NZ719694A - Wall cladding system - Google Patents

Abstract

A wall cladding system including a cladding panel, wherein the cladding panel has a body (14) formed from a first material (18), wherein the cladding panel includes a bead (16) for facilitating application of a coating to the cladding panel, wherein the cladding panel includes a coating of render (20) applied to an external surface of the body (14), and wherein the bead (16) is formed of render as part of said coating of render (20) to promote even thermal expansion of the bead (16) with the coating of render (20).

Description

WALL CLADDING SYSTEM Field of the Invention The invention relates to a wall cladding system and, more particularly, but not exclusively, to a wall cladding system in the form of an External Insulation Façade System (EIFS) having a render bead.

Background of the Invention It is known to provide a wall cladding system in the form of an External Insulation Façade System (EIFS) such as the façade system marketed by the applicant under the Exsulite product name.

The applicant has identified problems with existing External Insulation Façade Systems. In particular, the applicant has identified that there are problems in External Angle Beads and Starter Channels manufactured from differing materials other than EIFS expanding and contracting in weather conditions. There has been a decline in the number of qualified plasterers and a drop in the skill level of many tradespeople servicing the building industry. The applicant has determined that it would be advantageous to provide a system which (eliminates the need to use differing materials that have differing expansion and contraction rates to EIFS) and which assists the applicator in correctly applying and terminating render on foam cladding, both in achieving a solid termination point and in achieving the correct film thickness.

Examples of the invention seek to provide an improved wall cladding system which overcomes or at least alleviates disadvantages associated with existing wall cladding systems.

Alternatively or additionally, examples of the present invention seek to at least provide the public with a useful choice.

Summary of the Invention In accordance with one aspect of the present invention, there is provided a wall cladding system including a cladding panel, wherein the cladding panel has a body formed from a first material, and wherein the cladding panel includes a bead for facilitating application of a coating to the cladding panel.

Preferably, the body is formed as a unitary part.

Preferably, the bead is a render bead adapted for facilitating application of a coating of render to the cladding panel.

In a preferred form, the bead is formed as part of the cladding panel. More preferably, the bead is formed as an integrally formed part of the body made from said first material.

Preferably, the cladding panel includes a coating of render applied to an external surface of the body. More preferably, the bead is formed of render as part of said coating of render to promote even thermal expansion of the render bead with the coating of render. Even more preferably, the render is polymer render.

The cladding panel may include a reinforcing mesh. Preferably, the reinforcing mesh is embedded in said coating of render.

Preferably, the bead is arranged to regulate an even layer of a render material applied to said coating of render. More preferably, the bead has a height of 2 to 5mm.

In a preferred form, said coating of render is weatherproof.

It is preferred that said coating of render facilitates adhesion of said layer of render material to the cladding panel.

Preferably, the body is formed of polystyrene. More preferably, the body is formed of expanded polystyrene (EPS).

In a preferred form, the cladding panel is adapted to be fixed to (metal or timber) framing (or as an over clad to masonry construction). More preferably, the wall cladding system includes one or more fasteners for fastening the cladding panel relative to the (metal or timber) framing (or masonry construction).

Preferably, the cladding panel is adapted to be cut to size.

Preferably, the wall cladding system is in the form of an external insulation façade system.

In a preferred form, the cladding panel has a length and a constant cross- sectional profile along the length from one end of the panel to an opposite end of the panel.

In accordance with another aspect of the present invention, there is provided a wall cladding system including a cladding panel, wherein the cladding panel has a body formed from a first material, wherein the cladding panel includes a bead for facilitating application of a coating to the cladding panel, wherein the cladding panel includes a coating of render applied to an external surface of the body, and wherein the bead is formed of render as part of said coating of render to promote even thermal expansion of the bead with the coating of render.

In accordance with another aspect of the present invention there is provided a set of cladding panels wherein each of the cladding panels is a cladding panel as defined above, and wherein the cladding panels include a plurality of cladding panel models, each model having a different profile to suit different applications.

