render may 13 comprise providing at least two layers of render and it may be performed by a 14 vertical spraying machine on both sides of the at least two portions of insulation panels simultaneously.

17 The benefits of using a substantially vertical configuration for carrying out the 18 method is that it is possible to provide two layers of renders at both sides of the 19 insulation panels simultaneously and the cost of producing a prefabricated insulation panel may be significantly lower. Another benefit of the diagonal or 21 vertical configurations is that the floor area required for carrying out the method 22 is smaller than in the horizontal configuration.

24 Using a spraying machine for applying the layers of render in a vertical configuration greatly simplifies this process over other methods of applying the 26 layers of render. Additionally, by applying a layer of render at each side of the 27 insulation panels simultaneously balances the forces exerted on the insulation 28 panels and therefore the risk of being moved or displaced is minimised.

Alternatively the method may be carried out on a substantially horizontal 31 surface, such as a processing table. More advantageously, the method may be 32 carried out on a niultifunction bridge with plastering capability.

1 A horizontal surface is suited to carry out the method because it is easier to 2 support a layer of render and the insulation panels embedded thereon on a 3 substantially horizontal surface. A multipurpose bridge with a plastering fitting is 4 more convenient because it facilitates the step of providing at least on layer of render.

7 Preferably the step of drying the at least on layer of render may be carried out in 8 a different location than the previous steps. By moving the fresh prefabricated 9 insulation panels to another location for drying, the place for producing the fresh panels is freed for producing further fresh panels. The drying of the fresh 11 insulation panels takes a long time as it cannot be speeded up by heating or 12 ventilation as this would create tensions and produce cracks and crevices in the 13 layer(s) of render.

Additionally the method may comprise the step of cutting in the production place 16 the prefabricated insulation panels after drying. By cutting the prefabricated 17 insulation panels to a desired dimension in the production facility, the 18 installation of the panels on a building is greatly simplified. Cutting the panels to 19 a desired dimension in the production place serves to accommodate the prefabricated insulation panels' dimensions to the building's dimensions and 21 shapes prior to transporting the panels outdoors, at the building location. This is 22 very convenient as it reduces the time spent at the installation site, the costs of 23 installation personnel and improves the frequency in which external insulation 24 installations are viable due to weather restrictions. The fact that the prefabricated insulation panels according to this invention can be of the size of 26 several commercial or standard insulation panels makes the installation process 27 so much more rapid and more advantageous for external insulations.

29 Preferably the step of cutting the prefabricated insulation panels may be carried out with a CNC controlled saw with the prefabricated insulation panels in a 31 vertical position.

33 Optionally the step of cutting the prefabricated insulation panels is carried out 34 with a multipurpose bridge fitted with computer numeric control (CNC) and a 1 circular saw fitting. The use of a multipurpose bridge with CNC and a circular 2 saw fitting allows a more precise and faster cutting of the prefabricated 3 insulation boards. Another advantage is that the external dimensions of the 4 building can be acquired by scanning the building and the dimensional data can be transferred to the CNC of the multipurpose bridge. This enables a better 6 planning of the cutting process and well as optimising the use of material for the 7 insulation of a building. Additionally, error measurements are minim ised.

9 Embodiments of the second aspect of the invention may include one or more features of the first aspect of the invention or its embodiments or vice versa.

12 According to a third aspect of the invention, there is provided a method of 13 installing the prefabricated insulation panels produced according to the second 14 aspect of the invention on a building comprising the steps of transporting the prefabricated insulation panels to the building location, lifting each of the 16 prefabricated insulation panels with the aid of a vacuum lifting device, applying 17 a layer of adhesive on one side of each of the prefabricated insulation panels, 18 facing each of the prefabricated insulation panels to a wall of the building to be 19 insulated, applying pressure to each of the prefabricated insulation panels against the wall of the building, attaching corner and revealing beads after the 21 exterior walls of the building are covered with prefabricated insulation panels, 22 applying a topcoat on the prefabricated insulation panels and leaving the 23 topcoat to dry.

Optionally the method of installing the prefabricated insulation panels may 26 comprise the step of applying mechanical fixing means, such as mechanical 27 dowels.

29 Preferably the step of facing the prefabricated insulation panels to a wall of the building is carried out with the aid of a vacuum lifting device. The use of vacuum 31 lifting devices greatly facilitates the handling of the very large prefabricated 32 insulation panels.

1 Optionally the method of installing the prefabricated insulation panels may 2 comprise the step of using a crane or a mini crane to install the prefabricated 3 insulation panels at high locations.

The use of a crane or a mini crane is beneficial because it avoids using 6 scaffolding surrounding the building. The use of scaffolding takes time to erect it 7 and adds to the cost of installation. If the use of scaffolding is avoided, it will be 8 more likely that external insulation of buildings can be implemented at a large 9 scale, due to affordable costs and short times taken for installation.

