GB2560812A

GB2560812A - Improved insulated building section

Info

Publication number: GB2560812A
Application number: GB1801640.2A
Authority: GB
Inventors: Nunez Ronnie; Hayashi Yuki; Elliott Timothy; Tomkins Cameron; O'chee Milton
Original assignee: James Hardie Technology Ltd
Current assignee: James Hardie Technology Ltd
Priority date: 2017-02-01
Filing date: 2018-02-01
Publication date: 2018-09-26
Also published as: GB201701678D0; GB201801640D0; AU2018100127A4; GB2560812A8

Abstract

The insulated section comprises at least one framing section, each comprising framing members 120, with a space between the framing members defining a stud bay for receiving insulation 180, where first and second faces of each framing section define first and second major surfaces, with cladding 160, 170 on at least one of the major surfaces, the thickness of the insulation being less than the thickness between the major surfaces so forming a cavity 190 between 20mm and 50mm thick for service supply lines 192 between the second major surface and the insulation, at least one framing member having an aperture for accommodating a service supply line. Weather resistant barriers 127 may be located between the major surfaces and cladding. The insulation may be a batt, block, roll, matt, or pillow of inorganic wool. The cladding may be interior or exterior, be fibre cement, and be finished with sealer, primer, or paint. Joints between adjacent sections may be sealed for weatherproofing. The service supply lines may be electricity, water, gas, data, energy, air-conditioning, or television. Also claimed is a method of constructing the insulated building section.

Description

(56) Documents Cited:

E04B2/56 (2006.01) E04B5/48 (2006.01) E04B 9/04 (2006.01) (71) Applicant(s):

James Hardie Technology Limited

Europa House, Second Floor, Harcourt Centre,

Harcourt Street, Dublin, D02WR20, Ireland

GB 2459936 A JP 2000291172 A US 4488390 A US 20120096785 A1 JP H0932140 JPH02171447

FR 002941249A1 US 5953883 A US 4393633 A (72) Inventor(s):

Ronnie Nunez Yuki Hayashi Timothy Elliott Cameron Tomkins Milton O'Chee (58) Field of Search:

INT CL E04B Other: EPODOC, WPI (74) Agent and/or Address for Service:

Jamie Hardie Technology Limited

Europa House, Second Floor, Harcourt Centre,

Harcourt Street, Dublin, DO2 WR20, Ireland (54) Title of the Invention: Improved insulated building section

Abstract Title: Insulated building section with cavity for service supply lines (57) The insulated section comprises at least one framing section, each comprising framing members 120, with a space between the framing members defining a stud bay for receiving insulation 180, where first and second faces of each framing section define first and second major surfaces, with cladding 160, 170 on at least one of the major surfaces, the thickness of the insulation being less than the thickness between the major surfaces so forming a cavity 190 between 20mm and 50mm thick for service supply lines 192 between the second major surface and the insulation, at least one framing member having an aperture for accommodating a service supply line. Weather resistant barriers 127 may be located between the major surfaces and cladding. The insulation may be a batt, block, roll, matt, or pillow of inorganic wool. The cladding may be interior or exterior, be fibre cement, and be finished with sealer, primer, or paint. Joints between adjacent sections may be sealed for weatherproofing. The service supply lines may be electricity, water, gas, data, energy, air-conditioning, or television. Also claimed is a method of constructing the insulated building section.

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IMPROVED INSULATED BUILDING SECTION

FIELD OF THE INVENTION

The present invention relates to buildings and in particular to insulated building sections.

The invention has been developed primarily for use as an improved insulated building section for use in residential or commercial building construction and will be described hereinafter with reference to this application. However, it will be appreciated that the invention is not limited to this particular field of use.

BACKGROUND OF THE INVENTION

Any discussion of the prior art throughout the specification should in no way be considered as an admission that such prior art is widely known or forms part of the common general knowledge in the field.

Insulating cavities in a building section to improve thermal, acoustic and other properties by fully filling the cavity space with an insulating material, such as fibre glass batts, is known. This approach sometimes creates problems when service supply lines, for example, electrical wiring or plumbing and the like are installed within the cavity. Installation of the supply lines can disrupt the insulation layer by penetrating through it or by providing a “cutout” resulting in a lower insulation value of the building section. If the insulation is intended to improve fire resistance of a building section, such as a wall section, any break, or reduction in thickness of the insulating material, could compromise the fire resistance performance.

It is desirable to provide an improved insulated building section that can accommodate installation of service supply lines without compromising insulation performance, particularly in relation to thermal, acoustic, fire resistance properties and the like.

OBJECT OF THE INVENTION

It is an object of the present invention to overcome or ameliorate at least one of the disadvantages of the prior art, or to provide a useful alternative.

