KR20040058223A - Wall construction method - Google Patents

Abstract

FIELD OF THE INVENTION The present invention relates to a method of forming a composite wall (1), which method comprises standing up a frame (2) generally comprising a plurality of studs (3) spaced upright, and most cladding sheets. arranging a plurality of outer cladding sheets 4 generally above the frame in a horizontal direction such that a cladding sheet extends across at least two said studs, and in an adjacent relationship to substantially contact the sheets 4. Fastening to the frame to form a generally flat wall substrate, and applying a surface renderer 10, 12 comprising a reinforcing mesh substantially uniformly over the substrate. A structural wall is formed that includes the steps and thus has the appearance of a primed bricklayer without providing auxiliary internal primitives, struts or reinforcements.

Description

Wall construction method

The prior art described herein is not to be considered as tolerate conventional general knowledge that is widely known or formulated in the art.

One building construction technique currently commonly used for residential spaces involves first making a structural frame, usually of wood or metal, and applying an external veneer or shell to the frame. One preferred form of veneer is formed from a single layer of bricks and mortar. This has the advantage of providing a very cheap appearance of the "two-ply brick" structure. Nevertheless, "brick veneers" and similar types of bricklayer structures are relatively time consuming and expensive to install. Another disadvantage of the basic brick veneer structure is that there is a limited range of changes in the appearance of the brickwork to meet various architectural styles and personal tastes.

In an attempt to provide aesthetic diversity, various brickwork priming systems have been developed, such as "stucco" priming. This has the advantage of providing a robust "monolithic" appearance. The system also provides excellent flexibility in terms of surface texture, color and finish, while maintaining a desirable impression of the material and firmness that characterizes the bricklayer structure. Typically, however, the system requires special expertise for effective application, in addition to building time and building costs, and can cause other problems such as sag, separation and environmental degradation.

In an attempt to solve these problems, other claddings including various forms such as aluminum cladding, vinyl cladding, fiber cement sheeting, corrugated steel sheeting, weatherboarding, etc. The system is being developed. These systems are typically cheaper than bricklayer structures, especially primed bricklayer structures, and are somewhat functional at the basic level. However, in most cases, depending on the particular materials involved, these systems are less durable, less flexible in terms of surface finishes, less insulated, or have lower strength properties, and materials related to primitive bricklayer structures. Lack of a desirable appearance of robustness.

In an attempt to resolve this deficiency, the applicant has already developed a system in which fiber reinforced cement (FRC) sheets are applied to the building frame and primed out to embed the bonds between the sheets. However, such a system had its own disadvantages. In particular, internal reinforcements were needed to provide the necessary grade A struts. This typically took the form of a layer of back render applied by spraying on the inner surface of the cladding sheets between the studs or over an auxiliary inner strut. In either case, the construction time and cost is considerable, but it was deemed necessary to provide the strength and structural integrity of the composite wall to the required level. In addition, in such a system, the adjacent sheets needed to be joined on top of the frame studs, further adding to the construction time and creating significant material waste in the form of off-cuts.

Another problem caused by some known priming systems used in conjunction with FRC sheeting is that the joining material is visually exposed through the priming material such that under certain lighting conditions the lower sheet is " read " There is a problem that the primary material may be cracked near the coupling portion.

It is an object of the present invention to overcome or substantially ameliorate one or more of the disadvantages of the prior art, and at least to provide a useful alternative.

The present invention relates to a method of building a house.

The present invention has been developed primarily for use in wall construction of residential spaces and is described with reference to such construction. However, it will be appreciated that the present invention is not limited to this particular field of use and is readily applicable to the manufacture of floors, ceilings and other common flat surfaces in residential as well as commercial and industrial environments.

1 is a schematic cutaway perspective view showing a composite wall formed according to the method of the present invention;

FIG. 2 is a schematic cross-sectional view of the wall system of FIG. 1 applied to a multilayer structure in which a rear superficial material is applied to the lower layer but omitted from the upper layer; FIG.