11 Embodiments of the third aspect of the invention may include one or more 12 features of the first or second aspects of the invention or their embodiments and 13 vice versa.

According to a fourth aspect of the invention there is provided a building or 16 construction, the exterior walls of which have been insulated with prefabricated 17 insulation panels according to the first aspect of the invention.

19 A building or construction that has been insulated with prefabricated panels according to the first aspect of the invention will be less prone to thermal 21 bridging or to develop cold spots, due to the fact that the render between the 22 individual insulation panels has been dried in conditions where cracks and 23 crevices are minimised and the render between the prefabricated insulation 24 panels has had more time to dry in favourable conditions. Additionally, a building isolated with the prefabricated insulation panels will be less prone to 26 develop points of moisture ingress to the walls of the building for the same 27 reason as mentioned before.

29 Embodiments of the fourth aspect of the invention may include one or more features of the first, second or third aspects of the invention or their 31 embodiments and vice versa.

1 Brief description of the drawings

3 Embodiments of the present invention will now be described, by way of example 4 only, with reference to the accompanying drawings, in which: 6 FIG. 1 A is an illustration of the first step of the method of producing a 7 prefabricated thermal insulation panel according to an embodiment of the 8 present invention.

FIG. 1 B is an illustration of the second step of the method of producing a 11 prefabricated thermal insulation panel according to an embodiment of the 12 present invention.

14 FIG. 1 C is an illustration of the third step of the method of producing a prefabricated thermal insulation panel according to an embodiment of the 16 present invention.

18 FIG. 1 D is an illustration of the fourth step of the method of producing a 19 prefabricated thermal insulation panel according to an embodiment of the present invention.

22 FIG. 1 E is an illustration of the fifth step of the method of producing a 23 prefabricated thermal insulation panel according to an embodiment of the 24 present invention.

26 FIG. 2 is an illustration of a 3 dimensional scan of a building to be insulated, 27 according to the installation method provided by an embodiment of the present 28 invention.

FIG. 3 is an illustration of the additional step of cutting a prefabricated thermal 31 insulation panel according to an embodiment of the present invention.

1 Detailed description of preferred embodiments

3 Referring now to Fig. 1 A, the first step of the method of producing prefabricated 4 insulation panels according to an embodiment thereof will now be described. In Fig. 1 A there is shown a computer numerically controlled (CNC) multifunction 6 bridge 1, such as the model WMS-1 70 supplied by Weinmann 7 Holzbausystemetechnik GmbH typically used in the carpentry industry. The 8 multifunction bridge is equipped with a process table 2 and a numerical control 9 unit 3. The multifunction bridge 1 is fitted with a plastering head 4.

11 It must be noted that the use of a multi-function bridge is not an essential part of 12 the invention, but it will greatly facilitate its implementation. Alternatively, other 13 machines different from a multi-function bridge could be used in order to 14 implement the present invention, as it will be described in another embodiment.

16 In this first step, a mesh cloth 5 is laid on the process table 2 by the operators 17 (not shown). Other reinforcing materials may be used.

19 Referring now to Fig. 1 B, the subsequent step of the method of the present invention according to an embodiment thereof will now be described. The 21 multifunction bridge MS-170 fitted with a plastering head 4 covers the mesh 22 cloth 5 with a base coat render 6 to a thickness of up to 4 mm. It will be 23 understood that other render thickness may be applied without departing from 24 the scope of the invention.

26 Referring now to Fig. 1 C, the subsequent step of the method of the present 27 invention according to an embodiment thereof will now be described. The 28 operatives (not shown) place standard or commercially available EPS 4.8 m x 29 1.2 m insulation boards 7 on top of the base coat render and mesh cloth strip and butted tightly together lengthwise and end to end to cover approximately an 31 area 8 of 24 m x 2.4 m. The insulation boards have flat edges in this 32 embodiment but it may be understood that also insulation boards with matching 33 profiled edges may be used. Other insulating materials or combinations thereof 34 may be used.

2 Referring now to Fig. 1 D, the subsequent step of the method of the present 3 invention according to an embodiment thereof will now be described. The 4 multifunction bridge MS-i 70 1 fitted with the plastering head 4 covers the 24 m x 2.4 m area 8 where the EPS panels 7 are located with a second thick render 6 coat9ofupto4mm.

8 After this, another mesh cloth portion 10 is embedded onto the recently applied 9 render layer, as can be seen in Fig. 1 E, and the render surface is smoothed flat by the multifunction bridge.

12 Once a supersized preassembled insulation panel is produced 20, it is 13 transferred to another table and left to dry under controlled drying conditions. In 14 order to flip the supersized prefabricated insulation panels for drying the lower side of it, it is convenient to use a butterfly table.

