GB2575764A

GB2575764A - Wall cladding system and methods of fabricating

Info

Publication number: GB2575764A
Application number: GB1718649.5A
Authority: GB
Inventors: Penston Christopher
Original assignee: Fab Lite Ltd
Current assignee: Fab Lite Ltd
Priority date: 2017-11-10
Filing date: 2017-11-10
Publication date: 2020-01-29
Also published as: GB201718649D0

Abstract

The system comprises a plurality of slips 310. The slips comprise an external face 301 facing away from a surface to be clad and an internal face facing towards the surface to be clad. Each slip also includes a groove formed within the edge of the slip. A clip 420 is disposed between the slips in use, such that the clip can be disposed in the grooves of one or more slips at any point along a groove. The slips may be located on a backing board 302 between the internal face and the structure. The grooves may exist along the full length of the slip and each slip may comprise multiple grooves. A clip may be square shaped in a front view and may also be T shaped. Also claimed: a method of producing a wall cladding system; a method of producing a wall with the cladding and a kit of parts including the system.

Description

DESCRIPTION

WALL CLADDING SYSTEM AND METHODS OF FABRICATING

Field

The present invention relates to a wall cladding system and methods of fabricating. In particular, a wall cladding system for cladding an external surface of a building and methods of pre- and post-fabricating such cladding is described.

Background

Cladding has become a popular method of finishing or renovating buildings. In particular, providing the appearance of stone or solid brickwork provides a pleasing aesthetic appearance.

Furthermore, cladding allows for the appearance of solid brickwork with significant weight-saving over using actual bricks. The use of cladding also improves the speed at which a building can be finished and consistency of appearance. In some cases, a much lower amount of actual bricks can be used, which obviously has benefits for weight and cost.

Typically such cladding is held onto an external surface of a building using a combination of adhesive and mechanical fixings. Figure 1 shows such a known panel, generally called a slip 110. In use 200 as shown in figure 2, slips 110 are stuck to a backing board 201, which has been mounted to battens 210 affixed to the external surface of a building. Screw fixings 220 secure the board to the battens.

However, whilst slips 110 help to improve the fagade of a building, the slips 110 are still only secured to the board 201 by adhesive. Accordingly, slips may fall off a building if a section of adhesive fails. While not a regular problem, a means for better securing slips to a backing board is desirable.

An alternative means of securing the slips is described in WO2017/077268, which uses a U-shaped clip that is mounted to the backing board. However, such a system relies on joint brackets that run along the length of the slips, which increases cost and further provide no support between adjacent slips. Furthermore, the brackets described are steel rails that are heavy, difficult to assemble and provide limited scope for positioning and securing.

An alternative system is therefore desired that at least ameliorates the above issues.

Summary

According to a first aspect of the present invention, there is provided a wall cladding system for cladding an external surface of a building, said system comprising: a plurality of slips, each slip comprising: an outer face facing away from the external surface; an inner face facing towards the external surface; and a groove formed within an edge of the slip; and one or more clips disposed between the slips, each clip comprising a tongued surface for engagement with grooves of one or more slips at any point along the groove.

The present invention provides an alternative system for affixing slips to an external surface of a building, and in particular allows greater stability compared to adhesive alone. The system also allows greater flexibility of where the slips are secured to the board. This provides the option to secure the slips at predefined points along the board, and may also allow the board to be modified to accommodate the clips at a particular position. This also provides greater flexibility in the bond pattern of the brickwork cladding, and in the joint size and profile of the mortar between brick slips. For example, the present system allows for intricate patterns such as herringbone arrangments, which are not possible through the use of rails that require specific attachment arrangments.

In an embodiment the groove may be formed within the full edge of the slip. By this is meant that the groove is formed along the full length of at least one edge of the slip.

The slip may comprise a plurality of grooves along multiple edges of the slip. This allows clips to secure slips along multiple edges and allows clips to secure slips horizontally and/or vertically, which is difficult to achieve with prior art systems.

In some embodiments each clip is substantially square shaped. In such examples, the tongued portion forms a substantially flat upper plate. It can be appreciated that other shaped clips may be utilised (such as circular clips have circular tongued portions.

The tongued surface may engage with the groove along approximately half the edge of the width of the tongued surface.

The clips may be secured to the external surface of the building such that the slips are secured to the external surface via the clips. Additionally, the securing means may sit proud of the inner face. In embodiments, the securing means is substantially level with the groove.

The clip may be formed of a plastics material, preferably polypropylene. This reduces cost compared to a metal clip or rail.

As noted above, the tongued surface of each clip may engage two or more slips. This ensures that the slips are held in place by the least amount of clips needed.

In embodiments the slip may be substantially rectangular. Brick slips imitate bricks in that they vary in size and shape. The present clip design offers flexibility to vary the position to suit the materials restrained. This offers a further advantage over continuous rails. In such examples the groove may be formed within the shorter edges of the slip.

The system, in embodiments, may comprise a backing board between the inner face and the external surface. The inner face of the slip may be affixed to the backing board. Adhesion is typically used to affix the slip to the backing board.

