NL2010034C2

NL2010034C2 - Method and composite building element for the at least partial cladding or covering of a building construction.

Info

Publication number: NL2010034C2
Application number: NL2010034A
Authority: NL
Inventors: Joannes Augustinus Antonius Hendriks
Original assignee: Insulation Solutions B V
Priority date: 2012-12-20
Filing date: 2012-12-20
Publication date: 2014-06-23

Description

Title: Method and composite building element for the at least partial cladding or covering of a building construction

Description 5 The invention relates to a method of using a composite building element for the at least partial cladding or covering of a building construction.

A known method for the cladding or covering of building constructions uses what is known in the prior art as cassettes. A cassette is a steel receptacle for receiving insulation and cladding materials. First, each cassette is 10 manually fixed to a steel support of the building construction. After the cassettes have been fixed in position, the insulation layer is placed in the cassette and then the cladding layer is positioned on the cassette.

A disadvantage of the current method for cladding and covering building constructions with cassettes is that it is very labour intensive.

15 It is therefore an object of the present invention to provide an improved method for covering a building construction.

The present inventors have therefore found a method of using a composite building element for the at least partial cladding or covering of a building construction on a building site comprising at least two supports, the composite 20 building element comprising: - a plate-like element; - a first layer of insulation material positioned on a side of the plate-like element; - a frame positioned at a side of the first layer of insulation material, which side is directed away from the plate-like element, which frame is connected to the 25 plate-like element by at least two connecting means extending between the plate-like element and the frame; wherein the method comprises the step of covering the building construction by fixing the plate-like element of the composite building element to the building construction.

30 An advantage of the method according to the invention is that the composite building element can be prefabricated. This not only enables quality control of the manufactured composite materials but also allows a number of composite building materials to be manufactured and stored so that a number of ready-to-use composite building elements can be delivered at the same time to the 2 building site. The prefabricated composite building elements can then quickly be directly attached to the building construction. With this, the object of the invention is achieved.

By using a prefabricated composite building element, a high level of 5 quality is assured. Surprisingly, it was found that by using prefrabricated composite building elements, a better insulation value is obtained. The use of a frame connected to the plate-like element enables the insulation to already be present in the composite building element when the composite building element is fixed to the building construction, and the frame also removes the need for connecting ledges as 10 used in the traditional cassette. In traditional cassettes, the cladding is attached to the cassette via the connecting ledges. However, the connecting ledges extend along the length of, and extend from the inside face to the outer face of the cassette and thus thermal transfer can occur via these connecting ledges. The connecting ledges have a drastic effect on the thermal insulation value of the cassette as they 15 form a so-called cold bridge between the inside and outside faces of the cassette. Instead, in the invention, the cladding is attached directly to the frame, which frame is secured to the inner face of the composite building element by at least two connecting means, preferably consisting of cylindrical elements, such as a screw, bolt or the like, wherein the connecting means may be placed at discrete points 20 between the frame and plate-like element. These connecting means are designed and arranged such that heat transfer between the plate-like element and the frame is minimized, for example by minimising a cross-sectional area. Subsequently, by using these connecting means there are no elements extending along and through the whole cassette and thus the thermal leakage is reduced.

25 A further additional advantage of the invention is the ability to use thinner layers of insulation. The composition of the composite building element according to the invention enables less thick layers of insulation to be used because the thermal leakage is less as already described.

An advantage of the composite building element of the present 30 invention is that manufacturing of the composite building element may be carried out at a location distant from the building site. Manufacturing the composite building element can be carried out in a factory remote from the site of the building construction onto which the composite element is to be placed. This has the advantage that the composite building element can be manufactured in high quality, 3 manufacturing facility with quality control procedures to ensure the product according to the invention meets all necessary industry standards.

However, the benefits of the invention are also achieved in an embodiment when the composite building element is prefabricated on the building 5 site. This enables the composite building element to be easily fabricated, and subsequently connecting the complete composite building element to the building.

In an embodiment, the method may further comprise transporting the composite building element to the building site.