In one form of the invention, it is intended to provide an improved insulated building section for accommodating installation of service supply lines without compromising insulation performance of the building section, particularly in relation to thermal, acoustic, and fire resistance properties.

SUMMARY OF THE INVENTION

According to one embodiment there is provided an insulated building section comprising: at least one framing section, each framing section comprising a plurality of framing members and at least one space disposed between the plurality of framing members, each framing member comprising a first face, a second face, and a framing member thickness between the first face and the second face; each framing section is configured such that the first face of each framing member defines a first major framing section surface, the second face of each framing member defines a second major framing section surface, the framing member thickness of each framing member defines a framing section thickness and the at least one space disposed between the plurality of framing members defines a stud bay comprising a height, a width and a stud bay thickness equal to the framing member thickness;

at least one interior or exterior cladding element, disposed on at least one major framing section surface;

one or more insulating elements disposed in the stud bay such that at least one first major face of at least one of the one or more insulating elements is contiguous to and planar with the first major framing section surface of the at least one framing section, wherein each insulating element comprises a first major face and a second major face and a thickness between the first major face and the second major face and wherein the thickness between the first major face and the second major face of at least one or more insulating elements is between 20 to 50mm less than the thickness of the framing section thickness such that a cavity space is formed between the second major face of the one or more insulating elements and the second major framing section surface wherein the cavity space is configured to accommodate at least one service supply line; and wherein at least one framing member further comprises at least one aperture for accommodating at least one service supply line.

In use, at least one service supply line is accommodated in the cavity space without requiring any penetration through, or damage to, a respective insulating element during installation of the at least one service supply line. In this way it is possible to maintain complete coverage of each stud bay by an insulating element, which provides an improved performance of a constructed insulated building section.

In one embodiment, the configuration of the plurality of framing members and the at least one space between the plurality of framing members is such that the one or more framing members are arranged to form a frame structure which surrounds the at least one space wherein the frame defines the height, the width and the thickness of the stud bay.

In one embodiment, each insulating element further comprises a height and a width configured to substantially correspond to the height and the width of a respective stud bay. In one embodiment, the height and width of each insulating element is sized such that it is slightly larger than the height and width dimensions of the respective corresponding stud bay in which it is being placed such that a self-supporting, friction fit between the insulating element and the surrounding framing member is provided. In this way, the or each insulating element provided in the stud bay of each framing section is secured within the framing members such that there are no gaps between the or each insulating element and the surrounding framing members.

According to one embodiment, the thickness of the one or more insulating elements is approximately 30mm less than the framing section thickness.

According to one embodiment, at least one of the one or more insulating elements is formed from a composite material.

According to one embodiment, at least one of the one or more insulating elements is provided in the form of a batt, block, roll, mat, and/or pillow.

According to one embodiment, at least one of the one or more insulating elements is formed from an inorganic wool.

In one embodiment the at least one interior or exterior cladding element comprises an interior cladding element, wherein the interior cladding element is disposed on the at least second major framing section surface of the insulated building section.

In a further embodiment, the at least one interior or exterior cladding element further comprises an exterior cladding element, wherein the exterior cladding element is disposed on the at least one first major framing section surface of the insulated building section.

According to one embodiment, the at least one interior or exterior cladding element comprises a fibre cement cladding element.

According to one embodiment, a weather resistant barrier is optionally disposed between the at least one of the first or second major framing section surface and the at least one interior or exterior cladding element of the insulated building section. In one embodiment the weather resistant barrier comprises a house wrap or a building paper.

According to one embodiment, wherein the insulated building section comprises a weather resistant barrier, the weather resistant barrier further comprises a sealing tape. In use, it is possible to seal any tears, cuts and/or joins in the weather resistant barrier with the sealing tape prior to installation of the at least one interior or exterior cladding element.

According to one embodiment, the at least one interior or exterior cladding element comprises a weather resistant surface finish. In a further embodiment, the weather resistant surface finish comprising a coating layer. In another embodiment, the weather resistant surface finish comprises at least one of a sealer, primer or paint layer.

According to one embodiment, a service supply line provides one or more services from the group comprising water, gas, electricity, lighting, communication, data transmission, security monitoring, security alerts, automation, energy management, television, home theatre, distributed audio, heating, ventilation, air-conditioning, vacuum cleaning, exhaust, and drainage.

