US20100192494A1

US20100192494A1 - Elongate abutment member of plaster

Info

Publication number: US20100192494A1
Application number: US12/594,296
Authority: US
Inventors: Tony Baccarini
Original assignee: Individual
Current assignee: Individual
Priority date: 2006-04-10
Filing date: 2007-02-13
Publication date: 2010-08-05
Also published as: US8117791B2; EA015214B1; WO2007116198A1; ES2531625T3; PL2010732T3; PT2010732E; DK2010732T3; GB2437083A; US20070245654A1; EP2010732B1; GB0607223D0; EP2010732A1; EA200870418A1

Abstract

An abutment is provided for use as a start or end post of a plasterboard partition wall or as a join between two such walls which run in different directions. The abutment comprises an elongate plaster moulding designed to run between the ceiling and the floor and having an abutment surface for abutment against the end of the partition wall, in a preferred embodiment, the abutment includes a tapered edge at the abutment surface to provide a space at the join in which a skim of plaster can be applied to provide a seamless join between the partition wall and the abutment.

Description

The present invention relates to abutments for internal partition walls made from, for example, plasterboard and an internal stud framework.
As used herein, the term “wall” is used broadly to connote any type of building structure, whether a whole structure or part of a larger structure, including without limitation partition walls, dry walls, external walls, columns, beams and the like.
Internal walls and partitions which do not have to be load bearing are conventionally constructed using plasterboards attached to a framework of vertical studs, which are usually made either of wood or of metal, and which normally include cross-bracings or noggins or the like for structural stability. At the end of a run of partition wall, an abutment detail is usually provided to join the partition wall with, for example, a glass partition. Alternatively, if the stud wall is to end in the middle of a room, then a radius or flat fair end post made from either timber or aluminium or rolled steel is fixed to the end of the partition wall. A covering section is then provided to hide the junction between the plasterboard and the abutment and mastic is used to hide erratic gaps between the plasterboard and the covering section. Similarly, where two runs of such partition wall meet, a metal beading is usually provided at the join to allow the two partition walls to be secured together. Normal tape and joint finish is then used to hide the join between the two walls.
The present invention aims to provide a new abutment detail for such partition walls and which can be used either as a joint or a start or end of run post.
According to a first aspect of the present invention, there is provided an abutment adapted for use as a start or end post or member of a wall such as a partition wall or as a join between two such walls, the abutment comprising: an elongate plaster body having at least one abutment surface running along its length for abutment against an end of the wall; and at least one formation adjacent the abutment surface which extends along a part of the length of the abutment for receiving a skim of plaster, so as to provide a seamless join between the abutment member and the wall upon receipt of the plaster skim. By providing a formation for receiving a skim of plaster the invention allows a seamless wall to be produced more easily.
Preferably, the abutment comprises at least one fixing substrate positioned along its length adjacent the abutment surface for allowing the plaster abutment to be fixed to the end of the wall. Preferably, the fixing substrates are made from one of wood and metal. Preferably, the fixing substrate comprises a lath which extends along at least a portion of the length of the abutment.
Preferably, the formation is a tapered side of the abutment. Preferably, the formation is a recessed portion of the abutment.
Preferably, the angle of the tapered side ranges between 5 and 25 degrees, more preferably between 10 and 15 degrees.
Preferably, the at least one formation has a depth ranging between 1.5 mm and 6 mm, more preferably between 2 mm and 4 mm.
Preferably, the abutment comprises at least one side wall which extend in a plane that is substantially perpendicular to the abutment surface to run parallel with an outer surface of the (preferably partition) wall and the at least one formation extends between the abutment surface and the at least one side wall.
Preferably, the abutment comprises a recessed groove in a side wall of the abutment, which extends along a major part of the length of the abutment for receiving a glass partition or the like.
Preferably, the abutment comprises a fair end extending along the length of the abutment opposite the abutment surface. Preferably, the fair end is flat along the length of the abutment. Preferably, the fair end lies parallel with said abutment surface. Preferably, the fair end is curved along the length of the abutment.
Preferably, the abutment is formed to provide two abutment surfaces, one for abutment against the end of the (preferably partition) wall and another for abutment against a window mullion. Preferably, the abutment is formed to provide two abutment surfaces, one for abutment against the end of the (preferably partition) wall and another for abutment against a wall which runs at an angle to the (preferably partition) wall. Preferably, the second abutment surface is for abutment against a wall which runs substantially perpendicular to the (preferably partition) wall.
Preferably, the abutment is formed from a moulding of plaster and fibrous material. Preferably, the abutment is formed as a plaster moulding.
The plaster material of the abutment may be hardened, for example in a kiln, to improve durability, and/or it may be a composite, including for example wood or fibre, to produce the appropriate desired properties.
The plaster material itself preferably affords a decorative or architectural surface, which for example can be left plain, or painted or decorated on.
Preferably, the abutment comprises one or more embedded strengthening members which extend within and along the length of the abutment moulding to provide strength to the moulding.
Preferably, the abutment is adapted for abutment against the end of a plasterboard partition wall.
Preferably, the formation is one of a tapered and recessed side which extends along the length of the body and which is located adjacent the abutment surface.
Preferably, the abutment comprises at least one side wall which extends in a plane that is substantially perpendicular to the abutment surface to run parallel with an outer surface of the plasterboard (preferably partition) wall and the tapered and/or recessed side extends between the abutment surface and the at least one side wall.
Preferably, the side wall defines a main body portion of the abutment and the abutment surface has a width perpendicular to the length of the abutment that is smaller than a width of the main body portion of said abutment.
Preferably, the abutment abuts a partition wall.
Preferably, the formation receives a skim of plaster. Preferably, a skim of plaster is received only in the formation, so as to provide a seamless join between said partition wall and abutment. Preferably, the formation extends between the abutment surface and a side of the abutment that is substantially perpendicular to the abutment surface, and the partition wall and the formation receive a skim of plaster up to the end of the formation, so as to provide a seamless join between the partition wall and abutment.
Preferably, the formation for receiving plaster is one of a tapered and recessed side which extends along the length of the abutment body and which is located adjacent the abutment surface.
Preferably, the abutment includes means for enabling alignment of the abutment with the wall.
According to a further aspect of the present invention there is provided an abutment adapted for use as a start or end post or member of a wall such as a partition wall or as a join between two such walls, the abutment comprising: an elongate plaster body having at least one abutment surface running along its length for abutment against an end of the wall; and means for enabling alignment of the abutment with the wall. By providing means for enabling alignment of the abutment with the wall the invention allows the abutment to be accurately positioned without requiring a high level of skill from the installer.
