ZA200903751B

ZA200903751B - Panelling

Info

Publication number: ZA200903751B
Application number: ZA200903751A
Authority: ZA
Inventors: Peter Edward Mccarter
Original assignee: Peter Edward Mccarter
Priority date: 2008-05-29
Filing date: 2009-05-29
Publication date: 2010-04-28

Description

BACKGROUND OF THE INVENTION

THIS invention relates to panelling and a method of manufacturing panelling to be used as wall cladding, floors, roofs or the like.

In the construction of buildings and with various types of housing, panelling or cladding is used as walls, roofs, floors and/or ceilings. For example, prefabricated buildings may be built in modules or transportable sections where wall panels are secured to frames, such as steel beams, prefabricated concrete plinths or wooden frames. These prefabricated buildings may be manufactured in a manufacturing plant or may be constructed on site.

Wall panels may comprise of different materials, for example galvanised sheeting, plywood etc. One problem that has been identified with panelling currently in use is that the material may be too thin and flexible, may have a structure that easily dents or deforms, or that may corrode over time.

The present invention aims to provide an improved method of manufacturing panelling and aims to provide alternative panelling that may be used for cladding walls of buildings or that may be used as roofs or floors. I

SUMMARY OF THE INVENTION

According to a first aspect of the invention there is provided panelling comprising a sheet of material having a waterproofing layer applied to it in which is embedded a layer of granules.

The waterproofing layer may be an adhesive waterproofing material such as a waterproof glue, waterproof paint or a fibreglass resin.

The layer of granules may be a layer of river or plaster sand, or the like.

Preferably the sheet of material may be galvanised iron sheeting, hardboard, chip board, plywood, fibreglass, nutec sheeting or the like.

Typically, the panelling may further comprise a layer of plaster, paint or mortar applied on top of the layer of granules.

According to a second aspect of the invention there is provided a method of manufacturing panelling to be used as wall panels, flooring or roofing, the method comprising: providing a sheet of material; applying a waterproofing layer to at least one surface of the sheet of - material; and embedding a layer of granules in the waterproofing layer.

Typically, the waterproofing layer is applied to one surface of the sheet of material through the use of a roller or rollers, e.g., a sponge roller, a brush or by spraying a waterproofing layer onto the surface. Similarly, the layer of granules is embedded into the waterproofing layer through the use of a roller or rollers, a brush or by spraying the layer of granules over the waterproofing layer. :

Applying the waterproofing layer to at least one surface may comprise applying multiple layers of waterproofing material on the sheet of material thereby to ensure a thick waterproofing layer to embed the granules in.

The method may further comprise plastering the sheet of material once the - waterproofing layer has dried with the layer of granules embedded therein.

Alternatively, the method may comprise applying a layer of mortar to the sheet of material once the waterproofing layer has dried with the layer of granules embedded therein, thereby allowing the sheet of material to be tiled.

In addition, the method may comprise painting the sheet of material once the waterproofing layer has dried with the layer of granules embedded therein.

The waterproofing layer may be applied to a top and bottom surface of the sheet of material.

The layer of granules may be a layer of river or plaster sand, or the like.

The method may additional include joining two panellings installed adjacent each other by applying a sealant to a channel defined between the two panellings, embedding a layer of granules in the sealant and allowing the sealant to cure.

The method may alternatively include joining two panellings installed adjacent each other by applying a membrane over a channel defined between the two adjacent panellings and applying a layer of granules to the membrane.

Preferably, the membrane is a polypropylene membrane impregnated with a waterproofing solution, which is allowed to cure once the layer of granules has been applied to the membrane.

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 shows a perspective view of panelling in accordance with an example embodiment of the invention; "Figure 2 shows a simplified flow diagram of a method in accordance with an example embodiment of the invention; and

Figures 3 and 4 show cross-sections of adjacent panels formed by panelling which have been joined to each other, in accordance with further aspects of the invention.

Co 2009703751

DESCRIPTION OF PREFERRED EMBODIMENTS

Turning to Figure 1, panelling in accordance with an example embodiment of the invention is generally indicated by reference numeral 10. The panelling may be used as cladding for walls of buildings, e.g., prefabricated buildings, or as floors or roofs. The panelling 10 is shown as a single panel which comprises a sheet of material 12 that may be selected from any suitable material. For example, the sheet of material may be galvanised iron sheeting, hardboard, chip board, plywood, fibreglass, nutec sheeting or the like.

One or more rollers, e.g., a sponge roller, is used to apply a waterproofing : layer, e.g., a layer of adhesive waterproof material 14, onto at least one surface 16 of the sheet of material 12. Alternatively, a brush may be used : to apply the waterproofing layer or the waterproofing layer may be sprayed : onto the at least one surface.

The waterproof adhesive material 14 may be any type of suitable waterproofing material, such as a waterproof ‘glue, waterproof paint or fibreglass resin (to be used on a layer of fibreglass as the sheet of material).