FIG. 2A is an enlarged detail view of the wall section of the upper layer of FIG. 2; FIG.

3 is a plan view illustrating the application of cladding or building sheets to vertical frame studs in a horizontally staggered or “bricking” type pattern such that the sheets extend across a plurality of studs.

4 is a plan view similar to FIG. 3 showing the installation of the building sheets around the window opening and the use of PVC off-stud joints.

5A and 5B are enlarged perspective views showing the off-stud assembly in more detail.

6A and 6B are enlarged perspective views showing complementary interlocking edge features in the building sheets as an alternative to the off-stud assembly of FIGS. 5A and 5B.

7A and 7B are vertical cross-sectional views illustrating the installation of a horizontal control coupling to accommodate expansion and contraction of the building sheets.

Fig. 7C is a horizontal sectional view showing the installation of the vertical control coupling portion.

FIG. 8 is a vertical sectional view showing the finishing detail of a wall adjacent to the edge of a lower concrete slab that includes a horizontal control coupling extending along the slab edge. FIG.

9A, 9B and 9C are vertical cross-sectional views showing a series of alternative methods of finishing and coalescing the wall into a window frame or window sills;

10 is a horizontal sectional view showing the outer corner detail of the wall;

Accordingly, the present invention provides a method of forming a composite wall, the method comprising

Uprighting a frame comprising a plurality of studs that are generally spaced upright;

Placing a plurality of outer cladding sheets over the frame in a generally horizontal direction such that most of the cladding sheets extend across at least two said studs,

Fastening the sheets to the frame in an adjacent relationship with substantially contacting them to form a generally flat wall substrate;

Applying a substantially uniform surface render comprising a reinforcing mesh over the substrate,

Thereby a structural wall is formed having the appearance of a primed bricklayer without providing auxiliary internal priming, struts or reinforcement.

Preferably, the frame is substantially formed of timber. However, it should be understood that a frame formed of metal or other suitable material may optionally be used. The studs are preferably spaced approximately 450 mm between centers.

Preferably, the outer cladding sheets are formed of fiber reinforced cement (FRC). The FRC sheets preferably have a thickness of about 4 mm to 20 mm, more preferably about 6 mm to 10 mm, and ideally 7 mm to 8 mm.

Preferably, the outer cladding sheets are substantially rectangular with a pair of ends that are substantially parallel to a pair of longitudinal sides that are substantially parallel in shape. In particular, the sheets are approximately 2.4 m long, approximately 0.45 m wide and approximately 7.5 mm thick and have a density of about 10 kg / m 2. However, it should be understood that the size may vary depending on the material of the cladding sheets, the structure of the frame elements, and the particular application used.

In a preferred embodiment, the elongated cladding sheets are staggered or " brick-like " in a horizontal direction, with the longitudinal edges of the sheets extending substantially perpendicularly across the frame studs. Is applied to the frame in a pattern.

Preferably, the outer surface of each FRC cladding sheet is roughened to facilitate mechanical and chemical attachment to the surface superficial material. Also preferably, each building sheet comprises at least one square edge such that adjacent building sheets can contact each other with minimal exposure at the joining portion. More preferably, each edge of each building sheet is substantially square in order to facilitate joining and finishing in contact with each other due to the mating and finishing compatible structure.

Ideally, the building sheets are arranged such that the joining ends of adjacent sheets are joined to each other over the top of the lower stud. However, one unique advantage of the present invention is that "off-stud joining" of the sheets is possible without compromising the dimensional stability and structural integrity of the wall. In such a case, however, it is desirable to use special use of "off-stud joiners" to join the ends of adjacent sheets together. This assists in stabilizing the vertical and horizontal edges of the unsupported sheets during priming and helps prevent cracking in subsequent priming mixtures.

Another distinctive advantage of the present invention is that a rear superlumber layer is unnecessary on the opposite side of the building sheets, although rear superlumber can be applied as needed.

Preferably, however, if no rear priming is applied to the inner surfaces of the building sheets between the studs, all the exposed surfaces of the fiber reinforced cement sheets are covered with a rear priming by brush, roller or spray. Apply.