17 The drying conditions are such that the render coats dry off at a slow rate to 18 avoid cracks and crevices taking place. Preferably the drying takes place at a 19 temperature between S and 15 °C. The drying rate is very important, because if the render coats dry too quickly, then it is likely that cracks and crevices form, 21 especially where the individual insulation panels join, and therefore the eventual 22 building insulation will not be of appropriate quality, as it would have points of 23 moisture ingress and thermal bridging or cold spots.

Now referring to figure 2, when a retrofit insulation project is undertaken, a 3D 26 scan 11 of the external dimensions of the building 13 that is to be insulated is 27 performed, including the dimensions of doors, windows or any other areas that 28 should not be insulated. The external area 12 to be insulated is divided is 29 smaller areas 14 which can be covered with a supersized preassembled insulation panel.

32 Referring now to Figure 3, the dimensions of the smaller areas 14 in Fig. 2 are 33 then transferred to the CNC multifunction bridge 1 fitted with a circular saw 34 attachment 15. Fig. 3 shows a CNC multifunction bridge 1 fitted with a circular 1 saw attachment 15 cutting a supersized preassem bled insulation panel 2 according to the measured smaller areas 14. The off cuts 16 can be recycled for 3 other panel shapes and sizes.

The cut panels are arranged in installation order and transported to the 6 installation site.

8 In order to facilitate the handling and installation of the supersized 9 preassembled panels, vacuum lifting equipment is used, such as the Cladboy and Rotaboy, manufactured by 4 Cladding Services Limited.

11 The cut supersized preassembled insulation panels are attached to the exterior 12 walls of the building to be insulated. The attachment can be effected by 13 applying a suitable adhesive, a mortar, anchors, metal fittings etc. However the 14 preferred method is to apply a Polyurethane (PU) adhesive, because it is less time consuming. It is necessary to apply pressure to the panels to ensure a 16 good adhesion to the substrate.

18 When a building is of considerable height, it is also necessary to use a mini 19 crane to install the panels which are to be located in the highest parts of the building.

22 When all the panels have been attached to the facade, then corner and reveal 23 beads are attached in preparation for the topcoat render. The last step is to 24 apply a plaster topcoat render onto the prefabricated insulation panels attached to the walls. It will be understood that other topcoats might be applied, such as 26 "dry dash" topcoat, "wet dash" topcoat, brick topcoat, etc. 28 It will now be described how the prefabricated insulation panels according to the 29 present invention can also be produced by another embodiment of the second aspect of the invention, performed in a vertical configuration.

32 Firstly, an operative places 120mm thick EPS 4.8m X 1.2m insulation boards 33 butted tightly together one on top of each other to form approximately 4.Bm long 34 X 2.4m high EPS panel into a vertical frame.

1 A vertical stucco' spraying machine, such as the Randek PMOO1 vertical 2 stucco' machine, simultaneously applies a base render coat of approximately 3 4mm of thickness to both sides of the panel covering the whole with of the panel 4 except a vertical strip at each end of the panel. A mesh cloth wider than the S panel is embedded on both sides of the panel, leaving an unembedded vertical 6 strip of mesh cloth at each end of the panel for subsequent overlapping 7 between two adjacent panels. Typically the unembedded strip of mesh cloth has 8 twice the width of the un-plastered vertical strip. Finally, each surface is 9 smoothed flat by the machine blades, again simultaneously on both sides. The panel is then moved along to a different location where the drying process takes 11 place.

12 Once several panels are dry enough, they are joined together side by side to 13 form a continuous coplanar ensemble by applying sprayed render on the 14 unrendered strips and overlapping the loose ends of mesh cloths and embedding them in the freshly rendered strips. Then a smoothing of the surface 16 flat by the machine blades is carried out. As before this operation is performed 17 on both sides simultaneously.

19 After drying, the cutting of the prefabricated insulation panels is carried out with a CNC controlled saw with the prefabricated insulation panels still in a vertical 21 position.

23 The present invention provides a prefabricated insulation panel which allows an 24 easier and more economic installation of retrofit external thermal insulation due to its ability to be produced in large sizes. An off-site method for its production 26 that allows for render drying in enclosed locations is also provided together with 27 a method of installation of the prefabricated insulation panels. The production 28 method can be performed horizontally or vertically arranged with the aid of CNC 29 or CAD controlled machines. The installed insulation systems according to this invention are less prone to cracking and are easier, cheaper and require less 31 time to be installed.

1 Various modifications of the previous examples and embodiments may be 2 made within the scope of the invention as herein intended] and other 3 embodiments of the invention may include combinations of features other than 4 those expressly described herein.