Where galvanised iron sheeting is used as the sheet of material, the galvanised iron sheeting is transformed into a material that will be corrosion resistant as water will not penetrate through the waterproofing layer 14. In circumstances where hardboard, chip board or plywood is used as the sheet material, the waterproofing layer 14 ensures that the sheet of material 12 does not deteriorate due to water ingress or the like. In some example embodiments, e.g., where nutec sheeting is used as sheet of material, i.e., the base material, the nutec sheeting may first be treated to improve its impact resistance by priming one or both sides of the nutec sheeting with a bonding liquid or the like, i.e., a primer for various types of cementitious materials.

Multiple layers of the waterproofing material 14 may be applied to a surface of the sheet of material 12 in order to ensure that the adhesive material has a sufficient depth to embed a layer of granules 18 into the adhesive material. Typically, the waterproofing material 14 is still wet when the layer of granules 18 is embedded therein. The waterproofing layer 14 would therefore be more effective if it is an adhesive waterproofing layer. In an example embodiment of the invention, the layer of granules 18 may be river or plaster sand or the like, e.g., any other suitable particulate material.

The layer of granules 18 may be embedded in the layer of waterproofing material 14 through the use of a second roller (or rollers) that is run across the surface 16 of the sheet of material 12. Alternatively, a brush may be used to apply the layer of granules 18 or the layer of granules 18 may be sprayed over and onto the waterproofing layer 14.

The granules embedded in the layer of waterproofing material 14 provide a : rough finish with mechanical bonding properties that can be used to plaster the panel, once secured to a frame or wall of a building. For example, once the waterproof adhesive layer 14 has dried with the layer of granules 18 embedded therein, the sheet of material 12 may be secured to a frame and may then be plastered and optionally painted. Figure 1 shows the layer of granules sheet of material, with the adhesive layer 14 and layer of granules, to which a layer of plaster 20 has been applied. Alternatively, the panelling may be painted without being plastered.

In circumstances where the panelling is used as flooring, a layer of mortar may be applied to the sheet of material with granules embedded in the waterproof layer, thereby allowing the surface of the sheet of material to be tiled.

Depending on the requirements of the panelling in a particular application, the layer of waterproofing material 14 may be applied to a top and bottom surface of the sheet of material 12. Similarly, the layer of granules 18 may be embedded in one or both of these waterproofing layers.

The present invention provides improved properties to base materials in the form of sheets of material that may be used for panelling used for cladding, flooring or roofing.

Where galvanised iron sheeting is used as cladding, the sheeting is typically too thin, flexible, deformable and sounds metallic and tinny when struck to provide in itself an acceptable cladding material. Also, galvanised iron sheeting is susceptible to corrosion. By applying a waterproof adhesive material to the galvanised iron sheeting, the material becomes corrosion resistant. As mentioned above, with the granules of river or . plaster sand embedded in the waterproofing layer, the rough finish allows the sheet of material to be plastered or tiled. Once plastered, the properties of the sheeting improve in that the sheeting is rigid, thicker, cannot dent easily, has an improved look and feel and is fire resistant. :

Furthermore, the panelling has increased thermal insulation properties, as well as sound insulation properties. It will be appreciated that this panelling may be used as walls, roofing or flooring.

Similarly, in the case of hardboard, the panelling, especially when : plastered, ensures that the sheet of material is waterproof, more rigid, stronger, has improved fire resistance, sound and thermal insulation properties. Panelling constructed from hardboard, chip board or plywood as the base material may be used as walling, preferably indoor walling. ~ Panelling constructed from chip board or plywood as the base material may be used as cladding for walls and roofs, flooring, exterior walling and lightweight roofing.

Where fibreglass is used as the sheet of material, the fibreglass sheeting is first treated with a wet fibreglass resin and while still wet, the resin is impregnated (as described above) with granules of sand, e.g., plaster or river sand. The panelling provided in accordance with the invention by fibreglass has improved qualities of impact resistance, fire resistance and fe £ life span. This type of panelling also shows an improvement in sound and thermal insulation properties.

Turning to Figure 2 a simplified flow diagram of a method of manufacturing panelling to be used as wall panels, flooring or roofing is generally indicated by reference numeral 30. The method comprises providing a sheet of material (shown by block 32), which sheet of material may be galvanised iron sheeting, hardboard, chip board, plywood, fibreglass, nutec sheeting or the like. As shown by block 34, a waterproofing layer is then applied to at least one surface of the sheet of material with one or more rollers, a brush or through a spraying mechanism. A layer of granules is further embedded in the waterproofing layer (block 36).

In a further step according to the method, the sheet of material comprising the waterproofing layer with embedded granules may then either be plastered (block 38), painted (block 40) or a layer of mortar may be applied to it (block 42) thereby to enable the sheet of material to be tiled.

According to a further aspect of the invention two adjacent panels, as described above, may be joined to each other, typically after the panels have been connected to frames during the construction of a building element or alternatively, during construction of a building, eg. a prefabricated house. As shown by Figure 3, once the panels 50 and 52 have been secured next to each other to a frame, a sealant 54 such as polyurethane, silicone, acrylic or the like is used to fill a channel or gap 56 between the two panels 50 and 52. While the sealant is still wet, a layer of granules 58 is embedded into the wet sealant and left until the sealant has cured. The joint can then be painted, plastered or tiled (shown by reference numeral 60), similar to the process described above.