Preferably, the means for enabling alignment comprises a formation for cooperating with the wall.
Preferably, the cooperating formation is adapted to engage with the wall.
Preferably, the cooperating formation comprises a recess in said abutment surface to receive the wall.
Preferably, the recess is shaped and sized to receive a stud in the wall.
Preferably, the recess is adapted to extend less than the entire width of the stud.
Preferably, the abutment includes a flat surface adapted to extend parallel with a surface of the wall.
According to a further aspect of the invention there is provided an abutment adapted for use as a start or end post or member of a wall such as a partition wall or as a join between two such walls, the abutment comprising: an elongate plaster body having at least one abutment surface running along its length for abutment against an end of the wall; and a flat surface adapted to extend parallel with a surface of the wall. By providing a flat surface the invention allows the plasterer to more easily produce a seamless finish between the abutment and the wall.
Preferably, the flat surface is at least 3 mm, more preferably at least 5 mm in width.
Preferably, the flat surface extends substantially the entire length of the abutment.
Preferably, the abutment further comprises at least one formation adjacent the abutment surface which extends along at least part of the length of the abutment for receiving a skim of plaster, so as to provide a seamless join between the abutment member and the wall upon receipt of the plaster skim, the flat surface being adjacent the formation, whereby the skim of plaster can extend up to the junction of the formation and the flat surface.
Preferably, the abutment is suitable for use as at least part of a frame of a closure.
According to a further aspect of the present invention there is provided an abutment adapted for use as a start or end post or member of a wall such as a partition wall or as a join between two such walls, the abutment comprising: an elongate plaster body having at least one abutment surface running along its length for abutment against an end of the wall, the abutment being suitable for use as at least part of a frame of a closure. By providing an abutment suitable for use as a frame of a closure the invention allows seamless closure frames.
Preferably, the abutment includes a formation for framing the closure.
Preferably, the abutment is a post or lintel of a door.
According to a further aspect of the present invention there is provided a kit of parts comprising two abutments, suitable for use as at least part of a frame of a closure, as door posts, and one abutment, suitable for use as at least part of a frame of a closure, as a door lintel.
Preferably, the ends of the abutments that are adapted to cooperate are mitred, and a formation is formed in each of the abutments adjacent the mitre to receive plaster so as to enable a seamless join between the abutments.
According to a further aspect of the present invention there is provided a plaster door frame.
Preferably the abutment is adapted to receive a panel, for example a transparent panel
Preferably, the abutment is adapted to be skirting board, ceiling board, or cornice.
Preferably, the abutment is generally in an “L” shape and adapted to clad the corner of a wall.
According to a further aspect of the invention there is provided a combination of an abutment as herein described and a (preferably partition) wall, the abutment abutting the (preferably partition) wall.
Preferably, the at least one formation receives a skim of plaster.
Preferably, the formation for receiving plaster is one of a tapered and recessed side which extends along the length of the abutment body and which is located adjacent the abutment surface.
Preferably, the skim of plaster is received only in the at least one formation, so as to provide a seamless join between the (preferably partition) wall and abutment.
Preferably, the formation extends between the abutment surface and a side of the abutment that is substantially perpendicular to the abutment surface, and the (preferably partition) wall and the formation receive a skim of plaster up to the end of the formation, so as to provide a seamless join between the (preferably partition) wall and abutment.
Preferably, tape is positioned, within said formation for receiving plaster, before receiving said skim of plaster.
Preferably, the tape extends from said formation to said wall.
Preferably, the combination further comprises a stud attached to said abutment prior to said abutment being combined with said wall.
According to a further aspect of the present invention there is provided a method of making an abutment for use as a start or end post or member of a wall such as a partition wall or as a join between two such walls, the abutment comprising: an elongate plaster body having at least one abutment surface running along its length for abutment against an end of the wall; the method comprising: providing an elongate mould having at least one mould part, which defines a desired shape of the abutment; providing liquid plaster in the mould; allowing the plaster to harden; and removing the hardened plaster abutment from the mould.
Preferably, the method further comprises adding fibrous material to the plaster for strengthening the abutment.
Preferably, the method further comprises adding a core of one of wood, metal and rope to the plaster for strengthening the abutment.
Preferably, the method further comprises placing one or more fixing substrates into the mould before plaster is provided in the mould so the fixing substrate is cast into the plaster abutment when hardened.
Preferably, the method further comprises placing one or more fixing substrates into the mould after the plaster has been provided in the mould, but before the plaster has hardened, so that the fixing substrate is cast into the plaster abutment when the plaster hardens.
Preferably, the placing step places the fixing substrate adjacent a surface of the mould that will define an abutment surface of the abutment.
Preferably, the method further comprises providing the abutment in a length longer than desired, and cutting the abutment to the desired length.
Preferably, the method further comprises providing the abutment in one or more standard lengths.
According to a further aspect of the invention there is provided an abutment adapted for use as a start or end post of a partition wall or as a join between two such walls, the abutment comprising an elongate plaster body having at least one abutment surface running along its length for abutment against an end of the partition wall, the abutment comprising at least one fixing substrate positioned along its length adjacent the abutment surface for allowing the plaster abutment to be fixed to the end of the partition wall.
Preferably, the fixing substrate is substantially parallel to the end of the partition wall.
Preferably, the fixing substrate runs substantially the whole length of the abutment.
Preferably the abutment further comprises at least one strengthening core. Preferably, the strengthening core is made from wood, metal or rope.
According to one aspect, the present invention provides an abutment for use as a start or end post of a partition wall or as a join between such walls. The abutment comprises an elongate plaster moulding, typically for extension between the floor and ceiling, and having at least one abutment surface running along its length for abutment against an end of the partition wall.
In a preferred embodiment, the abutment has two parallel side walls which extend in planes that are substantially perpendicular to the abutment surface and which run parallel to the respective outer surfaces of the partition wall and two tapered sides which extend between the abutment surface and those side walls. The advantage of using such tapered sides is that they provide a space in the regions of the join between the abutment and the partition wall in which a plasterer can “skim” the join, in one operation without having to perform a surface treatment on the abutment.
