WO2016019441A1

WO2016019441A1 - A wall panel and method of fixing a panel to a concrete pad

Info

Publication number: WO2016019441A1
Application number: PCT/AU2015/050450
Authority: WO
Inventors: Ian MASSEY
Original assignee: Insulation Systems Pty Ltd
Priority date: 2014-08-07
Filing date: 2015-08-07
Publication date: 2016-02-11

Abstract

An exterior wall panel comprises: a stud frame; a rigid thermal insulation layer on an exterior facing side of the stud frame; an exterior finish forming an external facing surface of the wall panel; a reinforced aerated concrete layer attached to the stud frame; and an interior surface finish forming an interior facing surface of the wall panel.

Description

A Wall Panel and Method of Fixing a Panel to a Concrete Pad Field of the Invention The present invention relates to wall panels used to construct buildings and to fixing wall panels to a concrete pad.

Background Offsite construction of building materials is known for decreasing construction time of building. Known panels comprise a frame with an insulating foam core and plywood or fibre cement skins.

The present wall panel seeks to provide an alternative wall panel.

In this specification the terms "comprising" or "comprises" are used inclusively and not exclusively or exhaustively.

Any references to documents that are made in this specification are not intended to be an admission that the information contained in those documents form part of the common general knowledge known to a person skilled in the field of the invention, unless explicitly stated as such.

Summary of the Invention

According to an aspect of the present invention there is provided an exterior wall panel comprising:

a stud frame;

a rigid thermal insulation layer on an exterior facing side of the stud frame;

an exterior finish forming an external facing surface of the wall panel;

a reinforced aerated concrete layer attached to the stud frame; and

an interior surface finish forming an interior facing surface of the wall panel.

In an embodiment the wall panel comprises a vapour barrier on a surface of the thermal insulation layer.

In an embodiment the rigid thermal insulation layer is a thermoset layer. In an embodiment the reinforced aerated concrete is formed of an autoclaved aerated concrete. In an embodiment the reinforced aerated concrete layer is attached to the stud frame by a spacing member fixed on an interior facing surface of the stud frame.

In an embodiment the interior surface finish is attached to the reinforced aerated concrete layer.

In an embodiment the vapour barrier is air permeable/breathable.

In an embodiment the vapour barrier is between the thermal insulation layer and the stud frame. In an embodiment the vapour barrier is between the thermal insulation layer and the exterior finish.

In an embodiment the stud frame is formed of timber. In an embodiment the stud frame is formed of metal. In an embodiment the thermal insulation layer is provided with a foil layer on at least one side and preferably on both sides.

In an embodiment the exterior finish is a render, such as a polymer render or a cementitious render.

In an embodiment the exterior finish is a weather board.

In an embodiment the spacing element is one or more horizontally disposed top hat sections.

In an embodiment the interior surface finish is a plaster board.

In an embodiment the wall panel comprises a vertical side stud, the side stud forms one of a tongue or a groove. In an embodiment of the wall panel is in the form of a corner panel comprising of vertically extending corner, a first vertically extending end and a second vertically extending end, wherein the respective ends of the corner panel are at an angle to each other. In an embodiment of the stud frame comprises a horizontal first bottom beam. In an embodiment the first bottom beam is recessed inwardly from a lower edge of the aerated concrete. In embodiment the first bottom beam is recessed inwardly from the bottom of the thermal installation layer. In an embodiment of the lower edge of the thermal insulation layer extends lower than lower edge of the aerated concrete layer.

In embodiment the stud frame comprises a horizontal top beam. In an embodiment the wall panel comprises a wall plate beam fixed to the horizontal top beam so as to form a structural ring beam. In an embodiment the wall panel comprises a plurality of tie down rods projecting from a second bottom beam for insertion into corresponding holes in a slab. In an embodiment the first bottom beam is fixed onto the second bottom beam.

According to another aspect of the present invention there is provided a method of fixing a wall panel to a concrete slab, comprising

providing a concrete slab;

forming a plurality of holes along a periphery of a top surface of the slab;

attaching a plurality off tie down rods to a bottom beam of a wall panel so that the tie down rods are spaced apart along the length of the bottom beam and so that the tie down rods project downwardly from the bottom beam when the wall panel is fixed to the concrete slab;

inserting a projecting part of each tie down rod into a corresponding one of the holes in the concrete slab;

bonding the projecting part of each tie down rod to the slab with a bonding agent.