Alternatively, and as shown by Figure 4, adjacent panels 70 and 72 may be joined by first applying a membrane 74 over the joint, i.e. over the channel or gap 76. The adjacent panels may be joined once they have been secured to frames during the construction of a building element or alternatively, during construction of a building, e.g., a prefabricated house. :

The membrane 74 may preferably be a polypropylene membrane which is impregnated with a waterproofing solution. As described above, a layer of granules 78 may then be applied to the membrane and once the waterproofing of the membrane 74 has cured, the joint can then be painted, plastered or tiled (shown by reference numeral 80).

Claims

Ne CL ¥ - CLAIMS

1. Panelling comprising a sheet of material having a waterproofing layer applied to it in which is embedded a layer of granules.

2. Panelling as claimed in claim 1 wherein the waterproofing layer is an adhesive waterproofing material.

3. Panelling as claimed in claim 2 wherein the adhesive waterproofing material is waterproof glue.

4. Panelling as claimed in claim 2 wherein the adhesive waterproofing material is a waterproof paint.

5. Panelling as claimed in claim 2 wherein the adhesive waterproofing material is a fiberglass resin.

6. Panelling as claimed in any one of claims 1 to 5 wherein the layer of granules is a layer of river or plaster sand.

7. Panelling as claimed in any one of claims 1 to 6 wherein the sheet of material is galvanized iron sheeting, hardboard, chip board, plywood, fiberglass or nutec sheeting.

8. Panelling as claimed in any one of claims 1 to 7 comprising a layer of plaster, paint or mortar applied on top of the layer of granules.

9. A method of manufacturing panelling to be used as wall panels, flooring or roofing, the method comprising: providing a sheet of material; applying a waterproofing layer to at least one surface of the sheet of material; and

. Co -11- embedding a layer of granules in the waterproofing layer.

10. A method as claimed in claim 9 wherein the waterproofing layer is applied to one surface of the sheet of material through the use of a roller or rollers, a brush or by spraying a waterproofing layer onto the surface.

11. A method as claimed in claim 10 wherein the roller is a sponge roller.

12. A method as claimed in any one of claims 9 to 11 wherein the layer of granules is embedded into the waterproofing layer through the use of a roller or rollers, a brush or by spraying a waterproofing layer onto the surface.

13. A method as claimed in any one of claims 9 to 12 wherein applying the waterproofing layer to at least one surface comprises applying multiple layers of waterproofing material on the sheet of material thereby to ensure a thick waterproofing layer to embed the granules in.

14. A method as claimed in any one of claims 9 to 13 wherein the method further comprises plastering the sheet of material once the waterproofing layer has dried with the layer of granules embedded therein.

15. A method as claimed in any one of claims 9 to 13 wherein the method further comprises applying a layer of mortar to the sheet of material once the waterproofing layer has dried with the layer of granules embedded therein, thereby allowing the sheet of material to be tiled.

16. A method as claimed in any one of claims 9 to 14 wherein the method comprises painting the sheet of material once the waterproofing layer has dried with the layer of granules embedded therein.

17. A method as claimed in any one of claims 9 to 16 wherein the waterproofing layer is applied to a top and bottom surface of the sheet of material.

18. A method as claimed in any one of claims 9 to 17 wherein the waterproofing layer is an adhesive waterproofing material.

19. A method as claimed in claim 18 wherein the adhesive waterproofing material is waterproof glue.

20. A method as claimed in claim 18 ‘wherein the adhesive waterproofing material is a waterproof paint.

21. A method as claimed in claim 18 wherein the adhesive waterproofing material is a fibreglass resin.

22. A method as claimed in any one of claims 9 to 21 wherein the layer of granules is a layer of river or plaster sand.

23. A method as claimed in any one of claims 9 to 22 wherein the sheet of material is galvanised iron sheeting, hardboard, chip board, plywood, fibreglass or nutec sheeting.

24. A method as claimed in any one of claims 9 to 23 further comprising joining two panellings installed adjacent each other by: applying a sealant to a channel defined between the two panellings; embedding a layer of granules in the sealant; and allowing the sealant to cure.

25. A method as claimed in any one of claims 9 to 23 further comprising joining two panellings installed adjacent each other by:

‘ I'd : SE -13- applying a membrane over a channel defined between the two adjacent panellings; and applying a layer of granules to the membrane.

26. A method as claimed in claim 25 wherein the membrane is a polypropylene membrane impregnated with a waterproofing solution, which is allowed to cure once the layer of granules has been applied to the membrane.

27. A panelling substantially as herein described and illustrated with reference to any one of the accompanying drawings. DATED THIS 29™ DAY OF MAY 2009 oo SPOOR & FISHER APPLICANT'S PATENT ATTORNEYS