GB2437732A

GB2437732A - Ventilated rainscreen system

Info

Publication number: GB2437732A
Application number: GB0608808A
Authority: GB
Inventors: Brian Geoffrey Newell
Original assignee: SHACKERLEY
Current assignee: SHACKERLEY
Priority date: 2006-05-04
Filing date: 2006-05-04
Publication date: 2007-11-07
Also published as: GB0608808D0

Abstract

An aluminium support structure for mounting a plurality of ceramic panels G in a configuration which provides ventilated pressure equalised rainscreen is provided. The ceramic panels G are secured with gaps of 10mm between panels on to vertically aligned horizontally fixed aluminium profile rails 8 mounted directly onto rigid foam insulation board 6. The ceramic cladding panels G have affixed to their back face interlocking profiles C, D by anchors E. The profile C is inserted into the upwardly open channel of a lower rail 8, then swung upwardly and the upper end of rail C is fixed to the lower part of an upper rail 8 by a fixing 5 as shown, accessible between panels G. The system permits prefabrication and removal of individual panels after installation. The fixings for the rails may pass through the insulation board 6 and into an underlying support structure 1.

Description

Page 1 2437732

SURECLAD VENTIRAIL -CERAMIC VENTILATED RAINSCREEN SYSTEM

DESCRIPTION

The invention relates to a system for cladding the elevations of a structure mainly external but can be used internally using an aluminium grid attached to the structure of a building upon which a plurality of ceramic granite panels are mechanically fixed in accordance with the requirements of a pressure equalised ventilated rainscreen system.

Such systems are known but suffer from the disadvantage that they necessitate bracket fixings through the rigid foam insulating panels of a structure being clad significantly breaching the thermal integrity of the rigid foam panel insulation and allowing thermal bridging via said brackets. It is known to be difficult to cut the insulation panels accurately around such brackets on a site based installation or when fabricating off site in a factory and thereafter it is difficult to make good the insulation around such fixing brackets and therefore such brackets are best avoided.

Other such systems are known but suffer from the disadvantage that they do not allow the replacement of an individual ceramic granite panel in isolation to other panels and require many panels to be removed or moved to access a single panel for replacement or temporary removal.

Other such systems are known but suffer from the disadvantage that they have no way of mechanically securing each individual ceramic granite panel permanantely to prevent a lateral creeping movement caused by thermal expansion or wind rattle.

An object of this invention is to provide a system that allows ceramic granite panels to be installed as part of a rainscreen without cutting apertures in the rigid insulation foam sheeting forming the insulating layer of a building constructed either on or off site or in a factory prefabrication process.

Accordingly the aluminium (VR profile) is designed in such a way as to have too vertically aligned aluminium feet which continuously support the (VR profile) against its interface with the rigid foam insulating panels preventing compression of the foam insulating panel and spreading the load of the ceramic cladding panels over the full length of the horizontal aluminium (VR profile) the aluminium (VR profile) is fixed through the rigid foam insulation and weather resistant cement particle sheathing board with self drilling self tapping screws securing a fixing into the metal framing system of the structures façade.

Page 2 The ceramic granite panels to be mounted as part of the rainscreen system are pre-drilled with undercut holes in the rear and an aluminium strap made of two interlocking sections (profile C&D) is attached to the ceramic granite panel using stainless steel expanding profiled anchors compressible PVC foam pads are inserted between the outer section tile strap (profile D) and the ceramic granite panel to accommodate minor irregularities in the tile surface and prevent rattling in windy conditions.

The ceramic granite panel complete with interlocked straps (C&D profile) attached by means of stainless steel profiled anchor is offered up to the framework slotting the lower ends of the straps (profile C) into the slot (A) in the primary cross rails (profile VR) the upper protruding end of the strap (profile C) is set against the flat surface of the next cross rail (profile VR) above. The joints between the panels are regulated to be between 6-10 mm and the upper end of the straps (profile C) are fixed in position using self drilling stainless steel screws.

The joints between ceramic panels are left open to allow ventilation and pressure equalisations.

An object of the design is to allow simple removal and replacement of ceramic panels in isolation when surrounded by other ceramic panels.

Accordingly the fixing screws on the straps (profile C) are directly in line with the horizontal joint between the ceramic granite panels thus allowing individual ceramic granite panels to be removed should the need arise without disturbing the adjacent panels.