The abutment preferably includes one or more fixing substrates positioned along its length and cast within the abutment for allowing the abutment to be fixed to the partition wall. The fixing substrate may be formed, for example, from a wood or metal lath. The abutment may be formed to provide a flat or a curved fair end. The abutment may also be used to provide a join between two partition walls or between a partition wall and an existing wall of the building. A recess may also be provided in the abutment for receiving the end of a glass partition.
Preferably, the abutment comprises one or more fixing substrates positioned along its length adjacent said abutment surface for allowing the plaster abutment to be fixed to said end of the partition wall. Preferably, said fixing substrates are made from wood or metal. Preferably, one or more of said fixing substrates comprises a lath which extends along at least a portion of the length of the abutment.
Preferably, the abutment comprises at least one tapered side which extends along at least part of the length of the abutment and which is located adjacent said abutment surface.
Preferably, said abutment comprises at least one side wall which extends in a plane that is substantially perpendicular to said abutment surface to run parallel with an outer surface of said partition wall and said at least one tapered side extends between said abutment surface and said at least one side wall.
Preferably, the abutment comprises a recessed groove in a side wall of the abutment, which extends along at least a major part of the length of the abutment for receiving a glass partition or the like.
Preferably, the abutment comprises a fair end extending along the length of the abutment opposite said abutment surface. Preferably, said fair end is flat along the length of the abutment, in which case preferably said fair end lies parallel with said abutment surface. Alternatively, preferably said fair end is curved along the length of the abutment.
Preferably, the abutment is formed to provide two abutment surfaces, one for abutment against the end of the (preferably partition) wall and another for abutment against a window mullion. Alternatively, preferably the abutment is formed to provide two abutment surfaces, one for abutment against the end of the (preferably partition) wall and another for abutment against a wall which runs at an angle to the (preferably partition) wall.
Preferably, said second abutment surface is for abutment against a wall which runs substantially perpendicular to the (preferably partition) wall.
Preferably, the abutment is formed from a moulding of plaster and fibrous material.
Preferably, the abutment comprises one or more embedded strengthening members which extend within and along the length of the abutment moulding to provide strength to the moulding.
Preferably, the abutment is adapted for abutment against the end of a plasterboard (preferably partition) wall.
The present invention also provides an abutment that is adapted for use as a start or end post of a (preferably plasterboard) partition wall or as a join between two such walls, the abutment comprising an elongate body having at least one substantially planar abutment surface running along its length for abutment against an end of the partition wall and at least one tapered or recessed side which extends along the length of the body and which is located adjacent the abutment surface.
Preferably, said abutment comprises at least one side wall which extends in a plane that is substantially perpendicular to said abutment surface to run parallel with an outer surface of said plasterboard partition wall and said at least one tapered or recessed side extends between said abutment surface and said at least one side wall.
Preferably, said side wall defines a main body portion of the abutment and said abutment surface has a width perpendicular to the length of the abutment that is smaller than a width of said main body portion of said abutment.
Preferably the abutment is formed as a plaster moulding.
Preferably the abutment is formed from a moulding of plaster and fibrous material.
According to a further aspect of the invention there is provided a method of making an abutment for use as a start or end post of a partition wall or as a join between two such walls, the abutment comprising an elongate plaster body having at least one abutment surface running along its length for abutment against an end of the partition wall; and at least one formation adjacent the abutment surface which extend along at least part of the length of the abutment for receiving a skim of plaster; the method comprising providing an elongate mould having at least one mould part, which defines a desired shape of the abutment; providing liquid plaster in the mould; allowing the plaster to harden; and removing the hardened plaster abutment from the mould.
The present invention also provides a method of making an abutment for use as a start or end post of a (preferably plasterboard) partition wall or as a join between such walls, the method comprising: providing an elongate mould having one or more mould parts, which define a desired shape of the abutment; pouring a liquid plaster into the mould; allowing the plaster to harden; and removing the hardened plaster abutment from the mould. During or prior to the moulding process, strengthening material may be added in the cavity of the mould so that it becomes cast within the plaster abutment. In this way, additional strength can be provided to the plaster abutment.
Preferably, the method further comprises adding fibrous material to the plaster for strengthening the abutment.
Preferably, the method further comprises placing one or more fixing substrates into the mould before plaster is provided in the mould so that the or each fixing substrate is cast into the plaster abutment when hardened.
Preferably, the method further comprises placing one or more fixing substrates into the mould after the plaster has been provided in the mould, but before the plaster has hardened, so that the or each fixing substrate is cast into the plaster abutment when the plaster hardens.
Preferably, said placing step places said one or more fixing substrates adjacent a surface of the mould that will define an abutment surface of said abutment.
According to a further aspect of the present invention there is provided a method of making an abutment for use as a start or end post of a plasterboard partition wall or as a join between two such walls, the method comprising: providing an elongate mould having one or more mould parts; providing liquid plaster into the mould; and running a cutting member having a profile corresponding to the desired profile of the abutment member over the wet plaster to cut out an abutment of the desired profile.
According to a yet further aspect of the present invention there is provided a method of making an abutment for use as a start or end post of a plasterboard partition wall or as a join between two such walls, the method comprising: providing an elongate mould having one or more mould parts, which define a desired shape of the abutment; providing liquid plaster in the mould; allowing the plaster to harden; and removing the hardened plaster abutment from the mould.
According to a further aspect of the present invention there is provided an abutment for use as a start or end post of a partition wall or as a join between two such walls, the abutment comprising an elongate plaster body having at least one abutment surface running along its length for abutment against an end of the partition wall.
Apparatus and method features may be interchanged as appropriate, and may be provided independently one of another. Any feature in one aspect of the invention may be applied to other aspects of the invention, in any appropriate combination. In particular, method aspects may be applied to apparatus aspects, and vice versa.
The invention extends to methods and/or apparatus substantially as herein described with reference to the accompanying drawings.

