WO2003006762A1

WO2003006762A1 - Building component and method

Info

Publication number: WO2003006762A1
Application number: PCT/AU2002/000930
Authority: WO
Inventors: Antonio Mucci
Original assignee: Unitex Granular Marble Pty Ltd
Priority date: 2001-07-11
Filing date: 2002-07-10
Publication date: 2003-01-23
Also published as: NZ530541A

Abstract

A corner reveal (10) or an edge reveal (23) is adapted for installation along the corner of a wall or at a penetration in the wall such as a door or window opening. The reveal is moulded or extruded from lightweight reinforced cement or modified cement based product and comprises an elongate member which, in cross-section, has two mutually perpendicular legs (11, 12) whereby the reveal 'wraps' around the corner. In the case of a corner reveal the legs are identical and each has a fibreglass mesh moulded therein and extending beyond the leg to form a wing which is incorporated into a coating to be applied to said wall surface. The legs have a thickness equivalent to the thickness of the applied coating. Each leg has a bevelled outer edge (15, 16). In the case of an edge reveal one leg (19) is the same as those of the corner reveal and the other leg (18) is thicker, has no mesh therein and is not bevelled at its outer edge. This thicker leg forms a reveal which abuts a door or window frame (27) when in use. A method of building construction using the reveal and an applied coating is also claimed.

Description

BUILDING COMPONENT AND METHOD

This invention relates to a building component as well as a method of construction and is particularly concerned with buildings having an applied coating on the outer surface thereof. Such applied coating may be a mineral or acrylic based, Tollable, trowelable, sprayable or paintable high or low build coating or may be a cement fibre reinforced light-weight render or other renders. The component is in the form of an edge reveal or a corner reveal.

Building construction utilising applied coatings is well known and has been used around the world for many years and to a lesser extent in Australia where brick veneer or weatherboard construction has been more popular in the housing industry.

One known construction technique which has become popular in Australia is a thermal wall system which uses an insulation board to cover a building frame structure, for example, and then uses an applied coating to cover the insulation board. In many instances the insulation board is cellular polystyrene foam in sheet form which is fixed to the frame structure or to a building internal wall and then covered with an applied coating. The insulation board is generally of a thickness in the range 50 - 150 mm and is fixed by mechanical fixing means to the building frame or may be glued and mechanically fixed to a building outer wall. The coating is of a thickness up to about 10 mm. The applied coating may also be applied over other wall surfaces including brick or concrete.

A problem or more precisely an inconvenience occurs with existing constructions using applied coatings where an opening or penetration is present in a building wall, such as, for example, a window, door or other aperture or a join where there is an ending (edge) of the wall. In such cases a tradesman applying the coating has to return the surface coating into the aperture in order to cover the edge of the wall or the edge of the foam sheet and this requires skill to ensure a straight and uniform corner which is perfectly vertical or horizontal as the case may be. This procedure is also time-consuming and hence costly. A similar situation exists at an external corner of a building wall which may be an opening in the wall or may be a corner at the end of a wall or even a join in a wall.

In instances where a window or door reveal (as described in our

Australian Petty Patent No. 702597 and Patent Application 85216/98) is fitted into an aperture prior to installation of the applied coating the aforementioned problem does not exist because the reveal projects outwardly from the wall surface providing an abutment up to which the applied coating is finished. However, not all buildings utilise the reveal and there are instances, such as outlined above where a reveal is not appropriate. Therefore there are many occasions where the time and labour intensive procedure described above is necessary.

Throughout this specification the term 'edge reveal' is used to denote a reveal which returns into a wall penetration such as a window or door penetration, for example, whereas the term 'corner reveal' denotes a reveal which extends around a corner in the wall such as an external or internal corner.

It is an object of this invention to provide a building component and a method of construction which overcomes the aforementioned problem or at least provides a useful alternative.

Thus the invention provides a building component comprising an elongate edge or corner reveal which in cross-section has two mutually perpendicular legs thus forming a generally L-shaped section adapted to extend along an edge or corner in a building wall, characterised in that, at least one said leg extends, in use, over part of a building first wall surface, and has a thickness equivalent to the thickness of a coating to be applied to said wall surface, said one leg having a fibreglass or plastics, or like mesh, moulded therein so as to extend beyond the extremity of said one leg to form a wing which, in use, is inco orated into said coating.

In another form the invention provides a method of building construction comprising the steps of fixing an edge or corner reveal over a corner of a building wall, said reveal extending continuously along the corner and having perpendicular legs which extend partly over the respective faces of the wall, at least one of said legs having a fibreglass or plastics, or like mesh, moulded therein so as to extend beyond the extremity of said one leg to form a wing, and applying a coating of lightweight render to the wall surface to cover said wing and abut said one leg, said coating being of a thickness equivalent to the thickness of said one leg.