Preferably, the reinforcing mesh is formed substantially of fiberglass and is applied over the top of the evenly applied first primer. Ideally, any joins in the fiberglass mesh are formed to overlap by at least 50 mm.

Preferably, the primary material is a high-build primary material formed of an acrylic-modified cementitious material selected to be plastered with a flat even finish when applied externally to a vertical surface. The primer is preferably applied at a depth sufficient to eliminate the possibility of sheet "read" in any conventional lighting conditions.

Also preferably, the method further comprises applying a selected fabric finish to the primitive to achieve the desired aesthetic appearance. Most preferably, high quality acrylic texture membrane paint is applied to the fabric finish, or to the primer when no separate fabric finish is used.

Preferably, a thermal insulation material is installed inside the building sheets between the studs, and then the wall space is preferably closed by an internal finishing material such as plasterboard. Any suitable mounting material can be used, including rock wool, glass wool or polyester batts.

Also, preferably, a suitable waterproof layer, ideally in the form of a vapor permeable sarking material, is applied between the inner surfaces of the building sheets and the adjacent insulation to provide optimum waterproof properties.

In this preferred embodiment, a finishing strip, ideally formed of aluminized stainless steel or PVC, is provided to provide straight edges to the finishing layer and to protect the sheet edges at the top and bottom of the wall.

Preferred embodiments of the present invention are now described by way of example only with reference to the accompanying drawings.

First, referring to FIGS. 1 and 2, the present invention provides a method of forming the composite wall 1. The first step of the method generally involves standing up the structural frame 2 comprising a series of upstanding studs 3 spaced approximately 450 mm between centers. The frame is preferably formed of wood, but may optionally be formed of metal or other suitable frame material.

The next step of the method involves placing a plurality of building or cladding sheets in a generally horizontal direction across the frame such that at least most of the cladding sheets extend across the plurality of studs. The sheets are ideally staggered in a racked structure, which may be normative or irregular, as shown in FIG. 3. 4 is similar, but illustrates the installation of the sheets typically around an opening such as a window or door.

In a preferred form of the invention, the building sheets are formed of fiber reinforced cement (FRC). The FRC sheets preferably have a thickness of about 4 mm to 20 mm, more preferably about 6 mm to 10 mm, and ideally about 7.5 mm. Most conveniently, the sheets are of rectangular shape with a pair of parallel longitudinal sides 5 and a pair of parallel ends 6 substantially shorter in length than the sides 5. In one preferred system, the longitudinal sides 5 are 2.4 m in length and the ends are 0.45 m in width, roughly corresponding to the stud space. The density of the FRC sheet is preferably 8 to 12 kg / m 2, ideally about 10 kg / m 2. The sheets are fastened to the lower studs using nails from a nail gun or optionally by screwing, flattening, riveting, gluing or other suitable fastening means.

One unique advantage of the building technique according to the invention is that the ends of adjacent sheets do not need to be joined over the top of the studs (known as “on-stud joining”). Advantageously, off-stud coupling is possible without compromising the structural integrity of the finished wall. In such a case, however, it is preferred that a special purpose off-stud assembly 8 be used to join the ends and / or sides of adjacent sheets together. This combination takes the form of an elongated PVC strip having a "H" shaped cross-sectional structure, as best shown in FIGS. 5A and 5B. This helps to stabilize the vertical and horizontal ends of the sheets not supported by the lower studs, especially during subsequent process steps. An alternative form of stabilizing the studs is shown in FIGS. 6A and 6B. In this case, no separate off-stud conjugates are used. Rather, complementary edge profiles 9 are formed in the sheets, such as interlocking tongues and groove shapes, which are adapted to prevent relative movement, in particular coplanar misalignment between adjacent sheets along the joint.