According to another aspect of the present invention there is provided a building formed with one or more of the above panels or formed by the one or more of the above methods. Brief Description of the Drawings In order to provide a better understanding of the present invention, preferred

embodiments will now be described, by way of example only, in which:

Figure 1 is a transverse vertical cross-section of a wall panel according to an embodiment of the present invention;

Figure 2 is a transverse vertical cross-section of a wall panel according to another embodiment of the present invention;

Figure 3 is a horizontal plan view of the wall panel of Figure 1 , with a damp proof course removed left of dashed line A and with the damp prop course and a portion of a wall plate 64 removed between dashed lines A and B;

Figure 4 is a longitudinal vertical cross-section of the wall constructed of a plurality of wall panels according to embodiment of the present invention;

Figure 5 is a horizontal cross-section of a corner wall panel according to an embodiment of the present invention;

Figure 6 is a transverse vertical cross-section of the wall panel of Figure 1 fixed to a concrete slab according to an embodiment of the present invention;

Figure 7 is a transverse vertical cross-section of a first wall panel connected to a suspended concrete slab and a second wall panel connected to the slab beneath the first wall panel which together form an infill between the concrete slab and adjacent structure according to an embodiment of the present invention; and

Figure 8 is a transverse vertical cross-section of a first wall panel connected to a steel structure and a second wall panel connected to the steel structure beneath the first wall panel.

Detailed Description of Embodiments

Referring to Figure 1 there is shown an exterior wall panel 10 having an exterior surface 12 and interior surface 14. The exterior wall panel 10 in use forms a part of an exterior wall of a bulling. The wall panel 10 comprises a stud frame having a plurality of vertical stud members 16 within an outer frame. The remainder of the wall panel 10 is built on either side of the stud frame. In an embodiment an insulating material may be provided inside the stud frame between the stud members 16. A rigid thermal insulation layer 20 is on an exterior facing side of the stud members 16. A vapour barrier 18 is on an inside surface of the thermal insulation layer 20. An exterior finish 22 forms the external facing surface 12. A spacing member in the form of a horizontally extending top hat shaped member 26 is on an interior facing surface of the stud members 16. A reinforced aerated concrete layer 28 is attached to the spacing member 26. Preferably the aerated concrete layer 28 is formed of autoclaved aerated concrete. An interior finish 30 forms the interior facing surface 14. The spacing member 26 provides an air gap 24 between the vertical stud members 16 and the autoclaved aerated concrete layer 28.

Preferably the vapour barrier 18 is air permeable/breathable. An example of a suitable vapour barrier 18 is Tyvec™ membrane, ProClima™ Solitex™ or ProClima™ Intello™ membranes.

Preferably the exterior finish 22 is in the form of a render. Preferably the render is a polymer render, although it may be a cementitious render.

The thermal insulation layer 20 is preferably a formed of thermoset material. Suitable material for the thermal insulation layer is expanded polymers, such as polystyrene (also known as EPS), polyurethane (also known as PU), polyisocyanurate (also known as PIR). Also suitable are extruded phenol resins. Example products suitable for the layer 20 are Kingspan™ K5 or K12, Owens Corning™ Foamular™ XPS, or Celotex PIR. Layer 20 is typically 50-80mm in thickness.

Preferably the stud members 16 are formed of timber. In an embodiment the stud members are formed of metal, such as steel. The stud frame, is load bearing through stud members 16. The stud frame is described in more detail below in relation to Figure 4.

In an embodiment the interior finish 30 is a board formed of a plaster like cementitious material formed between paper sheets, such as drywall, also known as gypsum board and plaster board. Typically this is 10mm in thickness.

Typically the reinforced autoclaved aerated concrete layer 28 is 50-75mm in thickness. Typically the air gap 24 is 16-35mm in thickness. The studs members 16 are typically 90mm in thickness when formed of timber, and 100mm in thickness when formed of steel. There may be an expanded metal lath (EML) or glass fibre mesh between the thermal insulation layer 20 and the exterior finish 22.