Yet another advantage of the invention is that the building element 10 is transported to the building site in a ready-to-use manner. The building element can then be placed on the building construction by a crane and thus there is a vast reduction in the manual handling steps required to cover and clad a building construction.

In an embodiment, the method may further comprise fixing the 15 composite building element to the at least two supports of the building construction. The supports may be, for example, vertical supports e.g. steel columns, or horizontal supports e.g. steel girders, in a steel framework of a building construction.

In the building industry, the standard distance between vertical steel columns is 5 meters and therefore the plate-like element may be at least 5 meters 20 long so that the composite building material may be fixed to two supports. The platelike element can also be manufactured with different lengths of 10 meters or 15 meters thus enabling the composite building element to be fixed to three or at even four supports.

In another embodiment, the method may further comprise placing a 25 further composite building element. The method also provides a means for fixing other composite building elements to the building construction. The further composite building elements are placed adjacent to the already placed composite building element, such that the further composite building element is placed in a horizontal direction or vertical direction.

30 In another embodiment, the method may further comprise placing at least a finishing element on the frame. The finishing elements provide a weather barrier thus making the building water and air tight. The finishing element may be chosen from a number of different materials, for example galvanized steel or aluminium. Preferably, galvanized steel coated with a durable coating is used. The 4 finishing element may have a number of different profiles depending on the level of protection and aesthetics required. The finishing elements can be placed in a horizontal or vertical pattern. The finishing elements are attached to the frame via self-tapping screws or nail-gun nails and the pattern in which the fixing means are 5 affixed can be either a diagonal or horizontal pattern.

A diagonal pattern of the fixing means has the advantage of needing fewer fixings per m2, which reduces heat transfer, and gives the optimum distribution of the load across the composite building element compared to a horizontal pattern of the fixing means. A horizontal pattern has, however, the advantage of being easier 10 to carry out than the diagonal pattern.

By means of an example, a plate-like element that has a length of 5 meters and a width of 3 meters, may be provided with a frame which also has a length of 5 meters and a width of 3 meters. The frame may further comprise three metal strips extending across the width of the frame and positioned at 1.25 meter 15 intervals along the horizontal (5 meter) length of the frame. A further metal strip extends across the length of the frame and is positioned at 1.5 meters along the width of the frame. The finishing element may be connected to the frame, therefore, at a distance of 1.25 meters in a first longitudinal direction and/ or at a distance of 1.5 meters in a direction perpendicular to the first longitudinal direction.

20 In a further embodiment of the invention, the manufacturing step comprises i) positioning at least two (sub)component elements next to each other and ii) fixing the thus positioned component elements to each other to produce a plate-like element. As described above the length of the plate-like element can be chosen to span two, three or four steel columns. The convention in the building 25 industry is to manufacture (sub)components, for example cassettes, in standard lengths of 5 meters. The inventors have therefore found, for example, that two (sub)components (c.f. cassettes) of 5 meters in length may be fixed together to produce a plate-like element with a length of 10 meters. In this way, a composite building material can be manufactured that spans at least two, preferably at least 30 three, steel supports and thus decreases the number of manual handling steps necessary to clad or cover a building construction.

The manufacturing step may further comprise positioning a first layer of insulation material at a side of the plate-like element, which side faces away from the plate-like element.

5

The manufacturing step may further comprise positioning a damp proof layer at a side of the first layer of insulation material, which side faces away from the plate-like element. In a traditional cassette, damp proofing is affected by the finishing elements, for example the outer cladding layer. However, it is possible for 5 water to leak into the cassette. In order to provide an extra water barrier, after placing a first layer of insulation material, a damp proof layer is also placed in the composite building element. This has the advantage of stopping water reaching the inner face of the composite building element, in the even of leak in the cladding. Such a construction ensures that the composite building element conforms to the 10 building norm B15 according to NEN3660/3661 regarding water proofing.

The manufacturing step may further comprise positioning a second layer of insulation material at a side of the plate-like element covered by the damp proof layer, which side faces away from the plate-like element. The placing of a second layer of insulation has a positive effect on thermal insulation value, as measured by 15 the Rc value. The Rc value is a standard way in which to measure the thermal resistance of a composite material, for example the composite building element according to the invention.

