GB2559113A

GB2559113A - Cladding system

Info

Publication number: GB2559113A
Application number: GB1621704.4A
Authority: GB
Inventors: Clark Jim
Original assignee: Enewall Ltd
Current assignee: Enewall Ltd
Priority date: 2016-12-20
Filing date: 2016-12-20
Publication date: 2018-08-01
Also published as: GB201621704D0

Abstract

The cladding system 10 comprises an outer façade layer 20, and an inner insulation layer 30 with an innermost surface having a plurality of vertical grooves 32 which at least partially define a plurality of vertical drainage channels. The innermost surface may be castellated. The system may be attachable to an existing substrate 104 of a building. The existing substrate may be a wall. The vertical grooves and the wall may co-operatively define the drainage channels. The insulation layer may be a moulded foam such as expanded polystyrene. The system may comprise a plurality of panels arranged in a staggered tile pattern. Each insulation layer may have a top edge and a bottom edge, the castellated surface defining vertical protrusions which extend toward but do not reach at least one of the top and bottom edges. The façade layer may comprise a render. The system may include a reinforcing mesh 40 for receiving the façade layer and attached to the insulation layer by adhesive.

Description

(54) Title of the Invention: Cladding system

Abstract Title: Cladding system for a building (57) The cladding system 10 comprises an outer fagade layer 20, and an inner insulation layer 30 with an innermost surface having a plurality of vertical grooves 32 which at least partially define a plurality of vertical drainage channels. The innermost surface may be castellated. The system may be attachable to an existing substrate 104 of a building. The existing substrate may be a wall. The vertical grooves and the wall may co-operatively define the drainage channels. The insulation layer may be a moulded foam such as expanded polystyrene. The system may comprise a plurality of panels arranged in a staggered tile pattern. Each insulation layer may have a top edge and a bottom edge, the castellated surface defining vertical protrusions which extend toward but do not reach at least one of the top and bottom edges. The fagade layer may comprise a render. The system may include a reinforcing mesh 40 for receiving the fagade layer and attached to the insulation layer by adhesive.

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Fig. 1 (Prior Art)

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Fig. 2 (Prior Art)

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Cladding System

The present invention relates to cladding for buildings. In particular, but not exclusively, the present invention relates to fa$ades for the exterior walls of timber clad buildings.

In the UK, most houses have typically been constructed from masonry blockwork. However, in Scotland, houses have always largely been built using a timber frame construction and their popularity is growing throughout the UK. Timber frame construction offers a number of advantages. One of these is the speed of construction. Unlike a block wall, which is built one block at a time, timber panels are typically prefabricated off-site and this significantly simplifies on-site construction, which can often take just a few days.

It is impossible to tell a timber-framed house from a masonry one because the external cladding is unaffected by the choice of internal walls. The outer decorative 'skin' can be finished in the same way as any traditional block house, using bricks, stone, timber cladding or rendered blockwork. There is a particular advantage in using timber cladding, since the cladding can be directly fixed to battens which themselves are directly fixed to the timber frame. This has been a popular choice for some types of housing such as for social housing. In recent years, over 90% of new buildings for Scottish housing associations have used timber cladding.

The main issues with timber frames and timber cladding are durability and maintenance. Timber is hygroscopic and, if not properly maintained, is subject to rot and infestation by fungi or insects. Proper drainage and ventilation for the cladding system can reduce moisture absorption. It is common to install a series of cladding battens to the timber frame. The cladding is then fixed to the battens. The battens create a space behind the cladding allowing water to drain down.

Typically, horizontal battens are used with vertical cladding boards and vertical battens are used with horizontal cladding boards. However, horizontal battens form a barrier to draining water. There are two common solutions to this. The first is, when using wooden battens, to install a second layer of battens below the first layer, the second layer having a vertical orientation to create the desired vertical channels for drainage. The second solution is to use battens, such as metal battens, which have pre-existing vertical channels (when the battens are horizontal). However, both solutions add to the cost and installation time involved.