The clip may be substantially T-shaped. By T-shaped, it is intended that the clip has a substantially flat tongued upper surface that forms a head of the clip, and a lower portion of the clip that is configured to receive a securing means for securing the clip to the external surface. The securing means may splay the lower portion of the clip when securing the clip to the external surface.

According to a second aspect of the present invention there is provided a method of producing a wall cladding system for an external surface of a building, said method comprising the steps of: affixing a first slip to a backing board, said first slip comprising a groove formed within an edge of the slip; slotting a tongued surface of a clip within the groove; securing the clip to the external surface at a desired point along the groove; and affixing a second slip to the backing board by slotting a grooved edge of the second slip into the tongued surface.

According to a third aspect of the present invention there is provided a method of producing a wall cladding system for an external surface of a building, said method comprising the steps of: affixing a first slip to a backing board, said first slip comprising a groove formed within an edge of the slip; affixing a second slip to the backing board, said second slip comprising a groove formed within an edge of the slip; slotting a tongued surface of a clip within the grooves of the first and second slip to a desired point along the groove; and securing the clip to the external surface.

In both the second and third aspects, the clips allow a degree of modularity to build of the system. By allowing slips and/or the clips to be slid into position either along the tongued portion of the clips or within the groove, the clips can be positioned at any desired location, which provides the greatest flexibility during construction. This may, for example, allow the clips to be secured to the external surface at a point of strength of the system, rather than at predefined locations.

Both the second and third aspect provide for prefabricating wall cladding system off-site before then attaching the backing board of the pre-fabricated wall cladding system produced to an external surface of a building. This allows control of the process and allows the adhesive to fully dry etc.

Alternatively, it may be appreciated that the method of fabricating the wall cladding system may be done on site, in which case an initial step of: attaching the backing board to an external surface of a building may be undertaken.

According to a fourth aspect of the present invention there is provided a kit of parts for assembling a wall cladding system as defined in the first aspect.

It can be appreciated that, although certain examples and embodiments described above have been primarily described with respect to a single aspect, the features described are also applicable to the other aspects defined herein.

These and other aspects of the invention will be apparent from, and elucidated with reference to, the embodiments described hereinafter. The above discussion is not intended to represent every example embodiment or every implementation within the scope of the current or future Claim sets. The Figures and Detailed Description that follow also exemplify various example embodiments. Various example embodiments may be more completely understood in consideration of the following Detailed Description in connection with the accompanying Drawings.

Brief description of Drawings

Embodiments will be described, by way of example only, with reference to the drawings, in which figure 1 illustrates a prior art slip;

figure 2 illustrates a system for covering an external surface of a building using the slips of figure 1;

figure 3 illustrates a fagade covering an external surface of a building using the system of the present invention;

figure 4 is an illustration of a clip used in the system of figure 3;

figure 5 is a schematic of the system shown in figure 3;

figure 6a is a cross-section along the line A-A in figure 5; and figure 6b is a close-up of a portion of figure 6a.

Detailed description of embodiments

Figure 3 shows a pre-fabricated brick slip panel, sometimes referred to as a fagade, 300 covering an external surface of a building. A backing board 301 is provided, capable of being secured to an external surface of the building (in a similar manner to shown in figure 2). Slips 310 or panels are secured to the board 301 as will be described below. The slips 310 are affixed to the board 301 using adhesive and clips. Each slip 310 is provided with a groove 311 along at least one edge, preferably along at least two opposing edges.. The groove 311 typically runs along the entire height of the slip 310.

Figure 4 illustrates a clip 420 used to secure a slip 310 to the board 301. The clip is generally a T-shaped object having a squared tongued portion or surface 421. The tongued portion 421 may be considered to be an upper portion or head of the clip 420. A lower portion 422 of the clip 420 provides a means of stabilising the clip against the external surface or the backing board 301. The lower portion 422 allows the clip 420 to stand proud of the backing board 301, away from any adhesive typically used and present on the backing board. The lower portion comprises a central bore 423, which may be provided with a screw tap or may be configured to splay when a screw or other securing means is passed through the bore 423. A flared upper recess 424 formed in a general frustoconical shape is shaped to receive a head of a screw or other securing means (not shown).

Figure 5 is a schematic of the system of figure 3, showing the clips 420 visible through the slips 310. In the example shown, a first slip 310’ is secured to a horizontally adjacent second slip 310” by a first clip 420’. A second clip 420” secures the second slip 310” to another horizontally adjacent slip. Additionally, as shown, a third clip 420’” secures the first slip 310’ to another vertically adjacent slip.

It may be appreciated that the clips 420 can be secured to the slips 310 at any point along the length of the groove 311 within the slips. This allows particular slips to be reinforced with multiple clips, for example, which may be useful if particular slips are subject to greater external forces (such as high winds) than other slips. Additionally, by allowing the clips to secure the slips at any point along the groove, the clips can secure the slips at the most secure or strongest point on the external surface or backing board 301.