These and other features and advantages of the invention will become apparent from the following detailed description of preferred embodiments, in which:

FIG. 1 is a cross-sectional view of a partition wall and showing a cross-section of an abutment for providing a flat fair end to the partition wall;

FIG. 2 is a cross-sectional view of a partition wall and showing a cross-section of an abutment for providing a radius end for the partition wall;

FIG. 3 is a cross-sectional view of two partition walls running at right-angles to each other and showing a cross-sectional view of an abutment joint which provides a right-angled join between the two partition walls on an inside surface and which provides a curved join on an outside surface;

FIG. 4 is a cross-sectional view illustrating a cross-sectional view of an abutment for providing a join between a window mullion and a partition wall;

FIG. 5 is a cross-sectional view of an abutment that provides a join between a partition wall and another wall running at ninety degrees to the partition wall;

FIG. 6 is a cross-sectional view illustrating an abutment which can be used at the end of a partition wall to provide a join with a glass partition which runs at ninety degrees to the partition wall;

FIG. 7 is a cross-sectional view illustrating an alternative abutment which can be used to define a fair end for a partition wall;

FIG. 8 schematically illustrates the abutment shown in FIG. 1 when used with plasterboards having a tapered end at the join with the abutment;

FIG. 9 is a cross-sectional view illustrating an alternative embodiment of abutment with a recessed pocket for aligning the abutment and a stud;

FIG. 10 a is a cross-sectional view of an alternative embodiment of abutment which has the recessed pocket feature, which can be used at the end of a partition wall to join with a glass partition running perpendicular to the partition wall;

FIG. 10 b illustrates the abutment shown in FIG. 10 a when used with plasterboards with both tapered and non-tapered ends;

FIG. 11 a illustrates an alternative embodiment of abutment for the inclusion of a glass partition;

FIG. 11 b illustrates an alternative embodiment of abutment for the inclusion of a glass partition;

FIG. 12 is a cross-sectional view of an alternative embodiment of abutment adapted for use as a door frame;

FIG. 13 a is a cross-sectional view of an alternative embodiment of abutment adapted for use as a skirting board with a quirk detail feature;

FIG. 13 b is a 3-Dimensional representation of the abutment shown in FIG. 13 a;

FIG. 14 illustrates an alternative embodiment of abutment showing a single L-shaped corner-piece;

FIG. 15 is a flow chart illustrating one method that can be used to make the elongate plaster abutments illustrated in cross-section in FIGS. 1 to 14; and

FIG. 16 is a flow chart illustrating another method that can be used to make the elongate plaster abutments illustrated in cross-section in FIGS. 1 to 14.