According to the present invention there is provided a cladding system for a building, the cladding system comprising:

an outer fa$ade layer; and an inner insulation layer which has an innermost surface for presenting to the building, wherein the innermost surface includes a plurality of vertical grooves which at least partially define a plurality of vertical drainage channels.

Optionally, the innermost surface has a substantially castellated profile to provide the plurality of drainage channels.

Optionally, the cladding system is adapted to be attachable to an existing substrate of the building. Optionally, the existing substrate comprises a wall of the building. Optionally, in use, the plurality of vertical grooves and the building substrate co-operatively define the plurality of vertical drainage channels.

Alternatively, the cladding system may be adapted to be attachable to a frame member of the building. The cladding system may provide a wall of the building.

It is to be appreciated that the present invention can provide the structural cladding for the building or it can be a superficial fa$ade installed over the existing structural cladding of the building.

Optionally, the insulation layer comprises a moulded foam material. Optionally, the insulation layer comprises an expanded polystyrene material.

Optionally, the castellated profile is formed during moulding of the insulation layer.

Optionally, the cladding system comprises a plurality of cladding panels, each panel comprising an outer fa$ade layer and an inner insulation layer. Optionally, the cladding system comprises a plurality of cladding panels arranged in a staggered tile pattern.

Optionally, each insulation layer has a top edge and a bottom edge. Optionally, the castellated surface defines a plurality of vertical protrusions which extend towards the top and bottom edges. Optionally, each protrusion extends towards but does not reach at least one of the top edge and the bottom edge.

Optionally, the fa$ade layer comprises a render material.

Optionally, the cladding system includes a reinforcing mesh for receiving the fa$ade layer. Optionally, the mesh is attached to the outer surface of the insulation layer using an adhesive.

The invention will be described below, by way of example only, with reference to the accompanying drawings, in which:

Figure 1 is a perspective view of a prior art cladding system;

Figure 2 is a front view of battens of the prior art cladding system of Figure 1; and

Figure 3 is a sectional top view of a panel of a cladding system according to the invention.

Figure 1 shows a known cladding system 100 which has been partially installed to a building 102. The existing substrate of the building 102 comprises vertical timber slats 104. Horizontal battens 106 of the cladding system 100 have been fixed to the slats 104 to extend across the slats 104.

As shown more clearly in Figure 2, the battens 106 are made from sheet metal formed into a top hat section. The top and bottom horizontal surfaces of the battens 106 comprise a series of apertures 108. These provide drainage channels to allow any water above the battens 106 to drain downwards and through the battens 106.

Insulation panels 110 are attached to the battens 106. An outer fa$ade layer (not shown) can be fixed to the outer surface of the insulation panels 110.

Figure 3 shows a portion of a panel 10 of a cladding system according to the invention.

The panel 10 comprises an outer fa$ade layer 20 and an inner insulation layer 30. In this example, the facade layer 20 comprises a render material but any type of fa$ade may be used.

The insulation layer 30 comprises an expanded polystyrene material. This is formed using a moulding process and so it is straightforward to configure the mould to produce a material having a particular surface profile. The insulation layer 30 is formed to have an innermost surface which has a castellated profile. This profile defines a number of vertical grooves 32. When the panel 10 is presented to the surface of a building 102, the grooves 32 and building surface 104 together define vertical drainage channels which allow water to drain down.

The term groove is not intended to imply a particular width or depth. For instance, the grooves 32 may or may not have a width which is greater than the distance between the grooves 32. Similarly, the term castellation is not intended to imply a 'square wave' profile. For instance, the profile of the innermost surface may be corrugated.

The cladding system comprises a number of the cladding panels 10. The panels 10 are arranged in a staggered tile pattern, similar to bricks in a brick wall. The channels 32 are arranged such that, when arranged in this tiling pattern, the channels 32 of one panel 10 are horizontally aligned with those of the two panels 10 immediately below it. Thus, the vertical channels 32 continue uninterrupted from the top to the bottom of the cladding system.