The next main step of the building method involves applying an evenly cemented superlumber layer 10 over the outer surface of the building sheets 4 to substantially cover the sheets and the intermediate joining line. This primitive layer is ideally about several millimeters thick, as best shown in FIG. 2A. Advantageously, the outer surfaces of the building sheets are pre-roughened to enhance the adhesive strength between the primer and the underlying FRC substrate.

Thereafter, in the wet state before the superficial material is solidified, a layer made of a reinforcing mesh 11 is applied to the surface of the even initial material layer 10. Ideally, fiberglass reinforced mesh is used. However, it may be replaced by another suitable material. Most conveniently, the mesh is initially cut into squares with a side length of about 1 m in an easily handled cross section. However, if the mesh is applied to several zones, it is preferred that at least 50 mm of overlap be provided between adjacent zones.

With the reinforcing mesh 11 in place, the outer covering layer 12 of the prime material is applied to a thickness sufficient to completely bury the mesh so that it is not exposed. The bonding thickness of the superficial layers 10 and 12 including the embedded reinforcing mesh 11 is preferably 5 to 15 mm, ideally about 7 to 8 mm. The final thickness can be varied to accommodate deformation in the substrate and to suit the particular primer material composition and the field in which it is used. Ideally, however, the primer is applied at a depth sufficient to eliminate the possibility of sheet "identification" under any conventional lighting conditions, thereby ensuring the desired "integral" appearance of the primed bricklayer.

The material used as the primary material is ideally formed of an acrylic-modified cement-based thick film material which is intended to be plastered with a flat even finish when applied to the exterior. It will be appreciated that the two superlumber layers typically consist of the same composition, but different compositions may be used for different layers to suit a particular application. Additional layers of the same or different composition may be used.

The horizontal control couplings 13 are incorporated as shown in Figs. 7A and 7B. These couplings are ideally formed using longitudinally extending PVC control engagement projections 14 which overlie the frame member, such as top plate 15. This joint prevents cracking of the superficial material due to the differential expansion and contraction of the underlying building sheets.

In addition, the vertical control couplings 16 are preferably provided with a maximum horizontal distance between centers of 4.8 m, as shown in FIG. 7C. If possible, vertical control couplings are arranged behind adjacent window or door openings or behind a vertical downspout. These control couplings are formed by first securing the waterproof membrane 17 to the frame and then applying a suitable tape over the "V" area within the membrane. Thereafter, the sheets are installed, and between the ends there is provided a minimum gap of approximately 6 mm which is preferably not filled with the primer. 8 shows a technique for incorporating the horizontal control coupling 13 directly under the ground finishing strip 18 adjacent to the edge of the concrete slab 19.

An optional but preferred step, the next step involves applying a fabric finish layer 20 to the base material to produce a variety of aesthetic appearance. One preferred fabric applicator is finished to mimic the appearance of a conventional stucco.

In a preferred form of the invention, a finish formed of aluminum treated stainless steel or PVC is provided to provide a straight edge to the finishing layers and to protect the edges of the building sheets and the superficial material at the top and bottom of the wall. Ideally, the strip 18 is installed (see FIG. 8).

Finally, a layer 25 of high quality acrylic fabric membrane paint is applied to the fabric finish, or to the primer when no separate fabric finish is used (see FIG. 2A). This allows for more color choices, increases protection against water and weather and prevents environmental degradation.

If desired, a rear superficial layer 30 may be applied to the inner surfaces of the building sheets between the studs. This is shown, for example, in the bottom wall structure of FIGS. 2 and 8. When selectively used in this manner, the rear superlumber provides additional strength, heat dissipation and sound insulation, and increased durability. However, one of the main advantages of the present invention stems from the fact that it is possible to exclude the back reinforcement layer, or any other kind of auxiliary support or strut.

The system excluding the rear reinforcement is shown for comparison in the upper floor area of the wall of FIG. 2. In such a case, the wall space between the studs is simply filled with a layer of insulating material 32 such as rock wool, glass wool or polyester batt. The space is then closed from the inside using conventional interior finishing materials such as plasterboard sheet 35. In situations where no rear primer is applied and the inner surfaces of the building sheets are exposed, it is desirable to seal the inner surfaces of the sheets using a suitable primer or sealant that can be applied by a brush, roller or spray. Do.