According to one embodiment, the one or more framing sections comprises a plurality of framing sections. In one embodiment each of the framing sections in the plurality of framing sections are located adjacent to each other such that the insulated building section comprises an array of framing sections. Conveniently in such an embodiment, the at least one interior or exterior cladding element disposed on the at least one of the first or second major framing surface of adjacent framing section abut or overlap the other of the at least one interior or exterior cladding element disposed on the the first or second major framing surface of the adjacent framing section in order to form a closed joint between adjacent framing sections. In a further embodiment, sealant is disposed between any abutting or overlapping interior or exterior cladding elements to form weatherproof closed joints between adjacent framing sections.

According to one embodiment, there is provided a method of constructing an insulated building section comprising the steps of:

i. constructing at least one framing section, each framing section comprising a plurality of framing members and at least one space disposed between the plurality of framing members, each framing member comprising a first face, a second face, and a framing member thickness between the first face and the second face; each framing section is configured such that the first face of each framing member defines a first major framing section surface, the second face of each framing member defines a second major framing section surface, the framing member thickness of each framing member defines a framing section thickness and the at least one space disposed between the plurality of framing members defines a stud bay comprising a height, a width and a stud bay thickness equal to the framing member thickness, wherein at least one framing member further comprises at least one aperture for accommodating at least one service supply line;

ii. installing a first interior or exterior cladding element to cover one major framing section surface of each framing section;

iii. disposing one or more insulating elements the stud bay such that at least one first major face of at least one of the one or more insulating elements is contiguous to and planar with the first major framing section surface of the at least one framing section, wherein each insulating element comprises a first major face and a second major face and a thickness between the first major face and the second major face and wherein the thickness between the first major face and the second major face of at least one or more insulating elements is between 20 to 50mm less than the thickness of the framing section thickness such that a cavity space is formed between the second major face of the one or more insulating elements and the second major framing section surface wherein the cavity space is configured to accommodate at least one service supply line.

In one embodiment, the configuration of the plurality of framing members and the at least one space between the plurality of framing members is such that the one or more framing members are arranged to form a frame structure which surrounds the at least one space wherein the frame structure defines the height and the width of the stud bay.

In one embodiment, the method of constructing an insulated building section comprises the further step of iv. installing at least one service supply line into the cavity space.

In one embodiment, method step iv further comprises the step of penetrating framing members and or the interior or exterior cladding element if and as necessary.

In one embodiment, the method of constructing an insulated building section comprises the further step of

v. installing a second interior or exterior cladding element to cover the other or opposing major framing section surface of each framing section relative to the first interior or exterior cladding element installed at step ii of the method of constructing an insulated building section, such that the cavity space is enclosed.

In one embodiment, the method of constructing an insulated building section comprises the further step of vi. installing a weather resistant barrier between the first major framing section surface and the interior or exterior cladding element of step ii of the method of constructing an insulated building section.

In one embodiment the weather resistant barrier comprises a house wrap or a building paper.

According to one embodiment, wherein the insulated building section comprises a weather resistant barrier, the insulated building section further comprises a sealing tape. In use, it is possible to seal any tears, cuts and/or joins in the weather resistant barrier with the sealing tape prior to installation of the at least one interior or exterior cladding element.

Conveniently, the steps of the method together maintain complete coverage of the height and width of each stud bay by insulating element without requiring penetration of any service supply lines through the insulating element, thereby maintaining the integrity of the insulating material and providing an improved insulated wall section.

In a further embodiment, the method of constructing an insulated building section comprises the further step of painting the interior or exterior cladding elements to provide a weather resistant surface finish. Conveniently, the step of painting the interior or exterior cladding elements can be carried out on site or be a factory applied surface finish.

In a further embodiment, the method of constructing an insulated building section can be constructed in situ on site or alternatively constructed remotely and erected on-site.

In a further embodiment, the method of constructing an insulated building section further comprises the use of temporary bracing.

In a further embodiment, the method of constructing an insulated building section further comprises the use of temporary bracing which is installed prior to erection of the framing section on-site.

In a further embodiment, the method of constructing an insulated building section comprises forming the at least one insulating element in situ.

In a further embodiment, the method of constructing an insulated building section comprises forming the at least one insulating element in situ by spraying.