Referring to Figure 2, there an alternative exterior wall panel 10', which is similar to the panel 10 of Figure 1 , except for the following differences: the vapour barrier 18 is between the thermal insulation 20; and there is an alternative form of exterior finish. In an embodiment the insulation layer 20 is formed of a phenolic thermoset and is provided with a foil layer on at least one side, and preferably on both sides. In this example the exterior finish is in the form of counter battens 32 and weather board 34.

In this embodiment the thermal insulation layer 20 is typically 25-90mm in thickness.

The counter batons 32 are typically 45x20mm timber and the weather board 34 may be 6- 16mm, and is typically 9mm, fibre cement which have been painted off site.

Referring to Figure 3, the panel 10 is shown connected to an adjacent panel, a portion 10" of which is shown. Abutting finish 30 and finish of the panel 10" are taped 44.

Abutting layers of autoclaved reinforced concrete 28 and 28" are sealed and or bonded along line 46. The vapour barrier membrane 18 is returned on to the phenolic thermoset insulation layer 20 and the membrane 18 and thermoset layer 20 are bonded at line 50. Abutting end vertical stud members 68 and 68" of adjacent panels 10 and 10" are sealed along line 48. Line 48 is offset from lines 44 and 50 so that the inset of stud member 68 from the ends of exterior finish 22 and thermoset layer 20, on one side, and the autoclaved aerated concrete 28 and interior finish 30 on the other side, forms a groove. The ends of exterior finish and thermoset layer of the other panel 10", on one side, and the autoclaved aerated concrete 28" and interior finish of the other panel 10" on the other side, are set back from the stud member 68" such that it forms a tongue for mating with the groove.

A damp proof barrier 40, such as a damp proof course (DPC) is fixed on top of the wall panels 10 and 10". A DPC may also be fixed under a bottom horizontal wall plate 60 off site to facilitate wall air tightness.

Extending through the vertical side beam 68" is an electrical conduit 42 which allows connection of wiring to an electrical junction box 130. Referring to Figure 4 the stud frame is shown, comprising the plurality of vertical inner studs 16, horizontal first bottom plate 60, horizontal header plate 62, outer vertical studs 68, and outer horizontal members 64 and 74 of the frame. Plates 60 and 62 are typically timber beams. Studs 68 and members 64 and 74 are typically metal, such as steel, and typically 100mm x 50mm RHS. A header 66, typically formed of 150mm x 100mm RHS, is between plate 62 and member 64 to form a structural ring beam. A horizontal beam 62, commonly known as a header, connects to the top of stud members 16. Beam 62 connects to steel header 66. Wall plate 64 connects to head 66. There may be further timber studs (not shown) connected to frame studs 68. In a two story building, where one wall panel is on top on another, beam 74 of the upper wall panel may be formed from beam 64 in the lower wall panel.

Extending from the bottom member 74 are a plurality of tie down rods 72, which are used to anchor the panel to a concrete pad 120, as will be described in more retail below in relation to Figure 6.

Generally the panel height will be at least 2400mm and each vertical stud 16 will be at 600mm spacings, although other arrangements are possible. The arrangements of the studs will also vary according to requirements, such as to allow for windows and doors.

An electrical conduit 42 between a junction box and an electrical outlet and/or data point 78 and has wiring installed.

Referring to Figure 5, an embodiment of the wall panel 100 is in the form of a corner panel comprising of vertically extending corner 102, a first vertically extending end 104 and a second vertically extending end 106, wherein the wall portions between each respective end 104 and 106 and the corner 102 are at an angle to each other. Typically the angle is 90 degrees, but other common angles are possible for prefabrication. At the corner 102 is a corner post 90, formed in place of a timber vertical stud 16. The corner post 90 is typically formed of 100mm x 100mm SHS. The remainder of the structure of the panel 100 is similar to panel 10 described above. The ends 104 and 105 of the corner panel have straight panels 100 fixed thereto in a similar manner to that described in relation to Figure 3. Figure 6 shows the fixing of the panel 10 to a concrete slab 120 having a footing 122. The slab 120 and its footing 122 have a damp proof membrane lining 124.