The R-value is a measure of thermal resistance used in the building and construction industry, and is a well-known parameter to those skilled in the art. 20 Under uniform conditions it is the ratio of the temperature difference across an insulator (ΔΤ, SI unit K) and the heat flux (heat transfer per unit area, QA, SI unit W/m2) through it as described by: ΔΤ R =~Qa

The R-value is the unit thermal resistance, SI units m2K/W This is used for a unit value of any particular material, and where there is more than one material present 25 the thermal resistance across the materials present is defined as the Rc value. It can also be expressed as the thickness of the material (d, SI unit metres) divided by the thermal conductivity of the material, denoted by λ (lamba, SI unit W/m-K): d R ~λ

The higher R-value the better the building insulation's effectiveness.

The inventors have used computer simulations to calculate the Rc 30 value for composite building elements according to the invention and traditional 6 cassettes to show the surprising technical effect of two layers of insulation. For example the composite building element according to the invention with a total of two layers of insulation (lambda 0.032) with a thickness of 125 mm has an Rc value of 3.54 m2K/W. This is very much higher than a traditional cassette with one layer of 5 insulation material (lambda 0.032) which even with a thickness of 150 mm only reaches an Rc value of 3.45 m2K/W.

It may further be advantageous to use a different material for the second layer of insulation than in the first layer. In this way the skilled person can optimise the thermal insulation properties of the composite building element.

10 The manufacturing step may further comprise positioning a frame at the side of the plate-like element covered by the damp proof layer, which side faces away from the plate-like element, and connecting the fame to the plate-like element by means of at least two connecting means. As described above, the frame provides a means for fixing the cladding to the composite building element without the need 15 for connecting ledges extending from, and along the length of, the cassette. Examples of connecting means are steel rods or bars with small diameters, for example less than 10 mm, preferably less than 5 mm, more preferably less than 2 mm. The connecting means protrude out of the plate-like element to enable the frame to be connected to the plate-like element at distance determined by the length 20 of the connecting means, typically between for example 90 mm to 120 mm, for example 110 mm to 140 mm, for example 130 mm to 160 mm.

Computer simulations of composite building elements according to the present invention and to traditional cassettes show that the surprising reduction in thermal leakage in composite building element according to the invention, as 25 described by a higher thermal insulation value (Rc), is due to fewer cold bridges in the composite building element compared to the traditional cassette. For example, in a traditional cassette the heat penetrates more than half of the cassette, while in the composite building element according to the invention, the heat only penetrates less than the thickness of the second layer of insulation material. Consequently, the Rc 30 value for the element according to the invention is higher (3.54 m2K/W) than that of the traditional cassette (3.39 m2K/W)

The manufacturing step may further comprise positioning a water repellent protective film at a side of the second layer of insulation material, which side faces away from the plate-like element.

7

The manufacturing step may further comprise positioning a water repellent, breathable, protective film at a side of the frame, which side faces away from the plate-like element. To further improve the damp proofing and rain resistance of the composite building element, a water repellent and breathable protective film 5 can be placed at either side of the plate-like element covered by the second layer of insulation or at a side of the plate covered by the frame.

According to an aspect, the invention provides a composite building element for the covering of a construction comprising at least two supports on a building site, the composite building element comprising: 10 a plate-like element; a first layer of insulation positioned at one side facing away from the plate-like element; a frame positioned at a side of the plate-like element covered by the first layer of insulation material, which side faces away from the plate-like element 15 and which frame is connected to the plate-like element by at least two connecting means extending between the plate-like element and the frame.

Advantages of such a composite building element have already been described with respect to the method, some of which will be further addressed below.

20 In an embodiment, a damp proof layer is provided between the first layer of insulation material and the frame.

In an embodiment, a second layer of insulation material is provided between the damp proof layer and the frame.