However, if a panel 10 is not aligned correctly during installation, a channel 32 may become obstructed. To avoid this, the insulation layer 30 is moulded such that the protruding castellations do not extend as far as the top edge and bottom edge of the insulation layer 30. Therefore, there is a gap at the joint of two vertically abutting panels 10 which prevents water becoming trapped within the channels 32.

The cladding system includes a reinforcing mesh 40 for receiving the facade layer 20. The mesh 40 is attached to the outer surface of the insulation layer 30 using an adhesive.

An installation procedure will now be described.

A base profile 12 is first fitted to the building 102 using fixings 14. A first run of insulation layer panels 30 are positioned on the base profile 12. A sealant 16 is used around fixings 14 and at the lower abutting edge of the base profile 12 and building 102.

The insulation layer panels 30 may be installed directly to the building substrate. No separate battens 106 are required. The insulation layers 30 are fastened to the building 102 using fixings 12, preferably stainless steel fixings. If fastening to timber, stainless steel nails can be used. Typically, the fixings are spaced apart by 400 mm.

Subsequent rows of panels 30 are positioned such that the panels 30 are in a staggered tile pattern. Movement beads (not shown) can be used between panels. The panels 30 can be cut using a knife to fit around window and door details.

An adhesive is then prepared and applied to the outer surface of the insulation layer 30 to a thickness of 3 mm. A glass fibre reinforcing mesh 40 is embedded in the adhesive.

Render 20 is then prepared and applied to a thickness of 8 mm or greater. While the render is still soft, aggregate is applied.

The present invention simplifies the installation of a cladding system and reduces the time involved.

Various modifications and improvements can be made to the above without departing from the scope of the invention.

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Claims

Claims

1. A cladding system for a building, the cladding system comprising:

an outer fa$ade layer; and

5 an inner insulation layer which has an innermost surface for presenting to the building, wherein the innermost surface includes a plurality of vertical grooves which at least partially define a plurality of vertical drainage channels.

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2. A cladding system as claimed in claim 1, wherein the innermost surface has a substantially castellated profile to provide the plurality of drainage channels.
3. A cladding system as claimed in claim 1 or 2, wherein the cladding system is adapted to be attachable to an existing substrate of the building.
4. A cladding system as claimed in claim 3, wherein the existing substrate comprises a wall of the building, and wherein, in use, the plurality of vertical grooves and the building substrate co-operatively define the plurality of vertical drainage channels.

20 5. A cladding system as claimed in claim 3, wherein the cladding system is adapted to be attachable to a frame member of the building, and wherein the cladding system provides a wall of the building.

6. A cladding system as claimed in any preceding claim, wherein the insulation layer

25 comprises a moulded foam material.

7. A cladding system as claimed in claim 6, wherein the insulation layer comprises an expanded polystyrene material.

30 8. A cladding system as claimed in claim 6 or 7, wherein the castellated profile is formed during moulding of the insulation layer.

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9. A cladding system as claimed in any preceding claim, wherein the cladding system comprises a plurality of cladding panels, each panel comprising an outer fa$ade layer and an inner insulation layer.
5 10. A cladding system as claimed in claim 9, wherein the cladding system comprises a plurality of cladding panels arranged in a staggered tile pattern.

11. A cladding system as claimed in any preceding claim, wherein the or each insulation layer has a top edge and a bottom edge, and wherein the castellated surface defines a
10 plurality of vertical protrusions which extend towards the top and bottom edges.
12. A cladding system as claimed in claim 11, wherein each protrusion extends towards but does not reach at least one of the top edge and the bottom edge.

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13. A cladding system as claimed in any preceding claim, wherein the fa$ade layer comprises a render material.
14. A cladding system as claimed in any preceding claim, wherein the cladding system includes a reinforcing mesh for receiving the fa$ade layer.
15. A cladding system as claimed in claim 14, wherein the mesh is attached to the outer surface of the insulation layer using an adhesive.

Mr Joshua Nolan

23 May 2018

GB 1621704.4

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