BRIEF DESCRIPTION OF THE DRAWINGS

A preferred embodiment will now be described, by way of example only, with reference to the accompanying drawings in which:

Figure 1(a) to (h) shows a series of partially cut-away perspective views and one top sectional veiw outlining the construction of an improved insulated building section according to one embodiment. In the series of cut away perspective views of Figure 1, there is shown in Figure 1(a) a framing section installed in position; Figure 1(b) building paper or wrap installed over the framing section of Figure 1 (a); Figure 1 (c) a cladding element installed over the building paper or wrap of Figure 1(b); Figure 1(d) temporary bracing deployed on the side of the framing section remote from the cladding element of Figure 1 (c). It is to be understood that the temporary bracing is removed once the framing section is suitably secured in position; Figure 1(e) at least one insulating element being installed in a stud bay; Figure 1(f) a service supply line installed within adjacent stud bays; Figure 1(g) a further cladding element installed to close the stud bays; and Figure 1 (h) a top sectional view of the insulated building section;

Figure 2 (a) is a perspective view of a partial section of a “Zero lot” style wall section construction with two adjacent improved insulated building sections;

Figure 2(b) is a cross-sectional side view of the installation seen in Figure 2(a) showing two improved insulated building sections according to one embodiment, installed adjacent each other in a “Zero Lot” style application;

Figure 2(c) is a perspective view of a partial wall section of a “Zero lot” style construction where one wall section is constructed adjacent a pre-existing wall section;

Figure 2(d) is a perspective view of a partial wall section showing two improved insulated building sections constructed as intertenancy wall sections; and

Figure 3 is a perspective view of a partially constructed dwelling showing an improved insulated building section, with second cladding partially cut away to better show construction detail, and expanded view panels detailing an electrical service supply line, and secondly both an electrical service supply line and a water service supply line.

Referring now to the drawings and specifically Figures 1 (a) to (h), there is shown one embodiment following the method of construction of an improved insulated building section 100 providing a wall section.

Framing section 110, as best shown in Figure 1 (a), comprises a plurality of framing members 120, each framing member comprising a first face 122 and a second face 124 and a thickness 126. Framing members 120 may be timber or any generally accepted equivalent building material. Width and thickness dimensions of framing members may vary according to local building practice, with 90mm x 45mm being commonly used as nominal thickness and width dimensions respectively. Length can be user determined to meet local regulations or local building practice preference. For example, in Australia, there is a maximum length (equivalent to height in an installed wall framing section) of 3000mm allowed for each storey height in a residential dwelling when using 90mm x 35mm studs. This height can increase, for example, to 4200mm for a 90mm x 90mm stud size and so on, so long as the required structural capacity requirements are met.

In practice, timber framing members include both studs and noggings in addition to the top and bottom plates. In a wall section, such as that shown in Figure 1 (a) studs provide vertically oriented framing members 120a in an installed framing section, and noggings provide the horizontally oriented intermediate framing members 120b. The top and bottom plates provide the horizontal end framing members 120c (only the bottom plate is shown in Figure 1(a)). Stud spacings are controlled by local building practice and/or regulation. A typical stud spacing range would be at least 300mm, with alternate typical stud spacings ranging between approximately 400mm, 450mm or 600mm as desired by the end user. At least one framing section may also optionally include at least one bracing member 128, to improve bracing or racking strength. Each bracing member 128 may be made of timber, metal, plastic or other suitable building materials such as fibre cement, plywood and the like as are known in the art.

In one construction method, at least one framing section 110 is constructed in-situ. Each framing element 120 being fixedly connected to at least two other framing elements in its intended final in-service position. This is the traditional construction method used by builders and is well known in the art. In a newer, and alternate building method, at least one framing section 110 may be constructed remotely, and subsequently installed in a user determined position as one or more “modular’ framing section units. Construction of modular framing sections can be either carried out at a separate location on the construction site, or at a remote location such as at a manufacturer’s premises and subsequently transported to the construction site. During installation of one or more ‘modular’ framing sections in their intended in-service position, temporary bracing 196 (such as that shown in Figure 1(d)) may be used to provide temporary support of at least one individual framing section 110.

As best shown in Figure 1(b), once framing section 110 has been constructed, it may optionally have building wrap 127, also known as building paper or house wrap, applied to first major framing section surface 112 by any normal accepted means, such as stapling. Building wrap 127 may be applied after installation of framing section 110, in the case of a framing section constructed insitu, or prior to installation, in the case of a framing section constructed remotely. If more than one piece of building wrap is required to cover first major framing section surface 112, additional pieces may be used, and any joins, tears or punctures sealed by use of a suitable sealing tape (not shown). One suitable form of building wrap 127 would be a non-perforated, breathable, reflective and glare-safe type building wrap, such as HardieWrap™ Weather Barrier.

Although not shown, it is understood that one or more trim and/or flashing element may also be fixed through first major framing section surface 112 into framing section 110, to provide a desired aesthetic or functional effect. Examples of such elements include corner trimming, slab edge covering, cladding starter strip, water drainage, flashings, and the like. These accessory components may be positioned either under or over optional building wrap 127, as recommended by the manufacturer or supplier.