In order that the invention may be more readily understood particular embodiments will now be described with reference to the accompanying drawings wherein:

FIGURE 1 is a perspective view of part of a building component in the form of a corner edge reveal according to one embodiment of the invention;

FIGURE 2 is an end view of the component of FIGURE 1 ;

FIGURE 3 is a perspective view of part of a building component in the form of an edge reveal according to another embodiment of the invention;

FIGURE 4 is an end view of the component of FIGURE 3.

FIGURE 5 is a sectional plan view of part of a building wall showing an external corner with a corner reveal according to Figures 1 and 2 fixed in place, and;

FIGURE 6 is a sectional plan view of part of a building wall showing a window penetration with an edge reveal according to Figures 3 and 4 fixed in place.

Referring to Figures 1 and 2 the building component comprises a corner reveal in the form of an elongate member of L-shaped cross-section having mutually perpendicular legs 11 and 12 of like profile. The component 10 is moulded from lightweight reinforced cement based render and forms an external corner for a building wall. The extremity of each of the legs 11 and 12 is bevelled at 15, 16 respectively at an angle of about 45° such that the face of the bevelled edge is directed outwardly relative to a building wall to which the component is, in use, attached. In other words the shorter side of the leg 11, 12 is away from the wall surface.

Each of the legs 11 and 12 has a strip of fibreglass mesh such as E- glass mesh moulded therein and extending beyond the extremity of the leg to form wings 13 and 14 as is evident in the drawings. Each of the wings 13 and 14 extend beyond the extremity of the respective leg a distance approximately equal to the length of the leg. The thickness of each of the legs 11 and 12 is equivalent to the thickness of an applied coating to be installed on the external surface of a building wall.

Referring now to Figures 3 and 4 the building component comprises an edge reveal 23 in the form of an elongate member of generally L-shaped cross- section having mutually perpendicular legs 18 and 19. Again the component is moulded from lightweight reinforced cement based render and forms an external corner for a penetration in a building wall such as a window or door penetration.

Unlike the component of the previous embodiment the respective legs 18 and 19 are dissimilar. The leg 18 in use extends into the penetration, as will be apparent hereinbelow, and is of thicker section than the leg 19 which in use extends over the face of the wall. A strip of fibreglass mesh 28 such a E-glass mesh is moulded into the leg 19 and extends from the leg 19 along the length of the free edge 20 thereof. The free edge 20 is bevelled and the face of the edge 20 is, in use, directed away from the wall surface.

The component of each of the above described embodiments is moulded or extruded into the desired shape. In the case of the embodiment of Figures 1 and 2 the legs 11 and 12 are of a thickness equivalent to the thickness of a render coating to be applied to the wall surface. In the case of the embodiment of Figures 3 and 4 the leg 19 is of a thickness equivalent to the thickness of a render coating to be applied to the wall surface and generally the leg 18 is, as mentioned above, of thicker section. The thicker section provides greater resistance to impact damage which is particularly important when the reveal is packed out from the wall surface to achieve a vertical corner.

Figure 5 shows a corner reveal of described in relation to Figures 1 and 2 in use on a building wall. The corner reveal 10 is shown fixed to the corner of a brick wall 21. The reveal 10 is glued or otherwise attached to extend vertically over the height of the wall with the legs 11 and 12 extending over part of the respective wall surfaces. Once the reveal is affixed to the wall 21 a render coating 22 is applied to the outer wall surface of a thickness equivalent to the thickness of legs 11 and 12 . The mesh wings 13 and 14 are adjacent the inner side of the reveal and become embedded in the coating 22 close to the wall surface.

, Figure 6 shows an edge reveal 23 as described in relation to Figures 3 and 4, in use, as a window reveal. The window reveal 23 is fixed to the edge of a wall penetration by screw 24 which is attached to timber wall stud 25. In this particular embodiment the building wall is comprised essentially of foam sheet or blocks 26 which are attached to a timber wall frame of which only stud 25 is shown. The reveal 23 wraps around the edge of the foam at the wall penetration and ensures that the foam is flilly enclosed. A gap exists between the foam and a window frame 27 which is also fixed to the building wall frame and the leg 18 fits into the gap. The reveal is attached to the stud by screw 24 which passes through the reveal and the foam. In an alternative arrangement (not shown) a bracket extends between the stud 25 and the reveal and a screw passes through the reveal and fastens the reveal to one end of the bracket. The other end of the bracket attaches to the stud. An alternative or supplement to the screw attachment 24 is to use an adhesive.