In an embodiment of the horizontal bottom beam 60 is recessed inwardly from a lower edge 82 of the autoclaved aerated concrete 28. In embodiment the bottom beam 60 is recessed inwardly from a bottom edge 84 of the phenolic thermoset installation 20. In an embodiment of the lower edge 84 of the phenolic thermoset insulation layer 20 extends lower than lower edge 82 of the autoclaved aerated concrete layer 28. The slab 120 may have a step formed on the periphery for receiving the phenolic thermoset insulation layer 20. Alternatively the insulation layer 20 may rest on a square corner of the slab 120 and the insulation layer 20 may step down below the slab edge. The DPC 40 is between the thermoset layer 20 and the step of the slab 120. It extends over bottom edge 84 and up to side of member 74 to lap under membrane 18 on the side of bottom member 60.

The bottom edge 82 of the autoclaved aerated concrete layer 28 is sealed to slab 120.

Extending along a line extending into the page, the slab 120 has a plurality of holes 126 along a periphery of a top surface of the slab 120. Inserted into each hole 126 and chemically bonded in place is one of the tie down rods 72 that extend from bottom beam 74. A projecting end of each rod 72 is fixed, such as by welding to the bottom beam 74.

Thus the wall panel 10 (or another suitable wall panel) is fixed to the concrete slab 120 by forming the plurality of holes 126 along a periphery of a top surface of the slab 120, such as by drilling the holes. Other methods of forming the holes, such as casting may be used. The tie down rods 72 are attached to the hollow section beam 74, such as by welding, and the beam 74 is attached to the wall panel beam 60, such as by use of fasteners. The rods 72 may be 16mm steel rods. On site, a bonding agent is inserted into the holes 126 and the tie down rods 72 are inserted into the holes 126. When the bonding agent cures, the panel will be fixed to the slab 120. A suitable bonding agent is Rescon™ epoxy bonder, Spit™ EPOMAX™, or Everbuild™ Anchorset™.

Figure 7 shows the fixing of a pair of panels 10, 10' to a supported concrete slab 120 having a structural foot 122 supported by panel 10'. The slab 120 forms a part of a floor / ceiling. Above and below the slab 120, the panels 10, 10' form an infill between levels of the building structure.

In an embodiment the panels 10, 10' share a common phenolic thermoset insulation layer 20 and membrane 18. The concrete slab 120 and the foot 122 are recessed in a void formed between the panels 10, 10' and the membrane 18. The concrete slab 120 and the foot 122 are supported by other means and abut on its underside the frame header 64' of panel 10', which is in the form of a RHS beam. The bottom beam 74 of the panel 10 abuts the upper surface of the concrete slab 120. Additionally an anchor plate 132' is fastened to the foot 122. The reinforced autoclaved aerated concrete layer 28' of panel 10' abuts the plate 132'. The plate 32' fixes the panel 10' to the foot 122. Additionally an anchor plate 132 is fastened to a top surface of the slab 120, on which is abutted the reinforced autoclaved aerated concrete layer 28 of panel 10. The plate 132 fixes the panel 10 to the slab 120.

The floor slab ensures the panels are level. The bottom member 74 may be provided with stop and line plates 128 against which a vertical edge of the slab 120 abuts. Also the header 64' may be provided with stop and line plates 129 against which a vertical edge of the slab 120 abuts. Plates 128 and 129 plumb and line the panels 10, 10'.

In forming this structure, the panels 10, 10' may be craned into position. The fixing plates 132, 132' have holes along their length. The slab 120 has a plurality of holes 126, 126' drilled along a top surface of the slab 120 and the bottom surface of the foot 122. Holes in the plates 132, 132' may be used to guide the position of the holes 126 126'. Inserted into each hole through the plates 128, 129 and the corresponding hole 126, 126' in the slab 120 is an anchor bolt 72', which may be fastened such as by use of an expansion anchor. Thus the panels 10, 10' may be fastened to the slab 120 via the fixing plates 132, 132' by the fasteners.

In an embodiment a fire resistant board 130 may be provided between the thermoset insulation layer 20 and membrane 18. The fire resistant board 130 may be for example a Frychek™ board.

The vapour barrier membrane 18 from the panel 10 may overlap with the membrane 18' from panel 10'. In an embodiment the floor slab and columns would be cast as the building climbs. This arrangement allows the panels 10 and 10' to infill the gaps in the levels between concrete slabs of respective floors, and a slab and a ceiling.