Closing the system in a consistently aesthetic manner from around window and door openings can be easily accomplished using a variety of techniques. As an example, FIGS. 9A, 9B and 9C illustrate three different methods of forming the window sill and window sills 38 using complementary aluminum extrusion zones 40 aesthetically incorporated by the final fabric finish and paint application. Illustrated.

Corners can be similarly finished in various ways. By way of example, FIG. 10 illustrates one of the above methods, wherein the protective metal angular zones 45 are fastened to respective outer edges 46 and the inner edges 47 are finished with a waterproof material 48 to provide a suitable waterproof. Is achieved.

The wall construction method according to the invention provides a number of advantages over the prior art. According to the method according to the invention, the aesthetics and durability of the primed bricklayer structure is calculated, with significantly faster construction time and significantly lower material costs. In addition, the system is easier to apply than recently known primitive systems and improves surface cracking and separation.

Most notably, the present invention eliminates the need for an auxiliary internal strut, or without applying a rear primitive to the inner surface of the sheets, a combination of method steps as defined, for walls up to at least 3 m high. , Extensive investigation, development and experimentation sufficient to achieve essentially the equivalent of "Type A Structural Bracing" (ULS strut capacity of at least 3.3 kN / m) as described in AS1684 Residential Timber-Frames Construction Code. As a result of the unique realization identified only by the applicant. Until now, in order to achieve the required strength, robustness and durability, it has been considered that the auxiliary struts or rear priming are essential in the construction methods of the type described above. In practicing them, already known methods necessarily involve additional building processes, material costs, and special expertise, but such a need is eliminated by the present invention. Thus, the present invention represents a distinctive, practical and commercially significant improvement over the prior art.

Although the present invention has been described with reference to specific examples, those skilled in the art will appreciate that the present invention may be implemented in various other forms.

Claims (38)