In the description in this specification reference may be made to subject matter which is not within the scope of the appended claims. That subject matter should be readily identifiable by a person skilled in the art and may assist in putting into practice the invention as defined in the presently appended claims.

Brief Description of the Drawings The invention is described, by way of non-limiting example only, with reference to the accompanying drawings, in which: Figure 1 shows a perspective view of a cladding panel in accordance with an example of the present invention; Figure 2 shows a front view of the cladding panel; Figure 3 shows a perspective side view of a cladding panel in accordance with another example of the present invention; Figure 4 shows a detailed view of the cladding panel shown in Figure 3; Figure 5 shows an edge perspective view of the cladding panel shown in Figure Figures 6 to 12 show cross-sectional profile shapes of cladding panels in accordance with examples of the present invention; and Figures 13 to 20 show diagrammatic cut-away views demonstrating installation of foam cladding panels in accordance with the examples shown in Figures 6 to 12.

Detailed Description The applicant is a pioneer in the use of External Insulation Façade Systems (EIFS), designing and installing coating systems specifically for wall applications.

EIFS walling systems have been used in Europe for many years. In recent years, the use of lightweight cladding systems, as alternate solutions in the building and constructions industry has grown rapidly but proper system design and installation has not been considered.

The Building Code of Australia (BCA) (or National Construction Code (NCC)) requires appropriate design and installation controls to qualify any alternate solution and ultimate success requires a total system approach integrating design, componentry, installation and performance requirements.

The Exsulite facade system by Dulux AcraTex protects specifiers, surveyors, builders and their clients from the risks of mixed componentry being used with uncontrolled installation. Exsulite facade system by Dulux AcraTex offers a single supply source for the total lightweight facade system – from wall wrap to the weatherproofing coating. The Exsulite facade system is a lightweight exterior walling system that provides both weatherproofing and insulation of the building envelope and helps to eliminate thermal bridging that can occur through the wall frame.

The Exsulite facade system is designed as a total integrated non-load bearing lightweight facade system to deliver a weatherproof external building envelope with a self draining cavity for moisture management whilst providing high thermal performance (R value). The Exsulite facade system is certified as a total integrated facade system for use as either a cavity or non-cavity system.

The Exsulite facade system comprises of an Exsulite breathable wall wrap, flashing tape to all openings and penetrations, Exsulite EPS Panel or Exsulite Pre- Coated Composite Panel, Exsulite starter piece/cavity closer with weep holes, Exsulite fixing components, EPS "H" Grade wall cavity spacers where a cavity system is selected, Exsulite Matrix Basecoat with alkali resistant mesh, Exsulite Texture and Exsulite Membrane weatherproof protective coating or an approved Dulux AcraTex texture and AcraTex membrane topcoat system designed and supplied by Dulux AcraTex and installed by a Dulux AcraTex Exsulite trained and registered installer.

With reference to Figures 1 to 20 of the drawings, there is shown a wall cladding system in accordance with an example of the present invention. Advantageously, the wall cladding system uses an elevated bead on the edge of the cladding which is specifically designed to (eliminate the need to use differing materials that have differing expansion and contraction rates to EIFS) assist the applicator in applying and terminating render, both in achieving a solid termination point and in achieving a correct film thickness of the render. The elevated bead may be formed integrally as part of a polystyrene body of the cladding panel or integrally as part of a coating of render which is applied to the body of the cladding panel. By making the bead integral in this way, this ensures that the bead expands and contracts thermally in environmental conditions, evenly with the rest of the cladding panel such that the bead and the rendering remain attached to the cladding panel, reducing the likelihood of undesirable cracking and separation of the render from the panel (and reducing installation and coatings time and skill required).

More specifically, with reference to Figures 1 to 5 of the drawings, there is provided a wall cladding system 10 including a cladding panel 12. The cladding panel 12 has a body 14 formed from a first material, and the cladding panel 12 includes a bead 16 for facilitating application of a coating to the cladding panel 12. With reference to Figure 1, the body 14 is formed as a unitary part of polystyrene material 18 and, preferably, expanded polystyrene material (EPS). The bead 16 is a render bead adapted for facilitating application of a coating of render to the cladding panel 12. The render bead 16 is formed as part of the cladding panel 12.