As best shown in Figure 1(c), a cladding element 160 may be installed by positioning a first cladding element 161 in user defined positions on, or relative to, first major framing section surface 112 and fixing through first major framing section surface 112 to framing section 110. Cladding element 161 may be installed using any suitable means, such as for example any mechanical or chemical means known to the person skilled in the art. In one example, the fixing means could be mechanical fixings such as the fixing means 162 shown in Figure 1(g). One or more subsequent cladding elements 161’ can be installed in a similar way until first major framing surface 112 is covered by cladding elements 160. In one embodiment, cladding elements 160 may be installed prior to framing section 110 being installed into its permanent, in-service position. Such an approach is appropriate for boundary lot, or zero lot style construction techniques.

Cladding element 160 may be any suitable building cladding material known to the person skilled in the art, for example, in some embodiments, cladding element 160 may be in panel or plank form. If cladding element 160 is intended to provide an exterior wall cladding, it should be a material suitable for that application, such as, for example fibre cement cladding. If the wall section is intended to provide a 60/60/60 Fire Resistance Level (FRL), then the product should also be suited for that application. For example, it is possible to use a fibre cement panel that has a thickness that is greater than approximately 6mm, such as James Hardie’s EasyLap™ ZeroLot™ panel which is approximately 8.5mm thick. Installation of cladding element 160 should follow the manufacturer’s instructions regarding the use of any bond breaker tapes 164 (shown in Figure 1(g)), suitable joint sealants, or flashing/trim pieces.

Cladding elements 160 may require a protective surface treatment applied onsite, such as a paint coating, or it may be supplied with a protective treatment pre-applied.

If framing section 110 is constructed remotely, and subsequently moved into a user determined position, levelled and plumbed prior to being fixed to structural support 105, it may be temporarily supported in that position by means of temporary bracing 196, as best shown in Figure 1 (d), until framing section 110 is self-supporting.

As best shown in Figure 1 (e), each space between adjacent framing members 120 defines a stud bay 130, each stud bay comprises a height 140 and a width 150. First face 122 of each framing member 120 in a constructed framing section 110, together defines a first major framing section surface 112. Second face 124 of each framing member 120 in a constructed framing section 110, together defines a second major framing section surface 114. Thickness 126 of each framing member 120 in a constructed framing section 110, defines a framing section thickness 116.

Insulating element 180 is disposed in each stud bay 130. Each insulating element 180 comprises a height 182 and width 184 which are configured to completely fill a respective height 140 and width 150 of a (respective) stud bay 130. In one configuration, the height 182 and width 184 of insulating element 180 are slightly larger than the corresponding height 140 and width 150 of a respective stud bay 130 to allow a resistance fit of the insulating element 180 into the stud bay 130. It is estimated that a difference of approximately 5mm in each dimension is sufficient to ensure that the entire height 150 or width 140 of respective stud bay 130 is completely filled such that each installed insulating element 180 is placed slightly into compression in both directions to maintain a “friction fit” into the stud bay and prevent dislodgement of insulating element 180 during construction of the improved insulated building section 100. Each insulating element 180 is installed in a respective stud bay 130 by applying gentle pressure by hand to second major face 188 (Figure 1(h)), thereby urging insulating element 180 into stud bay 130 until first major face 187 (Figure 1 (h)) is level with first major framing section face 112.

Insulating element 180 may be formed from a homogeneous material such as an inorganic mineral wool. In some cases, that mineral wool may be specifically formulated and manufactured to provide high temperature resistance, such as is required to provide resistance to fire and the like. In one embodiment, insulating element 180 is a composite material formed by provided by covering either one or both major faces of a mineral wool “batt” type substrate with a protective and /or functional facing layer (not shown).

In an alternate configuration, insulating element 180 may be provided as a “pillow”, where a core of insulating inorganic wool is provided in a fabric casing, the fabric being either also insulating or sacrificial. In one embodiment it is preferable that the sizing of any pillow form insulating element 180 is such that the insulating material within the pillow’s covering material is approximately 5 mm larger in both height and width of any corresponding stud bay 130 dimensions.

In a further embodiment, insulating element 180 may be provided in a roll or mat format, where the user may bend, fold or otherwise manipulate the shape to meet the criteria that it completely cover each stud bay. Similarly to a simple batt style insulating element, the roll or mat format insulating element is sized such that it is slightly larger than the height 140 and width 150 dimensions of each stud bay 130 to provide a self-supporting, friction fit with no gaps between the roll or mat format insulating element 180 and a surrounding framing member 120.

Referring now to Figures 1(f) to 1(h). The thickness 186 of each insulating element 180, defined between each respective first major face 187 and second major face 188, is less than framing section thickness 116 thereby providing cavity space 190. Cavity space 190 is defined between second major face 188 of each insulating element 180 and second major framing section surface 114 can accommodate at least one service supply line 192, without requiring any penetration through insulating element 180 during installation, thereby maintaining complete coverage of height 140 and width 150 of each stud bay 130 by insulating element 180, and providing an improved performance of the constructed insulated building section.