Uprighting a frame comprising a plurality of studs that are generally spaced upright; Placing a plurality of outer cladding sheets over the frame in a generally horizontal direction such that most of the cladding sheets extend across at least two said studs, Fastening the sheets to the frame in an adjacent relationship with substantially contacting them to form a generally flat wall substrate; Applying a substantially uniform surface render comprising a reinforcing mesh over the substrate, A method of forming a composite wall, whereby a structural wall having the appearance of a primed brickwork is thereby formed without providing an auxiliary internal primer, strut or reinforcement. The method of claim 1, wherein the frame is substantially formed of timber. The method of claim 1, wherein the frame is substantially formed of metal. 4. The method of any one of the preceding claims, wherein the studs are spaced about 300 mm to 600 mm between centers. 5. The method of claim 4, wherein said studs are approximately 450 mm apart between centers. 6. The method of any one of the preceding claims, wherein the outer cladding sheets are formed from fiber reinforced cement (FRC). The method of claim 6, wherein the FRC sheets have a thickness of about 4 mm to about 20 mm. The method according to claim 6 or 7, wherein the FRC sheets have a thickness of about 6 mm to 10 mm. 9. The method of any one of claims 6-8, wherein the FRC sheets have a thickness of about 7 mm to 8 mm. 10. The method of any one of the preceding claims, wherein the outer cladding sheets are substantially rectangular in shape with a pair of ends that are substantially parallel to a pair of longitudinal sides that are substantially parallel. The method of claim 10, wherein the sheets are approximately 2.4 m long, approximately 0.45 m wide, and approximately 7.5 mm thick. The method of claim 10, wherein the sheets have a density of about 8 kg / m 2 to about 10 kg / m 2. 13. The elongated cladding sheets of claim 10, wherein the elongated cladding sheets are staggered in the horizontal direction, with the longitudinal edges of the sheets extending substantially perpendicularly across the frame studs. Or a composite wall forming method applied to the frame in a "brick-like" pattern. 14. The method of any one of claims 1 to 13, further comprising roughening the outer surface of each cladding sheet to facilitate mechanical and chemical adhesion to the surface superficial material. 15. The method according to any one of claims 1 to 14, further comprising providing at least one square edge to each building sheet such that adjacent building sheets can contact each other with minimal exposure at the joining portion. Composite wall forming method comprising. 16. The method according to any one of claims 1 to 15, wherein each edge of each building sheet is formed to be substantially square, thereby facilitating joining and finishing in contact with each other due to the mating and finishing compatible structure. Method of forming a composite wall. 17. A method according to any one of the preceding claims, wherein the building sheets are arranged such that the joining ends of at least one pair of adjacent sheets are joined over the top of the lower stud. 18. The method of any one of the preceding claims, wherein the building sheets are arranged such that the mating ends of at least one pair of adjacent sheets are off-stud bonded. 19. The method of claim 18, further comprising joining the adjacent ends of the at least one pair of building sheets together at an off-stud bond by an off-stud bond formation. 20. The method of claim 19, wherein said off-stud bond formation generally has an H-shaped cross-sectional profile. 19. A longitudinally extending complementary interlock according to claim 18, wherein the sheets are adapted to resist relative movement, in particular longitudinally adapted to prevent coplanar misalignment between adjacent sheets along the joining portions. A method of forming a composite wall formed of edge profiles. 22. The method according to any one of the preceding claims, wherein applying the surface supernatant is subsequent substeps, i.e. Applying an even layer of cementitious superlumber over the outer surfaces of the building sheets, substantially covering the sheets and intermediate bonding lines, Applying the layer of reinforcing mesh to the surface of the even superglare layer, in the wet state before the superelastic material is solidified, and And applying the outer coating layer of the superficial material to a thickness sufficient to completely bury the mesh so that it is not exposed. 23. The method of claim 22, wherein the bond thickness of the superficial layers comprising the embedded reinforcing mesh is on the order of 5 mm to 15 mm, ideally on the order of 7 mm to 8 mm. 24. The method of claim 22 or 23, wherein the bond thickness of the superficial layers comprising the embedded reinforcing mesh is on the order of 7 mm to 8 mm. 25. The method of any one of the preceding claims, wherein the reinforcing mesh is formed substantially from fiberglass. 26. The method of any one of the preceding claims, wherein the mesh is applied such that any joins are formed with a minimum overlap of 50 mm or so. 27. The method according to any one of claims 1 to 26, wherein the primer is a high-build primer. 28. The composite wall forming according to any one of claims 1 to 27, wherein the supermaterial is formed from an acrylic-modified cementitious material that is adapted to be plastered with a flat even finish when applied externally to a vertical surface. Way. 29. The method of any one of the preceding claims, wherein the primer is applied to a depth sufficient to eliminate the possibility of sheet "read" by the naked eye under conventional lighting conditions. 30. The method of any one of claims 1 to 29, further comprising applying a selected fabric finish to the primitive to achieve a particular desired aesthetic appearance. 31. The method of any of claims 1-30, further comprising applying an acrylic texture membrane paint as the outermost protective layer. 32. The method of any one of the preceding claims, further comprising applying a rear superficial layer to opposite sides of the building sheets in the middle of the frame studs. 33. The method of any one of the preceding claims, further comprising applying a rear primer layer to exposed surfaces of opposite sides of the fiber cement sheets. 34. The method of any one of the preceding claims, further comprising the step of installing a thermal insulation material inside the building sheets between the studs. 35. The method of any one of the preceding claims, further comprising applying a suitable layer of waterproofing material over the inner surfaces of the building sheets. 36. The method of claim 35 wherein the waterproofing material takes the form of a vapor permeable sarking material. 37. The method of any one of claims 1 to 36, further comprising closing the wall space with an interior finish material. 38. The method of any one of claims 1 to 37, further comprising installing a finishing strip to provide the finish layers with substantially straight edges and to protect the sheet edges at the top and bottom of the wall. Further comprising a composite wall forming method.