As shown clearly in the side perspective view of Figure 1, the cladding panel 12 includes a coating of render 20 applied to an external surface 22 of the body 14 and the render bead 16 is formed of render as part of the coating of render 20. This promotes even thermal expansion of the render bead 16 with the coating of render 20 to avoid separation of the render bead 16 from the body 14. The material forming the coating of render 20 may be in the form of a polymer render. Figure 2 shows a front view of the cladding panel 12 which shows the face of the external surface 22. Although the coating of render 20 is shown as having a thicker portion near the bead 16, in other examples the thickness of the coating 20 adjacent the bead 16 may extend over the entire external surface 22 of the cladding panel 12.

Figures 3 to 5 show a cladding panel 12 in accordance with another example of the present invention in which the cross-sectional profile of the cladding panel 12 is rectangular rather than having the angled edge 24 and stepped rear surface 26 as in the example shown in Figures 1 and 2. The cladding panel 12 of Figures 3 to 5 visibly shows a reinforcing mesh 28 which is embedded in the coating of render 20.

As an alternative to the examples shown in Figures 1 to 5, the bead 16 may be formed as an integrally formed part of the body 14 made from the polystyrene material 18. Either way, the render bead 16 is arranged to regulate an even layer of a render material to be applied on top of the coating of render 20. In preferred examples of the invention, the render bead 16 may have a height within the range of 2 to 5mm. In a preferred form, the render bead 16 may have a height of 2.5mm.

The coating for render 20 may be weatherproof and may facilitate adhesion of the layer of render material to the cladding panel 12.

The cladding panel 12 has a length (the length of the bead 16 and the corresponding face of the cladding panel 12) and a constant cross-sectional profile along that length from one end of the cladding panel 12 to an opposite end of the cladding panel 12. The cladding panel 12 is adapted to be cut to size, as may be facilitated by the polystyrene material of the body 14.

The applicant has determined that it would be beneficial for different profiles to be available for different purposes. For example, with reference to Figures 6 to 12 of the drawings, there is shown a set of cladding panels 12 wherein each of the cladding panels is a cladding panel generally similar to the panels 12 shown in Figures 1 to 5, only with a plurality of cladding panel models, each model having a different profile to suit a different application/installation type. Each of Figures 6 to 12 shows a profile of a different cladding panel model which is suitable for a particular application/installation type. Each of the cladding panel models shown in Figures 6 to 12 has a body 14, a bead 16 and a coating of render 20.

More specifically, Figure 6 shows a pre-coated cavity square starter block. In Figure 6, the panel 12 may be an M Grade 2400mm x 300mm panel, the render bead 16 may be a 2.5 mm render bead, the dimension indicated by the reference number 60 may be 75 mm, the dimension indicated by the reference number 62 may be 95 mm, the dimension indicated by the reference number 64 may be 300 mm, the dimension indicated by the reference number 66 may be 75 mm, and the angle indicated by the reference number 68 may be 115 degrees.

Figure 7 shows a pre-coated cavity reveal/slab starter block. In Figure 7, the panel 12 may be an M Grade 2400mm x 300mm panel, the render bead 16 may be a 2.5 mm render bead, the dimension indicated by the reference number 70 may be 75 mm, and the dimension indicated by the reference number 72 may be 300 mm.

Figure 8 shows a non-cavity pre-coated slab rebate starter block In Figure 8, the render bead 16 may be a 2.5 mm render bead, the dimension indicated by the reference number 80 may be 75 mm, the dimension indicated by the reference number 82 may be 50 mm, the dimension indicated by the reference number 84 may be 25 mm, the dimension indicated by the reference number 86 may be 1000 mm, and the dimension indicated by the reference number 88 may be 200 mm.