In an embodiment, the first and second layers of insulation material 25 have a total thickness of more than 105 mm but less than 145 mm The total thickness of the first and second layers is preferably less than 145 mm, more preferably less than 140 mm, even more preferably less than 125 mm. The total thickness of the first and second layers of insulation material is for example between 90 mm and 120 mm, for example between 110 mm and 140 mm, for example 30 between 130 mm and 160 mm.

The first and second layers of insulation may have for example a lambda value of 0.04 W / mK, or for example a lambda value of 0.036 W / mK or a lambda value of 0.032 W / mK. The insulation of the first and second layers of insulation can therefore be optimized to have an Rc value of at least 3.52 m2K/W.

8

The composite building element according to the invention may have an Rc value of at least 3.52 m2K/W, and the total thickness of the first and second layers may be preferably less than 145 mm and have a lambda value of 0.04 W /mK. For example the total thickness of the first and second layers may be more preferably less than 5 140 mm and have a lambda value of 0.036 W m/K. For example the total thickness of the first and second layers may be even more preferably less than 125 mm.

A benefit of the building element according to the invention that can be attributed to its novel structure is the ability to use less thick (total) layers of insulation material than in the traditional cassettes whilst maintaining high thermal 10 insulation values while. For example, in an embodiment of the present invention, a first layer of insulation of 95 mm and a second layer of insulation of 40 mm (total 125 mm) gave a Rc value of 3.54 m2K/W compared to an insulation layer of 130 mm that gave a Rc value of 2.54 m2K/W for a traditional cassette. This surprising technical effect of the invention is due to the reduction in heat transfer between the inner and 15 outer faces of the composite building element such that thinner layers of insulation can be used.

In another embodiment the first and second layers of insulation material is chosen from the group consisting of stonewool, glasswool, a foam, preferably polyurethane (PUR, more preferably polyisocyanurate (PIR. The invention 20 enable standard insulation materials that are available in plate-like form to be used. A preferred insulation material is a stone or glass wool. A particularly preferred insulation material is foam, for example an expanded polystyrene foam, a polyurethane or a polyisocyanurate.

In an embodiment aluminium foil is used as the damp proof layer. 25 The aluminium foil provides a damp proof layer to prevent moisture reaching the inner face of the composite building element.

In a preferred embodiment, the plate-like element is perforated. Approximately 19% of all traditional cassettes are perforated on the inner face so that the cassette can absorb sound from inside the building in order to optimize the 30 acoustics inside the building. The inventors have also found that the plate-like element may be perforated. Different perforation patterns are known by the skilled person, for example perfo 3 and perfo, 4 (manufactured by SAB-profile, IJsselstein, The Netherlands).

9

In an embodiment a finishing layer is provided between the platelike element and the first layer of insulation material. When the plate-like element is perforated it is particularly preferred to have an extra layer between the plate-like element and the first layer of the insulation material. This overcomes a problem of 5 the cassettes according to the prior art which may also have a perforated inner face. A perforated inner face allows for sound absorption but a problem with the use of perforated inner face in a traditional cassette is that the cassette is no longer air tight. This has obvious consequences for the environmental quality on the inside of the completed building.

10 An example of a finishing layer that can be provided according to the invention is an anti-condensation foil (Rockwool). Apart from the good moistureabsorbing properties (500 to 900 gr/m2), the membrane also offers extra sound absorption. The anti-condensation foil comprises fibres that clasp together, but which provide sufficient space to absorb condensation. When the temperature rises and 15 there is ventilation, the moisture absorbed is released to the air.

In an embodiment, the finishing layer is black glass fleece. The inventors have found that in buildings where the air flow in the ventilation channels can be very strong, the glass fleece protects the surface of the insulation against abrasion, which could be caused by the strong air flow. Another benefit to using 20 black glass fleece is that it gives a better aesthetic effect where the perforated platelike element does not completely hide the insulation layer. Furthermore, the skilled person may apply black fleece as acoustical proofing layer in building constructions with high acoustic requirements.

In yet another embodiment, the plate-like element has a width of at 25 least 3 meters and a length of at least 5 meters. The size of the plate-like element has been chosen to fit the current industry standards so that the new composite building element can be easily used on building sites. Furthermore, the plate-like element can have different lengths, for example at least 5 meters, at least 10 meters, at least 15 meters, so that the plate-like element can span at least two, at least three 30 and at least four steel columns of a building construction so that the number of handling steps, in particular, the number of fixing steps can be reduced relative to the traditional cassettes.