Each service supply line 192 providing one or more services from the group comprising water, gas, electricity, lighting, communication, data transmission, security monitoring, security alerts, automation, energy management, television, home theatre, distributed audio, heating, ventilation, air-conditioning, vacuum cleaning, exhaust, and drainage. At least one framing member 120 in a framing section 110 is provided with an opening 193 to allow a service supply line 192 to pass through one or more stud bays 130 to provide one or more services to a desired location within a constructed insulated building section 100. Each insulating element 180 has a thickness 186 that is approximately 20-50 mm, and preferably approximately 30mm, less than the structural framing section thickness 116. It is preferable that each service supply line 192 does not penetrate, crush or damage insulation element 180. For example, in one embodiment, where cavity 190 is approximately 30mm deep, each service supply line 192 should be no more than 25mm in diameter and should not penetrate, crush or damage insulation element 180.

Once any service supply line 192 has been installed, a further cladding element 170 may be disposed on second major framing section face 114, as best shown in Figure 1(g) and fixed through second major framing section face 114 to framing section using fixings 162, whilst taking care not to damage any installed service supply line 192. Wherever an inlet or outlet port 194 for each service supply line 192 is required on further cladding element 170, a penetration or opening through further cladding element 170 can be made as desired, and the opening finished by means of finishing plates, trims, and the like 174. If further cladding element 170 is to provide an interior wall surface, then any suitable building product may be used. If the constructed wall section requires a 60/60/60 FRL rating, then a building product that can provide adequate performance in that application is required. An example of such a product is a fibre cement panelized product which is at least 6mm thick, such as, for example, James Hardie’s Villaboard™ lining. Manufacturer’s recommendations regarding the use of joint sealants and the like should be followed to achieve the best outcome. If further cladding element 170 provides an interior wall surface, it may be provided with an aesthetic, decorative finish, such as paint or wallpaper, generally applied prior to completion of the building’s construction.

In one embodiment, when insulating element 180 is a fire resistant mineral wool batt completely covering each stud bay 130, and used in combination with suitable first and second fibre cement cladding materials 160 and 170 as exemplified above, improved insulated building section 100 can provide a 60/60/60 FRL. An FRL of 60/60/60 refers to the time in minutes which a constructed wall section will resist exposure to heat and flame without a loss of structural integrity when tested to Australian standard test AS1530 Part 4. The FRL has 3 component properties measured: structural adequacy, integrity, and insulation. A constructed wall section that meets a 60/60/60 FRL means that each property has been adequately maintained for 60 minutes. In addition, the improved performance of insulated building section 100 may be non-fire related thermal insulation performance and/or acoustic insulation performance.

In an alternate construction method, as shown in Figure 2(a) and in cross-sectional view in Figure 2(b), at least two improved insulated building sections 100 are constructed as exterior wall sections adjacent each other with an approximate 50mm minimum separation space 199 between them.

Walls constructed in this method can be used in “Boundary Lot” or “Zero Lot” style dwellings where each dwelling in row type housing is built separately to, but adjacent with, at least one other similar dwelling with minimum separation between individual dwellings. Alternatively, in a further embodiment the construction being built could be a new insulated building section construction 100 and a pre-existing wall section of another building 198, as best shown in Figure 2(c). In each instance, each wall section is installed on a separate structural substrate 105, such as a concrete slab. In this construction style, first improved insulated building section 100 of a first dwelling is constructed either in-situ or remotely and installed in a user determined position. A second improved insulated building section 100 is then constructed remotely and installed in a user determined position adjacent to, and separated from, first improved insulated building section 100, with cladding element 160 of a first improved insulated building section 100 facing cladding element 160 of a second improved insulated building section 100 or the existing wall structure 198. Each wall section 110 accommodates one respective service supply line 192 within respective cavity space 190.

In another alternate construction method, such as used to construct intertenancy walls between adjacent dwelling spaces within the same building construction, as best shown in Figure 2(d), two improved insulated building sections 100 are constructed adjacent each other separated by a minimum separation spacing 199 of approximately 30mm, or whatever is required under local building regulations. In this construction style, cladding element 160 of each improved insulated building section 100 is optional, and building wrap 127 is optionally applied to first major framing surface 112 of each framing section 110.