It should be noted that the Figures are diagrammatic and not drawn to scale. Relative dimensions and proportions of parts of these Figures have been shown exaggerated or reduced in size, for the sake of clarity and convenience in the drawings. The same reference signs are generally used to refer to corresponding or similar feature in modified and different embodiments.

Figure 6a shows a cross-sectional view through the line A-A in figure 5. In particular, this shows an external surface 301, a backing board 302 secured to the external surface in a similar manner to shown in Figure 2, and slips 310’, 310” secured via a clip 420’. A second clip 420” is also shown. Each clip is secured to the external surface through the backing board 302 using a securing means, such as screw 630. An adhesive layer 650 between the backing board 302 and the slips 420 is also shown.

Figure 6b is a close-up view of a portion of figure 6a. In addition to the elements described above, the tongued portion 421 and lower portion 422 of the clip 420 is shown. Screw 630 secures the clip through the backing board 302 into the external surface 301. In this figure, the role of the lower surface 422 to allow the clip 420 to stand proud of the backing board, away from adhesive layer 650 is evident. The securing means in this example is shown level with the groove 611 and tongued portion 421. A mortar or grout 640 is used to finish the fagade 300.

From reading the present disclosure, other variations and modifications will be apparent to the skilled person. Such variations and modifications may involve equivalent and other features which are already known in the art of building cladding structures, and which may be used instead of, or in addition to, features already described herein.

Although the appended claims are directed to particular combinations of features, it should be understood that the scope of the disclosure of the present invention also includes any novel feature or any novel combination of features disclosed herein either explicitly or implicitly or any generalisation thereof, whether or not it relates to the same invention as presently claimed in any claim and whether or not it mitigates any or all of the same technical problems as does the present invention.

Features which are described in the context of separate embodiments may also be provided in combination in a single embodiment. Conversely, various features which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable 5 sub-combination. The applicant hereby gives notice that new claims may be formulated to such features and/or combinations of such features during the prosecution of the present application or of any further application derived therefrom.

For the sake of completeness it is also stated that the term comprising does not exclude other elements or steps, the term a or an does not exclude a plurality, and reference signs in the claims shall not be construed as limiting the scope of the claims.

Claims

1. A wall cladding system for cladding an external surface of a building, said system comprising:

a plurality of slips, each slip comprising:

an outer face facing away from the external surface;

an inner face facing towards the external surface; and a groove formed within an edge of the slip; and one or more clips disposed between the slips, each clip comprising a tongued surface for engagement with grooves of one or more slips at any point along the groove.

2. The wall cladding system of claim 1, wherein the groove is formed within the full edge of the slip.

3. The wall cladding system of claim 1 or claim 2, wherein the slip comprises a plurality of grooves along multiple edges of the slip.

4. The wall cladding system of any preceding claim, wherein each clip is substantially square shaped.

5. The wall cladding system of any preceding claim, wherein the tongued surface engages with the groove along approximately half the edge.

6. The wall cladding system of any preceding claim, wherein the clips are secured to the external surface of the building such that the slips are secured to the external surface via the clips and wherein the securing means sits proud of the inner face, substantially level with the groove.

7. The wall cladding system of any preceding claim, wherein the clip is formed of a plastics material, preferably polypropylene.

8. The wall cladding system of any preceding claim, wherein the tongued surface of each clip engages two or more slips.

9. The wall cladding system of any preceding claim, wherein the slip is substantially rectangular, and wherein the groove is formed within the shorter edges of the slip.

10. The wall cladding system of any preceding claim, further comprising a backing board between the inner face and the external surface.

11. The wall cladding system of claim 10, wherein the inner face is affixed to the backing board.

12. The wall cladding system of claim 11, wherein the affixation is adhesive.

13. The wall cladding system of any preceding claim, wherein the clip is substantially T-shaped, such that the tongued surface forms an upper surface of the clip, and a lower portion of the clip is configured to receive a securing means for securing the clip to the external surface.

14. The wall cladding system of claim 13, wherein the securing means splays the lower portion of the clip when securing the clip to the external surface.

15. A method of producing a wall cladding system for an external surface of a building, said method comprising the steps of:

affixing a first slip to a backing board, said first slip comprising a groove formed within an edge of the slip;

slotting a tongued surface of a clip within the groove;

securing the clip to the external surface at a desired point along the groove; and affixing a second slip to the backing board by slotting a grooved edge of the second slip into the tongued surface.

16. A method of producing a wall cladding system for an external surface of a building, said method comprising the steps of:

affixing a second slip to the backing board, said second slip comprising a groove formed within an edge of the slip slotting a tongued surface of a clip within the grooves of the first and second slip to a desired point along the groove; and securing the clip to the external surface.

17. A method of cladding an external surface of a building, said method comprising the step of:

attaching the backing board of the pre-fabricated wall cladding system produced according to claim 15 or claim 16 to an external surface of a building.

18. The method of claim 15 or claim 16, further comprising the initial step of: attaching the backing board to an external surface of a building.

19. A kit of parts for assembling a wall cladding system of any of claims 1 to 14.