Figure 9 shows a pre-coated angled non-cavity starter block. In Figure 9, the panel 12 may be an M Grade 2400mm x 300mm panel, the render bead 16 may be a 2.5 mm render bead, the dimension indicated by the reference number 90 may be 75 mm, the dimension indicated by the reference number 92 may be 70 mm, the dimension indicated by the reference number 94 may be 225 mm, the dimension indicated by the reference number 96 may be 75 mm, the angle indicated by the reference number 98 may be 75 degrees, and the angle indicated by the reference number 99 may be degrees.

Figure 10 shows a pre-coated sill block. In Figure 10, the panel 12 may be an M Grade 2400mm x 300mm panel, the render bead 16 may be a 2.5 mm render bead, the dimension indicated by the reference number 100 may be 75 mm, the dimension indicated by the reference number 102 may be 300 mm, and the angle indicated by reference number 104 may be 25 degrees.

Figure 11 shows a pre-coated slab rebate starter block. In Figure 11, the panel 12 may be an M Grade 2400mm x 400mm panel, the render bead 16 may be a 2.5 mm render bead, the dimension indicated by the reference number 110 may be 75 mm, the dimension indicated by the reference number 112 may be 50 mm, the dimension indicated by the reference number 114 may be 25 mm, the dimension indicated by the reference number 116 may be 200 mm, and the dimension indicated by the reference number 88 may be 200 mm.

Figure 12 shows a pre-coated cavity angled starter block. In Figure 12, the panel 12 may be an M Grade 2400mm x 300mm panel, the render bead 16 may be a 2.5 mm render bead, the dimension indicated by the reference number 120 may be 75 mm, the dimension indicated by the reference number 122 may be 93 mm, the dimension indicated by the reference number 124 may be 300 mm, the dimension indicated by the reference number 126 may be 30 mm, the angle indicated by the reference number 128 may be 115 degrees, and the angle indicated by reference number 129 may be 25 degrees.

Figures 13 to 20 show examples of installations of cladding panels 12 of the present invention. Reference numbers are used in Figures 13 to 20 to indicate the following feature(s), dimension(s) and/or step(s), as set out in the table below: Reference number Feature(s), dimension(s) and/or step(s) 12 cladding panel 1000 wall insulation as specified 1002 washer to be secured 50mm down from the edge of angled starter block 1004 stud frame at 600mm max centres 1006 washer to be secured 10mm above roof flashing 1008 20mm clearance between starter block and top of metal flashing 1010 plasterboard wall lining 1012 roof insulation and spacer as specified 1014 metal flashing by others (secured under breathable wrap) provide packers as needed 1016 Exsulite® panel 1018 Exsulite® membrane fixed to stud framing 1020 Exsulite® cavity spacer fixed to stud framing 1022 expanding foam or approved equivalent 1024 Exsulite® acrylic texture over 1026 washer secured with screw at 275mm max. vertical centres or as specified 1028 Exsulite® matrix/acra-patch hb render with Exsulite® mesh with corner meshed beads 1030 metal deck roofing as specified 1032 timber roof purlin as detailed by the structural engineer 1034 timer roof beam as detailed by the structural engineer 1036 50 1038 10 1040 20 min 1042 roof insulation and timber batten as specified 1044 Exsulite® precoated angled cavity starter block 1046 roof truss or similar to engineers details 1048 roof tiles 1050 skirting 1052 specified flooring material with underlay as per manufacturers requirements 1054 concrete slab with edge footing to structural engineers details 1056 termite protection in accordance with AS3660.1:2014 & AS3660.3:2014. refer to manufacturers specifications for installation method where required 1058 water proofing membrane 1060 Exsulite® precoated slab starter block© 1062 flashing 1064 10 1066 75 1068 10mm min. clearance between slab set down and slab starter block. provide at maximum centres (1200mm) weeper with termite resistant polyurethane sealant or equivalent in between. 1070 slab edge to remain exposed and uncoated in accordance with Australian standard AS2870-2011 1072 10 1074 75 1076 exposed slab edge uncoated 1078 Exsulite® slab starter block with Exsulite® or Acratex® coating system with reinforcing mesh 1080 termite resistant polyurethane sealant or equivalent between weepers 1082 weepers 1200mm max centres 1084 line of 2.5mm rendered bead shown for clarity 1086 1200 max centres (nts) 1088 Exsulite® precoated cavity square starter block 1090 front face of rendered Exsulite® cladding to finish on the same plane as adjoining rendered masonry wall. control joint placement at junction of Exsulite® cladding and render wall at both ends of opening 1092 structural beam to engineers design 1094 timber packer as required 1096 6mm fibre cement sheet with render finish 1098 gap between starter block and fibre cement sheet shown greater for clarity 1100 Exsulite® pre-coated cavity square starter block© starter block to sit below soffit lining a minimum 10mm to a maximum 60mm 1102 soffit lining with painted finish 1104 60 max 1106 gap between starter blocking and soffit lining shown greater for clarity 1108 structural lintel to engineers design 1110 architrave as specified 1112 timber reveal 1114 bitumen adhesive 1116 specified window system 1118 bitumen adhesive flashing tape 1120 timber reveal 1122 architrave as specified 1124 Exsulite® precoated cavity reveal starter block© 1130 Selleys flexiseal or equivalent, placed around window frame, over base coat and under texture coat 1132 Exsulite® precoated sill block 1134 Exsulite® precoated non cavity starter block© 1138 60 1140 50 1142 10 1144 Exsulite® precoated slab rebate starter block In particular, Figure 13 shows installation of the cladding panel 12 of Figure 12 in relation to a metal deck roof. Figure 13 may also include the following installation notes:  Space between stud framing and Exsulite® cavity spacer is shown greater for clarity.