EMBODIMENTS

FIG. 1 is a cross-sectional view (in a horizontal plane) illustrating the end of a plasterboard partition wall 1. As is well known the partition wall 1 is defined by a central framework of vertical studs (which may be wood or metal), one of which is shown in FIG. 1 and referenced 3. The outer surfaces of the partition wall 1 are defined by two parallel runs of plasterboard 5-1 and 5-2, which are attached to the stud work 3 (usually by fixing screws, not shown). FIG. 1 also illustrates the cross-sectional view of an elongate abutment member 7-1 which typically runs vertically, from floor to ceiling. In this embodiment, the abutment member 7-1 provides a fair end 9 to the partition wall 1 and is preformed as a fibre and plaster moulding. Typically, the abutment member 7 will be moulded in lengths of 3 (or more) metres and then cut to size to fit between the ceiling and floor. As illustrated in FIG. 1, the abutment 7-1 also includes one or more wood laths 11 that extend along the length of the abutment member 7-1 adjacent the surface 13 which abuts against the end of the partition wall 1. The wood laths act as a fixing substrate, for allowing the abutment member 7-1 to be fixed to the stud 3 by appropriate fixing screws (not shown). The wood laths also provide strength to the abutment member 7-1.
FIG. 1 also shows that, in this embodiment, the abutment member 7-1 has tapered sides 15-1 and 15-2, which extend between the abutment surface 13 and two side walls 16-1 and 16-2. As illustrated in FIG. 1, the width (W) of the main part of the abutment member 7-1 is chosen so that the two side walls 16-1 and 6-2 lie in the same planes as the respective outer surfaces of the plasterboards 5-1 and 5-2. As a result of the tapering sides 15-1 and 15-2, spaces 17-1 and 17-2 are provided that facilitate the application of a skim of plaster in this join region to provide a “seamless” join between the abutment member 7-1 and the plasterboards 5-1 and 5-2. Further, as the abutment member 7-1 is formed from a plaster material, there is no need to pre-treat the abutment member 7 before applying the plaster skim.
In an alternative embodiment in addition to the application of a skim of plaster in the join region a skim of plaster is applied on the partition wall. Alternatively a wall covering, such as wallpaper, is applied to the partition wall and abutment depending on the desired finish.
As those skilled in the art will appreciate, partition walls 1 come in various different standard thicknesses depending on the width of the stud 3 and the plasterboards 5. Therefore, in this embodiment, abutment members 7-1 having different widths (W) are provided. The studs can be of varying dimensions, including standard dimensions. Standard stud widths for use in the UK include 50 mm, 75 mm, 100 mm and 145 mm. For other countries similar standard widths would be provided depending on the standard widths of partition walls used in those countries. For example, Imperial equivalent stud widths might be 2, 3, 4, or 6 inches. Further, the thickness (Th) of the abutment member 7-1 can also be varied depending on the application. In the embodiment illustrated in FIG. 1, the thickness is approximately 30 mm, with the tapered sides 15-1 and 15-2 starting 5 mm below the fair end surface 9. The angle of the taper can also vary, depending on the application. In this embodiment, the angle is chosen so that the abutment member 7-1 provides a recess of 3 mm at the abutment surface 13 on each side of the partition wall 1, but a figure of between 1.5 mm and 6 mm is practicable, preferably between 2 mm and 4 mm. Typical taper lengths are between 5 and 40 mm, more preferably between 10 and 30 mm, most preferably between 15 and 25 mm. This results in a taper with an angle of between 5° and 25°, preferably between 10° and 15°. The recess at the abutment surface is preferably less than or equal to half the width of the plasterboard (typical plasterboard is 12.5 mm wide, or ½″); more preferably the recess is less than or equal to a third of the width of the plasterboard, more preferably still the recess is less than or equal to a quarter of the width of the plasterboard. Recesses of this size provide adequate space to allow the plaster skim to be applied and “keyed” into the join, but are not too large to cause the plaster skim to crack when dry.
The formation for receiving a plaster skim may be a rectangular recess or a taper. It is preferred that the formation is a taper as the amount of plaster used will be less. Therefore, not only will the cost of use be cheaper, but the drying time will also be less.
In an alternative embodiment in which a plaster skim is applied to the partition wall as well as the recess the width of the abutment will be such that it will be the same thickness as the partition wall and the plaster skim combined. Alternatively, and depending on the application, the abutment will be the same width as the thickness of the partition wall without the plaster skim and as such the abutment will also receive a covering skim of plaster. In this alternative the thickness of the plaster skim may be tapered down to the abutment in the region of the recess.
When assembling the partition wall, the abutment member 7-1 may be prefixed to the stud 3 before the plasterboards 5-1 and 5-2 are attached. This offers the advantage that the abutment member 7-1 can be attached to the stud by inserting screws through the stud 3 into the wood lath 11. This is advantageous, because the fair surface 9 of the abutment member 7-1 does not have to be damaged by insertion of screws and then filled using an appropriate filler. Once the abutment member 7-1 is attached to the stud 3, the plasterboards 5-1 and 5-2 can then be fixed to the stud 3 in a conventional manner. The spaces 17-1 and 17-2 defined by the tapered sides 15-1 and 15-2 of the abutment member 7-1 can then be filled with an appropriate skim of plaster leaving a seamless join between the plasterboards 5-1 and 5-2 and the abutment member 7-1.
Alternatively, the abutment member 7-1 can be fixed to the end of the partition wall 1 after the plasterboards 5-1 and 5-2 have been secured to the stud 3. In this case, however, the abutment member 7-1 has to be secured to the stud 3 by drilling holes through the fair surface 9 of the abutment member 7-1 or has to be glued to the partition wall.
The abutment member 7-1 illustrated in FIG. 1 offers a number of advantages over the traditional techniques for providing similar fair end posts at the end of a partition wall. These advantages include:

- (i) As the abutment member 7-1 is formed as a fibre and plaster moulding, accurate fabrication is possible. This means, for example, that the abutments can be made completely straight along its length which makes it easier for the builder to ensure that the partition wall is also vertical. Further, as the abutment is made of plaster, a skim of plaster can be directly applied to the surface of the abutment without pre-treatment.
- (ii) As no metal angles or plasterboards need to be cut and taped and jointed to form the end post, the time taken to erect the partition wall is reduced, thereby making it cheaper to erect such partition walls.