In yet another embodiment the element has an Rc value of at least 3.50 m2K/W, preferably 3.54 m2k/W, more preferably 3.62 m2K/W. In order for 10 composite building elements to conform, for example, to Dutch building standards (Bouwbesluit), the Rc value must be at least 3.54 m2K/W. The present invention therefore provides a means for achieving the necessary Rc value by applying an inventive frame construction to the composite building element. As described above, 5 computer simulations have shown that using insulation having the same lambda value of 0.036, an Rc value of 3.56 can be achieved using the composite building element according to the invention comprising 140 mm of insulation, whereas a lambda of only 3,39 is reached when using a traditional cassette comprising 170 mm insulation.

10 The invention also relates to a building site comprising a composite building element as disclosed herein.

The invention shall now be illustrated by a number of non-limiting examples, by means of the accompanying figures, in which: 15 Fig. 1 - is a side view of a composite building element according to the invention, connected to a support of a building;

Fig. 2 - is a front view of a frame for a composite building element according to the invention;

Fig. 3 - is a perspective view of a plate-like element for a composite building 20 element according to the invention;

Fig. 4 - is a perspective view of the plate-like element of Fig. 3, denoting positions for the connecting means.

Figure 1 shows a composite building element 10 which is connected 25 to a support 7 of a building. The composite building element 10 comprises a platelike element 6, fixed to the support by connecting means 8. A first layer of insulation material 5 is provided at a side of the plate-like element. A damp proof layer 4 is provided at a side of the first insulation layer 5, which side is directed away from the plate-like element. A second layer of insulation material 3, is provided at a side of 30 the damp proof layer 4, which side is directed away from the plate-like element. A water repellent, breathable protective film 2, is provided at a side of the second layer of insulation material 3, which side is directed away from the plate-like element 6. A frame 1 is provided at a side of the water repellent, breathable protective film 2, 11 which side is directed away from the plate-like element 1. The frame 1, is fixed to the plate-like element 6 by elongate bodies such as bolts or screws 9

Figure 2 shows a frame 1 comprising a steel strip 11, which, in the embodiment shown, has a length of 5 meters and a steel strip 12, which has a length 5 of 3 meters. The frame may further comprise three metal strips 13, extending across the width of the frame and positioned at 1.25 meter intervals along the horizontal (5 meter) length of the frame. A further metal strip 14, extends across the length of the frame and is positioned at 1.5 meters along the width of the frame. The positioning of a number of connecting means 9 that extend between the plate-like element and the 10 frame is also indicated.

Figure 3 shows a plate-like element 6, comprising a number of subcomponents 15. Each subcomponent has a length 16, of 5 meters and the total width 17, of the plate-like element 6, is 3 meters.

Figure 4 shows a plate-like element 6, provided with a number of 15 connecting means 9, which connecting means all protrude from the same side of the plate-like element 6 and where the connecting means are positioned in a diagonal arrangement with respect to each other.

Example 1 20 A composite building element (10) was manufactured by providing a number of sub(components) (16) and positioning at least two (sub)component elements (16) next to each other and ii) fixing the thus positioned component elements to each other to produce a plate-like element (6). A number of connecting means (9) were 25 then fixed to the plate-like element (6). Subsequently a frame (1) was connected to the plate-like element by the said connecting means (9). A first layer of insulation material (5) was placed on the plate-like element (6), then a damp proof layer (4) was placed on the first layer of insulation material (5). Subsequently a second layer of insulation material (3) was placed on the damp proof layer (4) and then the damp 30 proof layer (4) was covered by a water repellent but breathable protective film (2).

12

Example 2 A composite building element (10) was connected to a steel support (7) of a building construction by using fixing bolts as a connecting means (8). Subsequent composite 5 building elements (10) were positioned and fixed one after the other until the desried sections of the building construction were covered. A cladding was then fixed to the frame (1) of the composite building element (10).