 Where a non-cavity system is selected, cavity spacers are not required.

 Expanding foam to be installed once all Exsulite® panels have been secured. Allow maximum 5mm gap between all panel junctions unless stated otherwise.

Figure 14 shows installation of the cladding panel 12 of Figure 12 in relation to roof tiles. Figure 14 may also include the following installation notes:  Space between stud framing and Exsulite® cavity spacer is shown greater for clarity.

 Where a non-cavity system is selected, cavity spacers are not required.

 Expanding foam to be installed once all Exsulite® panels have been secured. Allow maximum 5mm gap between all panel junctions unless stated otherwise.

Figure 15 shows installation of the cladding panel 12 of Figure 7 showing slab rebate detail. Figure 15 may also include the following installation notes:  Space between stud framing and Exsulite® cavity spacer is shown greater for clarity.

 Provide bushfire compliance weepa (bal) – to AS3959:2009 with vermin guard at a maximum 1200mm centre to centre.

 Do not install external cladding in areas where it may remain in contact with standing water or debris. Do not back fill.

 Where a non-cavity system is selected, cavity spacers are not required.

 Expanding foam to be installed once all Exsulite® panels have been secured. Allow maximum 5mm gap between all panel junctions unless stated otherwise.

Figure 16 shows installation of the cladding panel 12 of Figure 6 showing typical garage bulkhead detail. Figure 16 may also include the following installation notes:  Space between stud framing and Exsulite® cavity spacer is shown greater for clarity.

 Expanding foam to be installed once all Exsulite® panels have been secured. Allow maximum 5mm gap between all panel junctions unless stated otherwise.

 Where a non-cavity system is selected, cavity spacers are not required.

 Do not install external cladding in areas where it may remain in contact with standing water or debris. Do not back fill.

Figure 17 shows installation of the cladding panel 12 of Figure 6 showing typical parapet-balcony bulkhead detail. Figure 17 may also include the following installation notes:  Space between stud framing and Exsulite® cavity spacer is shown greater for clarity.

 Expanding foam to be installed once all Exsulite® panels have been secured. Allow maximum 5mm gap between all panel junctions unless stated otherwise.

 Where a non-cavity system is selected, cavity spacers are not required.