In this construction method, each framing section 110 may be constructed on a single, common structural substrate 105, such as a single concrete slab. In this construction method, first framing section 110 of a first improved insulated building section 100 is constructed either in-situ, or remotely and installed in a user determined position. Framing members 120 are fixedly connected together, such as by means of nails, screws or any other suitable fixings as are known in the art, to construct a first framing section 110 to user determined dimensions. In an optional step, building wrap 127 may be disposed on first major framing surface 112 of first framing section 110 and may be fixed to first framing section 110 by means such as stapling. If first framing section 110 is constructed remotely, it can then be installed in its user determined position, ready to receive at least one insulating element 180 in each stud bay 130.

Each insulating element is cut to height 182 and width 184 dimensions that are each approximately 5 mm larger than the corresponding dimension of a respective stud bay 130 into which it will be fitted. Each insulating element 180 is gently urged into respective stud bay 130, until second major face 188 of insulating element 180 touches building wrap 127 (if used) or is level with first major framing surface 112. Care should be taken that there are no gaps between each framing member 120 and a corresponding accommodated insulating element 180. Thickness 186 of insulating element 180 is less than framing section thickness 116 thereby forming cavity space 190 between first major face 187 of insulating element 180 and second major framing section surface 114 for each wall section. At least one service supply line 192 is then installed into cavity space 190, without disturbing or damaging insulating element 180, penetrating through framing members 120 where required.

In this example, each cavity space 190 requires a minimum thickness of 25mm to allow for installation of at least one service supply line 192, preferably the cavity space thickness is approximately 30mm to allow for the installation of up to a 25mm service supply line. Once service supply line 192 is installed, further cladding element 170 is installed by fixing to second major framing section surface 114. Cut-outs may be made in further cladding element 170 to accommodate inlet/outlet ports 194 for each service supply line 192 installed. These cut-outs may be finished by installing aesthetic or functional finishing plates 174, trim and the like such as skirting 172, switch plates, taps, drainage ports, and the like, to suit each service installed. Further cladding element 170 may be finished by optionally applying a decorative surface treatment, such as a paint coating or wallpaper or the like to suit the owner/resident’s taste.

Figure 3 shows an example of an improved insulated building section 100 in a dwelling construction, and includes partial expanded views of (a) finishing plate 174 in position on cladding 170 to provide a functional and aesthetic finish to (in this case) electrical inlet/outlet port 174 in the upper expanded view panel, and (b) both service supply line 192 providing water supply with outlet 194 and service supply line 192 providing electricity supply with electrical inlet/outlet port 174 in the lower expanded view section.

In another construction method, an improved insulated building section is constructed for use as a flooring section (not shown).

Although the invention has been described with reference to specific examples, it will be appreciated by those skilled in the art that the invention may be embodied in many other forms.

Claims

THE CLAIMS DEFINING THE INVENTION ARE AS FOLLOWS:

1. An insulated building section comprising: at least one framing section, each framing section comprising a plurality of framing members and at least one space disposed between the plurality of framing members, each framing member comprising a first face, a second face, and a framing member thickness between the first face and the second face; each framing section is configured such that the first face of each framing member defines a first major framing section surface, the second face of each framing member defines a second major framing section surface, the framing member thickness of each framing member defines a framing section thickness and the at least one space disposed between the plurality of framing members defines a stud bay comprising a height, a width and a stud bay thickness equal to the framing member thickness;

at least one interior or exterior cladding element disposed on at least one major framing section surface;

2. An insulated building section according to Claim 1, wherein the one or more insulating element further comprises a height and a width configured to correspond to the height and the width of a respective corresponding stud bay.

3. An insulated building section according to Claim 1, wherein the height and width of the one or more insulating element is sized such that it is slightly larger than the height and width dimensions of a respective corresponding stud bay in which it is being placed such that a self-supporting, friction fit between the insulating element and the surrounding framing member is provided.

4. An insulated building section according to any one of the preceding claims, wherein the thickness of the one or more insulating elements is approximately 30mm less than the framing section thickness.

5. An insulated building section according to any one of the preceding claims, wherein at least one of the at least one or more insulating elements is formed from a composite material.

6. An insulated building section according to any one of the preceding claims, wherein at least one of the at least one or more insulating elements is provided in the form of a batt, block, roll, mat, and/or pillow.

7. An insulated building section according to any one of the preceding claims, wherein at least one of the at least one or more insulating elements comprises an inorganic wool.

8. An insulated building section according to any one of the preceding claims, wherein the at least one interior or exterior cladding element comprises an interior cladding element, wherein the interior cladding element is disposed on the at least second major framing section surface.

9. An insulated building section according to Claim 8, wherein the at least one interior or exterior cladding element further comprises an exterior cladding element, wherein the exterior cladding element is disposed on the at least one first major framing section surface.