10

Claims

Method for covering or covering at least partially with a composite construction element a construction of a building consisting of at least two uprights, the composite construction element comprising: - a plate-shaped element; - a first layer of insulating material placed on one side of the plate-shaped element; 10. a frame placed on a side of the first layer of insulating material facing away from the plate-shaped element, which frame is connected to the plate-shaped element with at least two fixing members extending between the plate-shaped element and the frame; the method comprising the step of covering the structure of the structure by attaching the plate-shaped element of the assembled structural element to the structure.

Method according to claim 1, wherein the method comprises the step of manufacturing the assembled structural element at a location remote from the structure.

Method according to claim 2, wherein the method comprises the step of transporting the assembled structural element to the structure.

The method of claim 3, wherein the covering comprises attaching the plate-shaped element to the at least two uprights.

5. Method as claimed in claim 4, wherein the covering further comprises placing a composite construction element.

The method of claim 5, wherein the covering comprises placing at least one consideration element on the frame.

7. Method as claimed in claim 6, wherein the manufacturing comprises i) placing at least two sub-plates next to each other and ii) connecting the placed sub-plates with each other so as to form the plate-shaped element.

A method according to claim 7, wherein the manufacturing comprises placing the first layer of insulating material on a side facing away from the plate-shaped element.

A method according to claim 8, wherein the manufacturing comprises placing a vapor barrier layer on a side of the first layer of insulating material facing away from the plate-shaped element.

10. Method as claimed in claim 9, wherein the manufacturing comprises placing a second layer of insulating material on a side of the vapor-barrier layer directed away from the plate-shaped element.

11. Method as claimed in claim 10, wherein the manufacturing comprises placing the frame on a side of the second layer of insulating material facing away from the plate-shaped element, which frame connects the frame to the fixing members on the plate-shaped element.

A method according to claim 11, wherein the manufacturing comprises placing a water-retaining damopen protective film on a side of the second layer of insulating material directed away from the plate-shaped element.

13. Method as claimed in claim 12, wherein the manufacturing comprises placing a water-retaining vapor-proof protective film on a side of the frame directed away from the plate-shaped element.

A composite structural element for covering or covering a structure of a building, the composite structural element comprising: 20. a plate-shaped element; - a first layer of insulating material placed on one side of the plate-shaped element; - a frame placed on a side of the first layer of insulating material facing away from the plate-shaped element, which frame is connected to the plate-shaped element with at least two fixing members extending between the plate-shaped element and the frame;

A composite construction element according to claim 14, wherein a vapor barrier layer is provided between the first layer of insulating material and the frame

A composite construction element according to claim 15, wherein a second layer of insulating material is provided between the vapor-barrier layer and the frame.

The composite construction element of claim 16, wherein the first and second layers of insulating materials have a total thickness of less than 145, preferably less than 140 mm, preferably less than 125 mm.

18. Composite construction element according to claim 17, wherein the first and second layers of insulating material are selected from the group of mineral wool, in particular rock wool and glass wool, and a foam, in particular polyurethane (PUR) and polyisocyanurate (PIR), or one or more combinations thereof.

19. Composite construction element as claimed in one or more of the foregoing claims 14 to 18, wherein aluminum foil is applied as a vapor-repellent layer.

A composite construction element according to one or more of the preceding claims 14 to 19, wherein the plate-shaped element is perforated.

21. Composite construction element as claimed in claims 14-20, wherein a finishing material layer is provided between the plate-shaped element and the first layer of insulating material.

The composite construction element of claim 21, wherein the finishing material layer comprises black-glass fleece.

23. Composite construction element according to one or more of the preceding claims 14-22, wherein the plate-shaped element has a width of at least 3 meters and a length of at least 5 meters.

Composite construction element according to one or more of the preceding claims 14 to 23, wherein the element has an Rc value of at least 3.50 m2K / W, preferably at least 3.54 m2K / W, preferably at least 3.62 m2K / W.

25. Building structure, comprising one or more assembled construction elements according to one or more of the preceding claims 14-24. 30