In the embodiment shown in FIG. 1, the abutment member 7-1 has a flat fair end 9. FIG. 2 illustrates an alternative cross-section of an elongate abutment member 7-2 which provides a radius or curved fair end 21. The remaining features of the abutment member 7-2 are the same as those of the abutment member 7-1 shown in FIG. 1 and will not be described again.
In addition to providing end posts, the abutment member 7 may be used for joining two partition walls which run at angles to each other. FIG. 3 illustrates the cross-section of an elongate abutment member 7-3 which can be used for connecting two stud walls 1-1 and 1-2, which run perpendicular to each other. As illustrated in FIG. 3, the abutment member 7-3 in this embodiment includes four tapered sides 15-1, 15-2, 15-3 and 15-4 and is arranged to provide a curved outer surface 31 in the join between the two partition walls 1-1 and 1-2 and to provide a right-angled join 33 on the inside surface of the partition walls 1-1 an 1-2.
As those skilled in the art will appreciate, other types of abutment members 7 can be provided for connecting partition walls 1 which run at different angles (not necessary at right-angles). Further, the abutment member 7 may also be modified to provide a right-angled edge on the outer surface 31 as well as the right-angled edge 33 on the inner surface. Similarly, the inner surface 33 may also be curved to provide a curved inner join between the two partition walls 1-1 and 1-2.
In addition to providing end posts for a partition wall 1 or for providing a join between two partition walls 1-1 and 1-2, the abutment member 7 can also be used as the join between the start of a partition wall and an existing design detail within the building. FIG. 4 illustrates an example of this. In particular, FIG. 4 illustrates the cross-section of a window mullion 35 having a radius (curved) end face 37. FIG. 4 also illustrates a cross-sectional view of a plaster moulded abutment member 7-4 that has been moulded to have a curved inner surface 39 matching the curved profile of the mullion 35. FIG. 4 also illustrates that the abutment member 7-4 _abutsagainst the partition wall 1 in the same way as in the embodiment described with reference to FIG. 1. As illustrated by the dashed lines 41 and 43, tapered sides may also be provided at the join between the mullion 35 and the abutment member 7-4. As before, these tapered sides provide space to allow a skim of plaster to be provided in the region of the join between the mullion 35 and the abutment member 7-4 to make a seamless joint between the two.
FIG. 5 is a cross-sectional view illustrating the form of another elongate abutment member 7-5 that can be used to define the start of a partition wall 1 from an existing wall 51 running perpendicular to the partition wall 1. Wall 51 may also be a partition wall or it maybe a brick wall or the like. As shown in FIG. 5, the abutment member 7-5 includes the same two tapered sides 15-1 and 15-2 adjacent the join with the partition wall 1. The abutment member 7-5 also includes tapered sides 15-3 and 15-4 around the join with the wall 51. As before, the tapered sides 15-3 and 15-4 provide a space for a skim of plaster to be provided in the join area, thereby allowing a seamless join with the wall 51. As illustrated in FIG. 5, the abutment member 7-5 also includes a second wood lath 11-2 adjacent the second abutment surface 55, for allowing the abutment member 7-5 to be secured to the wall 51 using suitable fixing screws (not shown). Instead of or in addition to such fixing screws, cement or glue can be provided in the boundary between the wall 51 and the second abutment surface 55 for securing the abutment member 7 to the wall 51.
In addition to providing a join between two partition walls running in different directions, the moulded abutment 7 can also be used to provide a join between a run of partition wall 1 and a glass partition. The cross-section of an appropriate elongate abutment member 7-6 for this purpose is illustrated in FIG. 6. As shown, the abutment member 7-6 includes a U-shaped recess 56 into which the end of a glass partition 57 can fit. FIG. 6 also shows that the abutment member 7-6 includes a second abutment surface 58 which is for abutment against the right hand plasterboard 5-2. The remaining components of the abutments member 7-6 are the same as those shown in FIG. 1 and will be not, therefore, be described again.
In the above embodiments, the abutment member 7 was arranged to have one or more tapered sides 15 near the join with the plasterboard 5. As those skilled in the art will appreciate, it is not essential to have such tapered sides. Instead, an abutment member 7 may be provided with sides that are designed to lie flush with the outer surface of the plasterboard 5. In this case, tape or other filler could be used to cover the join between the abutment member 7 and the plasterboard 5. In a further alternative, as illustrated in FIG. 7, the abutment member 7-7 may be arranged to have stepped recesses 59-1 and 59-2 near the join with the plasterboards 5, to allow space for a skim of plaster to be applied to each recess to provide a seamless join between the abutment member 7-7 and the plasterboards 5.
In all of the embodiments described above, standard square edge plasterboard 5 has been used. In an alternative embodiment, as illustrated in FIG. 8, plasterboards 5 having a tapered edge 61-1 and 61-2 may also be used to provide larger areas around the joins between the abutment member 7-1 and the plasterboards 5 into which a skim of plaster can be made to provide a seamless join.
In the above embodiment, one or more wood laths were cast within and along the length of the elongate abutment members 7. The wood lath provided a fixing substrate for allowing the abutment member 7 to be fixed to the stud 3 of the partition wall 1 using fixing screws. As those skilled in the art will appreciate, other fixing substrates could be used to achieve this purpose. For example, one or more laths may be made out of metal (such as ferous metal or aluminium) or out of any other rigid product. In addition to providing a fixing substrate, the laths also act to strengthen the elongate abutment members 7. In addition to providing the laths, a separate metal, wood or rope core may be cast within the elongate abutment member 7 for providing further strength.
In an alternative embodiment, as illustrated in FIG. 9, the abutment 900 is a variation of that illustrated in FIG. 1 but having a recessed pocket, 902, adapted to accept the stud 904. The recessed pocket 902 enables the abutment to be located or aligned precisely in the correct location relative to the stud; thereby producing a vertical abutment given a vertical stud. The width of the recess pocket 902 will depend on the size of the stud being used; the width will be adapted to fit closely around the stud. The widths will therefore be, 50 mm, 75 mm, 100 mm or 145 mm or the imperial equivalents, 2″, 3″, 4″, or 6″. Alternatively, the width of the recess is adapted to fit closely around any other standard width of stud. The abutment is preferably attached to the stud when the stud is in place as part of the partition wall. Alternatively, the stud may be provided in the abutment before being taken to the installation site, thereby allowing for more accurate fixing and greater stability during transit. The recessed pocket 902 typically allows the width W of both limbs of the abutment to be equal on both sides of the partition wall, enabling the plasterboard 906 to align with a flat surface 908 without the requirement for extensive skill by the installer.
The recess pocket depth D, as shown in FIG. 9, of the recess pocket 902 is suitable for allowing the abutment 900 and the plasterboard 906 both to be fixed to the stud using suitable fixings, such as screws (not shown). Preferably, the depth D is half the width of the stud 904. Therefore, the value of D may range from 25 mm to 75 mm or more depending on the size of the stud used. However, the depth D may vary within this range as long as the primary requirement that both the abutment and plasterboard may be attached to the stud is fulfilled. Therefore, the depth D preferably ranges between ¼ of the stud width and ¾ of the stud width, or more preferably the depth D ranges between ⅓ of the stud width and ⅔ of the stud width.
Screws to attach the abutment 900 to the stud 904 are preferably placed in the area of the taper such that they are hidden from view after the plaster skim is applied. Alternatively, the abutment is “back-fixed” with screws (not shown) through the stud into the abutment in the region of the recess pocket; in this case a lath may be required to strengthen the abutment, similar to that shown in FIG. 1.
When the stud 904 is made from metal it preferably has a wood lath within the stud to enable the fixing screws to affix the abutment more securely.
As also described and shown previously, the flat surface 908 is preferably approximately 5 mm in width; however, alternatively this may range from 3 mm to 15 mm depending on the application the abutment is used in. This surface 908 is used as a leading edge to enable the plasterer to apply the skim of plaster to the taper uniformly. The surface 908 is adapted to be in a plane parallel to the outside surface of the plasterboard. The plasterer uses the two hard surfaces of the leading edge 908 and the plasterboard 906 to make a smooth flat skim of plaster to produce a seamless joint between the abutment and the partition wall. The recess pocket 902 therefore enables the leading edge surface 908 and the outside surface of the plasterboard 906 to be accurately in the same plane.