10. An insulated building section according to any one of the preceding claims, wherein the at least one interior or exterior cladding element comprises a fibre cement cladding element.

11. An insulated building section according to any one of the preceding claims, wherein a weather resistant barrier is disposed between the at least one of the first or second major framing section surface and the at least one interior or exterior cladding element.

12. An insulated building section according Claim 11, wherein the weather resistant barrier comprises a house wrap or a building paper.

13. An insulated building section according Claim 11 or Claim 12, wherein weather resistant barrier further comprises a sealing tape.

14. An insulated building section according to any one of the preceding claims, wherein the at least one interior or at least one exterior cladding element comprises a weather resistant surface finish.

15. An insulated building section according to Claim 14, wherein the weather resistant surface finish comprising a coating layer.

16. An insulated building section according to any one of Claim 14 or Claim 15, wherein the weather resistant surface finish comprises at least one of a sealer, primer or paint layer.

17. An insulated building section according to any one of the preceding claims, wherein the at least one service supply line provides one or more services from the group comprising water, gas, electricity, lighting, communication, data transmission, security monitoring, security alerts, automation, energy management, television, home theatre, distributed audio, heating, ventilation, air-conditioning, vacuum cleaning, exhaust, and drainage.

18. An insulated building section according to any one of the preceding claims, wherein the insulated building section comprises a plurality of framing sections located adjacent to each other such that the insulated building section comprises an array of framing sections.

19. An insulated building section according to Claim 18, wherein the at least one interior or exterior cladding element disposed on the at least one of the first or second major framing section surface of adjacent framing sections abut or overlap each other to form a closed joint between adjacent framing sections.

20. An insulated building section according to Claim 19, wherein a sealant is disposed between any abutting or overlapping at least one interior or exterior cladding element to form weatherproof closed joints between adjacent framing sections.

21. A method of constructing an insulated building section comprising the steps of:

iii. disposing one or more insulating elements in the stud bay such that at least one first major face of at least one of the one or more insulating elements is contiguous to and planar with the first major framing section surface of the at least one framing section, wherein each insulating element comprises a first major face and a second major face and a thickness between the first major face and the second major face and wherein the thickness between the first major face and the second major face of at least one or more insulating elements is between 20 to 50mm less than the thickness of the framing section thickness such that a cavity space is formed between the second major face of the one or more insulating elements and the second major framing section surface wherein the cavity space is configured to accommodate at least one service supply line.

22. A method of constructing an insulated building section according to Claim 21, wherein the method of constructing an insulated building section comprises the further step of;

iv. installing at least one service supply line into the cavity space.

23. A method of constructing an insulated building section according to Claim 22, wherein method step iv further comprises the step of penetrating framing members and or the first interior or exterior cladding element as necessary.

24. A method of constructing an insulated building section according to any one of Claim 21 to Claim 23, wherein the method of constructing an insulated building section comprises the further step of;

25. A method of constructing an insulated building section according to any one of Claim 21 to Claim 24, wherein, wherein the method of constructing an insulated building section comprises the further step of;

vi. installing a weather resistant barrier between the first or second major framing section surface and the interior or exterior cladding element of step ii and or step v of the method of constructing an insulated building section.

26. A method of constructing an insulated building section according to Claim 25, wherein the weather resistant barrier comprises a house wrap or a building paper.

27. A method of constructing an insulated building section according to Claim 25 or Claim 26, wherein the weather resistant barrier further comprises a sealing tape.

28. A method of constructing an insulated building section according to any one of Claim 21 to Claim 27, wherein the method of constructing an insulated building section comprises the further step of painting the first and/or second interior or exterior cladding elements to provide a weather resistant surface finish.

29. A method of constructing an insulated building section according to Claim 28, wherein the step of painting the first and/or second interior or exterior cladding elements can be carried out on site or be a factory applied surface finish.

30. A method of constructing an insulated building section according to any one of Claim 21 to Claim 29, wherein the method of constructing an insulated building section can be constructed in situ on site or alternatively constructed remotely and erected onsite.

31. A method of constructing an insulated building section according to any one of Claim 21 to Claim 30, wherein the method of constructing an insulated building section further comprises the use of temporary bracing.

32. A method of constructing an insulated building section according to Claim 31, wherein the use of temporary bracing is installed prior to erection of the at least one framing section.

33. A method of constructing an insulated building section according to any one of Claim 21 to Claim 32, wherein the method of constructing an insulated building section comprises forming the at least one insulating element in situ.

34. A method of constructing an insulated building section according to Claim 33, wherein the method of constructing an insulated building section comprises forming the at least one insulating element in situ by spraying.

Intellectual

Property

Office

Application No: Claims searched:

GB 1801640.2 1-34