Once the edge reveal is affixed a coating 22 is applied over the foam in a similar manner to the previous embodiment. The coating is the same thickness as the leg 19 of the reveal and again the mesh wing extending from leg 19 becomes embedded in the coating.

In a variation to the edge reveal (not shown) the leg 18 may be tapered whereby it is thicker at its outer or free end than it is at the end which joins with leg 19. This enables the reveal to be used as a window ledge whereby the upper surface of the ledge slopes downwardly and outwardly to allow water run-off.

In use a tradesman installs the corner reveal on a building outer wall surface at a corner of the wall or at a gap where two coplanar walls join or at any other location where a wall ends. The tradesman is able to install the component such that it is perfectly vertical or horizontal as the case may be and uses packing or additional adhesive to adjust the orientation. Similarly the edge reveal is installed at penetrations in the wall such as windows, doorways or other openings. When the reveals are fully installed the render coating is applied as previously described. In all applications a finish coating is applied over the render coating and reveal to provide weather protection and enhance aesthetics.

Clearly, use of the components of this invention simplifies application of coatings to building wall surfaces and avoids the time consuming and costly exercise of forming external corners or edges for penetrations through walls. The use of such a component virtually guarantees the external coating will be of the correct thickness and strength to provide impact resistance. The use of fibreglass mesh avoids problems with rust which can occur if the mesh is formed of metal although there may be some situations where metal mesh is utilized.

It will be appreciated that the invention described herein is susceptible to variations and modifications other than those specifically described. It is to be understood that the invention encompasses all such variations and modifications that fall within its spirit and scope.

Claims

Claims:

1. A building component comprising an elongate edge or corner reveal which in cross-section has two mutually perpendicular legs thus forming a generally L-shaped section adapted to extend along an edge or corner in a building wall, characterised in that, at least one said leg extends, in use, over part of a building first wall surface and has a thickness equivalent to the thickness of a coating to be applied to said wall surface, said one leg having a fibreglass or plastics, or like mesh, moulded therein so as to extend beyond the extremity of said one leg to form a wing which, in use, is incorporated into said coating.

2. A building component as defined in claim 1, characterised in that, said component is a corner reveal and the other said leg extends, in use, over part of the building wall surface which is perpendicular to said first wall surface, the other said leg has a thickness equivalent to the thickness of a coating to be applied to the respective wall surface, the other said leg having a fibreglass or plastics, or like mesh, moulded therein so as to extend beyond the extremity of said one leg to form a wing which, in use, is incorporated into said coating.

3. A building component as defined in claim 2, characterised in that, the free edge of each leg is bevelled such that the face of the bevelled edge is directed away from the wall surface.

4. A building component as defined in claim 3, characterised in that, said mesh extends from said bevelled edge at a position close to an inwardly directed face of the leg so that in use said mesh is close to the building wall surface.

5. A building component as defined in claim 1, characterised in that, said component is an edge reveal and the other said leg extends, in use, over the end of a wall and into a window, door or like cavity.

6. A building component as defined in claim 5, characterised in that, the free edge of said one leg is bevelled such that, in use, the face of the bevelled edge is directed away from the wall surface.

7. A building component as defined in claim 6, characterised in that, said mesh extends from said bevelled edge at a position close to an inwardly directed face of the leg so that in use said mesh is close to the building wall surface.

8. A building component as defined in claim 7, characterised in that, said other leg is thicker than said one leg and said one leg has a thickness equivalent to the thickness of a coating to be applied to the respective wall surface.

9. A building component as defined in claim 8, characterised in that, the free edge of the other said leg is a square end.

10. A building component as defined in any one of the preceding claims wherein said component is moulded or extruded from lightweight reinforced cement or modified cement based product and said mesh is E-glass mesh.

11. A method of building construction comprising the steps of fixing an edge or corner reveal over a corner of a building wall, said reveal extending continuously along the corner and having perpendicular legs which extend partly over the respective faces of the wall, at least one of said legs having a fibreglass or plastics, or like mesh, moulded therein so as to extend beyond the extremity of said one leg to form a wing, and applying a coating of lightweight render to the wall surface to cover said wing and abut said one leg, said coatmg being of a thickness equivalent to the thickness of said one leg.

12. A method as defined in claim 11, characterised in that, said reveal is a corner reveal and the other said leg also has a mesh wing, and said method includes applying a said coating to the wall surface over which said other leg extends to cover said wing and abut said other leg, said coating being of a thickness equivalent to the thickness of said other leg.