The design of the profile VR in the way the slot (A) is arranged to allow easy introduction of the tile strap (profile C) whilst positioning the tile but to give a secure hold when the ceramic granite panel is moved into a vertical position by virtue of the fulcrum point (B) on the profile VR is an ingenious security technique used in the sureclad ventirail system.

An object of the design of the (VR profile) aluminium rail is to allow sufficient continuous ventilation between the face of the rigid foam insulating panel and the back face of the tile.

Accordingly a further innovation of the (profile VR) rail is the perforated apertures aligned at regular intervals along opposing horizontal flanges. These aperatures are designed to supplement the airflow between to allow sufficient through ventilation to comply with the requirements of a pressure equalised ventilated rainscreen system when fixed directly to a flat background without the requirement for further bracketry to the substructure to obtain the required ventilated cavity.

Page 3 The components are:- 1. Primary cross rail section -profile VR 2. Top cross rail section -profile VR 3. Inner tile strap -profile C 4. Outer tile strap -profile D 5. Ceramic granite panel 6. Undercut anchor and bolt 7. Stainless steel fixing screw 8. Self drill self tap screw The system has 2 methods of application:- 1. The components are delivered to site and assembled piecemeal 2. The aluminium framework is assembled off site and delivered to site in prefabricated panels as part of an architectural façade frame system for erection on site thereafter the ceramic cladding panels are attached.

The system is made up of a series of horizontally configured aluminium rails which are attached onto the surface of the rigid insulating board which comprises the insulating layer of a structure.

When the horizontal (VR) profiles are correctly fixed at the designated regular intervals onto the rigid insulating layer they are ready to receive the prepared ceramic granite panel for installation. Claim

Claims

1. An aluminium support structure for mounting a plurality of ceramic

panels in a configuration which provides ventilated pressure equalised rainscreen by virtue of securing ceramic panels with open joints between panels of up-to 10 mm onto vertically aligned horizontally fixed rails of aluminium profile VR which are in-turn mounted by fixing screws directly onto rigid foam insulation board and secured into steel members comprising part of a façade framing system to be constructed on or off site where the ceramic panel is secured in position by virtue of the interlocking strap profiles C and D the positioning of the interlocked straps C profile into the corresponding profile VR aperture the interlocked straps C&D are brought into a vertical position during installation and in doing so the fulcrum point on the VR profile rail brings the strap into tension on the sureclad ventirail rail bearing surface and provides a secure friction fixing to the (lower end) of strap C.
2. As support structure claimed in 1 where ceramic panels are secured to the interlocked C&D profiles with stainless steel anchors and corresponding stainless steel bolt the underside of the bolt head being serrated to provide a locking action on the surface of the aluminium profile D the C profile being 60 mm longer than the D profile to provide fixing points off set from the rear face of the ceramic panel.

3. As support structure claimed in 1 and 2 where the interlocked straps profile C&D are secured in place with self drilling stainless steel screws the positioning of the strap and fixing screws on the corresponding bearing surface of the aluminium VR rail allows there removal through the ceramic panels open joint if required and thereafter by virtue of there removal allows the release of the tension provided by the fulcrum point on the corresponding lower aluminium VR rail profile which in turn facilities the ability to remove an isolated ceramic panel from within a surrounding area of securely fixed ceramic panels without there removal 4. As support structure as claimed in 1, 2 and 3 where the sureclad VR aluminium horizontal profile is perforated at 60 mm centres with rectangular 45 x 30 mm apertures on two opposite horizontal faces to promote air flow and pressure equalisation within the ventilated cavity between the back face of the ceramic panel and the rigid foam insulation sheeting without additional offsetting support bracketry.

5. As support structure detailed in 1, 2, 3 and 4 where the sureclad ventirail shall be mechanically fixed with proprietary self drill self tap fixing bolts against and through rigid foam insulation sheeting and thereafter through weather resistant cement particle sheathing board securing fixings into a proprietary metal façade framing system without the requirement for additional bracketry.

A=Slot B = Fulcrum C = C Profile Aluminium Section D = D Profile Aluminium Section E = Undercut Anchor F = Compression Pad G Ceramic Granite Cladding 1 = Metal Stud Structure 2 = Plasterboard Lining 3 = Cement Particle Board 4 Self-drill Stand-off Fixing = Self Tap Fixing 6 = Insulation 7 = Air Void 8 = Profile VR Key lof 1