Preferably, the joint between the abutment and the partition wall is taped to produce a joint that is less prone to cracking. The tape is placed such that one edge starts just within the tapered region of the abutment, but not encroaching onto the leading edge surface 908, and continues across the join and onto the plasterboard. Typically, tape of widths between 25 and 35 mm are used, and this may for example dictate the width of the taper, which might typically be half the width of standard 25 or 35 mm tape. In alternative embodiments both the abutment and the plasterboard has a tapered edge; in this case the tape is again placed such that one edge starts just within the tapered region of the abutment, and finishes just before the tapered edge of the plasterboard finishes.
In an alternative embodiment illustrated in FIGS. 10 a and 10 b, the abutment 1000 is shown again with a recess pocket 1002 for accepting the stud 1004 and aligning the abutment with the partition wall. In addition, there is a feature 1005 for accepting a glass partition enabling the partition wall to be continued in glass. The remaining features are similar to those described above in reference to FIG. 9. In this illustration FIG. 10 b shows the use of the abutment with both tapered 1006 and non-tapered plasterboard 1008, with the skim of plaster shown to produce the seamless finish in both circumstances, skims 1010 and 1012 respectively. The leading edge feature 1014 is again used, on both sides of the abutment, for producing the smooth finish of the skimmed plaster.
Two alternative embodiments of the abutment illustrated in FIG. 10 are illustrated in FIGS. 11 a and 11 b. In both these embodiments (1102 and 1104) there is an additional feature 1100 provided for the inclusion of a sealing gasket. In these embodiments the feature for accepting the skim of plaster to produce the seamless finish is shown as a recess 1106; however, these embodiments can equally use a taper. Also, the recessed pocket 1108 may or may not be required depending on the application of the abutment.
FIG. 11 a illustrates the inclusion of angle beads 1110, for example made of metal, cast into the corners of the abutment to provide protection for potentially fragile edges. This feature may be used in any of the above described embodiments, especially those that have sharp edge corners.
FIG. 12 illustrates an alternative embodiment of the abutment 1200 adapted to provide a door frame, or the frame of any closure. As described above a recessed pocket is provided to accept the stud 1202 and align the abutment with the partition wall. Equally, the plasterboard 1204 adjoins the abutment in a similar fashion, and the tapered skim 1206 is applied in the same manner, using the plasterboard and the leading edge to produce a smooth flat finish. The feature 1207 allows the door 1208 to sit within the abutment, producing a conventional door frame effect. Seals 1210 and 1212 may be included to produce a fire rated door frame installation.
The door frame is preferably provided as a kit of parts suitable for standard door widths of 24, 28, 30, 32, 34, 36 inches, or the equivalent metric sizes. The kit provides at least two upright posts and a lintel.
In addition to the taper to produce the seamless finish between the door frame and the plasterboard, a taper is also provided to produce a seamless mitred joint between the upright post and horizontal lintel. A single skim of plaster can therefore be used to finish both the mitre joint and the joint between the abutment and the partition wall. Alternatively, the joint between the mitre is not tapered, thereby enabling ease of manufacture, and distribution (since then the abutment can be manufactured and sold in longer lengths and cut to size on site).
The door frame embodiment of the abutment is preferably made from a composite material to achieve the desired properties of a door frame, such as durability and fire retardance. The composite is plaster based combined with any one, or more, of a number of different materials, such as wood chip/wood pulp mixed in to produce a suitable material. The composite material must be capable of accepting mortise features to enable hinges and the like to be attached. Alternatively, the door frame may be pre-fitted to include metal/wood plates to attach the hinges and the like.
An alternative embodiment is illustrated in FIGS. 13 a and 13 b. In this embodiment of abutment 1300 an example is provided of horizontal, as opposed to vertical use. The abutment is used as a skirting at the bottom of a wall. The same taper formation 1302 is utilised to produce a seamless finish between the bottom of the wall 1304 and the abutment 1300. In addition quirk details 1306 may be included to produce any desired feature. Alternatively, this embodiment may also be utilised at the top of the wall to join the wall to the ceiling.
In further embodiments the abutment may be used as a cornice to provide a seamless join between a wall and a ceiling.
A further embodiment is illustrated in FIG. 14. The abutment 1400 is an L-shaped corner-piece to enable the corner of a partition wall to be finished seamlessly. The abutment fits around the stud 1402 and the plasterboard 1404 is attached in a similar manner as described above. In the region of 1406, the corner of the L-shape abutment, a detail, such as a groove for accepting for example a piece of wood may be located
A number of different elongate plaster abutments 7 have been described above. These abutments 7 can be formed either by cutting wet plaster from an elongate rectangular block of plaster or by moulding the plaster using a suitable mould formed from one or more mould pieces. A description will now be given of the way in which a prototype abutment 7 was made by cutting plaster from an elongate block. A description will then be given as to how this prototype can be used to form a latex moulding which can then be used to make a number of similarly profiled abutment members 7.
All of the above described embodiments are preferably manufactured in a plaster material. Alternatively, the abutments are manufactured from composite material to produce the desired properties. The technique in which the plaster abutments are finished, such as kiln drying etc, can be varied in order to vary the properties of the abutment to suit different applications.
FIG. 15 is a flow chart illustrating the steps performed to make a prototype abutment member 7. As shown, in step s1, a zinc profile for the required shape of abutment is cut. A smooth plaster mix is then made by mixing 20 litres of water with due proportion of herculite and kermicast. In step s3, a layer of this plaster mix is applied to an elongate rectangular bench mould and a 300 mm width by 3 m jute scrim is incorporated into this layer of plaster. In step s5, four laths are incorporated into the plaster for flat fixing with the stud 3 and two laths are incorporated into the plaster for providing strength to the edge of the abutment member 7. In step s7, a rope scrim is added to the centre of the plaster and the remaining plaster mix is added. Finally, in step s9, the zinc profile is run over the wet plaster until the required shape is cut out and the abutment member 7 is formed.
As those skilled in the art will appreciate, all of the abutment members 7 described upon may be manufactured using this technique. However, for ease and efficiency of manufacture, the abutment members 7 are preferably formed from a suitably shaped mould. FIG. 16 is a flow chart illustrating the main steps for a production process for making the above described abutment members. As shown, in step s13, the prototype abutment member made in the manner described above is used to make a latex mould. This involves placing the prototype abutment member 7 within an open top watertight container which is wider than and as deep as the prototype abutment. Latex rubber is then poured over the model and is prevented from leaking by the container. Once the rubber has set, it is peeled off the prototype abutment and is ready for use as the mould for production.
In step s15, the thus formed latex mould is part filled with a base of plaster with GRG (Glass Reinforced Gypsum) matting (200 mm wide by 3 m long) inserted into the plaster together with 2 laths for fixing. GRG matting is formed from fibres similar to those used to make fibre glass boats. Then, in step s17, after the base of plaster has hardened the main plaster mix is added to fill the latex mould. In step s19, once all plaster and reinforcements have been incorporated into the mould, a recess is made along the length of the top of the plaster mould for studding purposes. Finally, once the plaster has hardened, the moulded abutment member 7 is removed from the mould. The mould can then be used again to make another abutment member 7 of the same profile.
It will be understood that the present invention has been described above purely by way of example, and modifications of details can be made within the scope of the invention.