 Do not install external cladding in areas where it may remain in contact with standing water or debris. Do not back fill.

Figure 18 shows installation of the cladding panel 12 of Figure 7 as well as the cladding panel 12 of Figure 10 in relation to a typical framed window head and sill.

Figure 18 may also include the following installation notes:  Space between stud framing and Exsulite® cavity spacer is shown greater for clarity.

 Where a non-cavity system is selected, cavity spacers are not required.

 Expanding foam to be installed once all Exsulite® panels have been secured. Allow maximum 5mm gap between all panel junctions unless stated otherwise.

Figure 19 shows installation of the cladding panel 12 of Figure 9 in relation to a typical non-cavity system. Figure 19 may also include the following installation notes:  Space between stud framing and Exsulite® cavity spacer is shown greater for clarity.

 Where a non-cavity system is selected, cavity spacers are not required.

 Expanding foam to be installed once all Exsulite® panels have been secured. Allow maximum 5mm gap between all panel junctions unless stated otherwise.

Figure 20 shows installation of the cladding panel 12 of Figure 11 showing a typical slab starter block and slab rebate detail. Figure 20 may also include the following installation notes:  Space between stud framing and Exsulite® cavity spacer is shown greater for clarity.

 Provide bushfire compliance weepa (bal) – to AS3959:2009 with vermin guard at a maximum 1200mm centre to centre.

 Do not install external cladding in areas where it may remain in contact with standing water or debris. Do not back fill.

 Where a non-cavity system is selected, cavity spacers are not required.

 Expanding foam to be installed once all Exsulite® panels have been secured. Allow maximum 5mm gap between all panel junctions unless stated otherwise.

Installation may be, for example, in a parapet wall construction to box cutter arrangement, in a window arrangement, or in a meter box penetration arrangement. The cladding panels 12 of the present invention may be adapted to be fixed to (timber or steel) framing by virtue of washers and screws.

While various embodiments of the present invention have been described above, it should be understood that they have been presented by way of example only, and not by way of limitation. It will be apparent to a person skilled in the relevant art that various changes in form and detail can be made therein without departing from the spirit and scope of the invention. Thus, the present invention should not be limited by any of the above described exemplary embodiments.

The reference in this specification to any prior publication (or information derived from it), or to any matter which is known, is not, and should not be taken as an acknowledgment or admission or any form of suggestion that that prior publication (or information derived from it) or known matter forms part of the common general knowledge in the field of endeavour to which this specification relates.

Throughout this specification and the claims which follow, unless the context requires otherwise, the word "comprise", and variations such as "comprises" and "comprising", will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.

Claims (9)

THE CLAIMS DEFINING THE INVENTION ARE AS FOLLOWS:

1. A wall cladding system including a cladding panel, wherein the cladding panel has a body formed from a first material, wherein the cladding panel includes a 5 bead for facilitating application of a coating to the cladding panel, wherein the cladding panel includes a coating of render applied to an external surface of the body, and wherein the bead is formed of render as part of said coating of render to promote even thermal expansion of the bead with the coating of render. 10

2. A wall cladding system as claimed in claim 1, wherein the body is formed as a unitary part.

3. A wall cladding system as claimed in claim 1 or claim 2, wherein the bead is a render bead adapted for facilitating application of a coating of render to the 15 cladding panel.

4. A wall cladding system as claimed in any one of claims 1 to 3, wherein the render is polymer render. 20

5. A wall cladding system as claimed in any one of claims 1 to 4, wherein the cladding panel includes a reinforcing mesh.

6. A wall cladding system as claimed in claim 5, wherein the reinforcing mesh is embedded in said coating of render.

7. A wall cladding system as claimed in any one of claims 1 to 6, wherein the bead is arranged to regulate an even layer of a render material applied to said coating of render. 30

8. A wall cladding system as claimed in claim 7, wherein the bead has a height of 2 to 5mm.

9. A wall cladding system as claimed in any one of claims 1 to 8, wherein said coating of render is weatherproof.