Claims

1. An abutment adapted for use as a start or end post or member of a wall such as a partition wall or as a join between two such walls, the abutment comprising:

an elongate plaster body having at least one abutment surface running along its length for abutment against an end of the wall; and

at least one plaster formation adjacent the abutment surface which extends along at least part of the length of the abutment for receiving a skim of plaster, so as to provide, upon receipt of said plaster skim only in the region of the said plaster formation, a seamless join between the abutment member and the wall.

2. The abutment according to claim 1, wherein said at least one formation is a tapered side of the abutment.

3. The abutment according to claim 2, wherein the angle of said tapered side ranges between 5 and 25 degrees, preferably between 10 and 15 degrees.

4. The abutment according to claim 1, wherein said at least one formation is a recessed portion of the abutment.

5. The abutment according to claim 1, wherein said at least one formation has a depth ranging between 1.5 mm and 6 mm, preferably between 2 mm and 4 mm.

6. The abutment according to claim 1, wherein said abutment comprises at least one side wall which extends in a plane that is substantially perpendicular to said abutment surface to run parallel with an outer surface of said wall and wherein said at least one formation extends between said abutment surface and said at least one side wall.

7. The abutment according to claim 1, including means for enabling alignment of the abutment with the wall.

8. An abutment adapted for use as a start or end post or member of a wall such as a partition wall or as a join between two such walls, the abutment comprising: an elongate plaster body having at least one abutment surface running along its length for abutment against an end of the wall; and means for enabling alignment of the abutment with the wall.

9. The abutment according to claim 8, wherein the means for enabling alignment comprises a formation for cooperating with the wall.

10. The abutment according to claim 9, wherein the cooperating formation is adapted to engage with the wall.

11. The abutment according to claim 10, wherein the cooperating formation comprises a recess in said abutment surface to receive said wall.

12. The abutment according to claim 11, wherein the recess is shaped and sized to receive a stud in said wall.

13. The abutment according to claim 12, wherein the recess is adapted to extend less than the entire width of the stud.

14. The abutment according to claim 11, wherein said recess is formed from at least one plaster limb extending from said abutment surface.

15. The abutment according to claim 14, wherein the or each said plaster limb has a further abutment surface running along the length of the abutment for abutment against a portion of said wall.

16. The abutment according to claim 15, wherein said further abutment surface is at the distal end of said plaster limb.

17. The abutment according to claim 15, further comprising at least one plaster formation adjacent the abutment surface which extends along at least part of the length of the abutment for receiving a skim of plaster, so as to provide, upon receipt of said plaster skim only in the region of the said plaster formation, a seamless join between the abutment member and the wall, and wherein the or each said plaster formation is adjacent said further abutment surface of said plaster limb.

18. The abutment according to claim 14, further comprising at least one plaster formation adjacent the abutment surface which extends along at least part of the length of the abutment for receiving a skim of plaster, so as to provide, upon receipt of said plaster skim only in the region of the said plaster formation, a seamless join between the abutment member and the wall, and wherein the depth of said plaster formation is less than half the width of said plaster limb.

19. The abutment according to claim 17, wherein the depth of said plaster formation is less than a quarter of the width of said plaster limb.

20. The abutment according to claim 1, comprising at least one fixing substrate positioned along its length adjacent said abutment surface for allowing the plaster abutment to be fixed to said end of the wall.

21.-80. (canceled)