Figure 8 shows the fixing of a pair of panels 10, 10' to an I-beam 134, wherein a floor member 120 forming a floor/ceiling is supported by the I-beam 134. The I-beam 134 comprises a C-channel is formed by the web 136 and internal flanges 138, 140 of the I- beam 134. Panels 10, 10' form an infill between levels of the building structure and are fixed to the I- beam 134. In an embodiment the phenolic thermoset insulation layers 20, 20' and membranes 18, 18' of panels 10, 10' tightly fit together to form an insulation assembly 142 comprising a phenolic thermoset insulation layer 20" and a membrane 18". The assembly may also comprise a fire resistant board 130". The I-beam 134 (and thus the concrete slab 120) is supported by other means. The frame header 64' of panel 10', which is in the form of a RHS beam that abuts the bottom of I-beams 134. The bottom beam 74 of the panel 10 abuts the top surface of I-beam 134.

Additionally the flange 140 of the I-beam 134 abuts the reinforced autoclaved aerated concrete layer 28' of panel 10'. The reinforced autoclaved aerated concrete layer 28 of panel 10 abuts the flange 138 of the I-beam 134.

In an embodiment a fire resistant board 130 may be provided between the thermoset insulation layer 20 and membrane 18.

The bottom member 74 may be provided with stop and line plates 128 against which a flange 144 abuts. Also the header 64' may be provided with stop and line plates 129 against which flange 146 abuts. In forming this structure, the panels 10, 10' may be craned into position. Outer flanges 144, 146 have a plurality of holes 126, 126' along their length into each of which is inserted a fastener 72, 72' for fastening the respective flange 144, 16 to the member 74 or header 64'. This structure allows for a closed wall structure to be tied down without opening it.

The wall panel 10 can be preassembled off site, delivered and erected is a short period of time, leaving only minor works to be done on site. The autoclaved aerated concrete layer 22 acts as a thermal mass which is shaded by the outer layers. The panel thickness may be in the order of 210-310mm providing an insulation rating in the order of R3.4 to R7.6. The interlocking (tongue and groove connection method) of vapour barrier 18 and sealing enable the wall to be air tight providing a good moisture barrier. Electrical conduits, grounds, backing boxes for switches, sockets and data points can be installed during construction of the panel off site. Cable pull strings can be blown through the conduit with a junction box at the top of each panel for connection of wiring in final offsite construction stages. On site work is therefore minimised. Where possible the panel joints can be located at the position of an internal stud wall, this is more desired. However if this is not possible then tape and joint methods can be used.

Other external finishes may be provided, such as stone effect, brick effect or others mouldings and texture finished panels.

Modifications may be made to the present invention within the context of that described and shown in the drawings. Such modifications are intended to form part of the invention described in this specification.

Claims

1 . An exterior wall panel comprising:

a stud frame;

a rigid thermal insulation layer on an exterior facing side of the stud frame;

an exterior finish forming an external facing surface of the wall panel;

a reinforced aerated concrete layer attached to the stud frame; and

2. An exterior wall panel according to claim 1 , wherein the wall panel comprises a vapour barrier on a surface of the thermal insulation layer.

3. An exterior wall panel according to claim 1 , wherein the rigid thermal insulation layer is a thermoset layer.

4. An exterior wall panel according to claim 1 , wherein the aerated concrete is an autoclaved aerated concrete.

5. An exterior wall panel according to claim 1 , wherein the reinforced aerated concrete layer is attached to the stud frame by a spacing member fixed on an interior facing surface of the stud frame.

6. An exterior wall panel according to claim 2, wherein the vapour barrier is air permeable/breathable.

7. An exterior wall panel according to claim 2, wherein the vapour barrier is between the thermal insulation layer and the stud frame.

8. An exterior wall panel according to claim 2, wherein the vapour barrier is between the thermal insulation layer and the exterior finish.

9. An exterior wall panel according to claim 1 , wherein the thermal insulation layer is provided with a foil layer on at least one side and preferably on both sides.

10. An exterior wall panel according to claim 1 , wherein the exterior finish is a render.

1 1 . An exterior wall panel according to claim 1 , wherein the exterior finish is a weather board.

12. An exterior wall panel according to claim 1 , wherein the wall panel comprises a vertical side stud, the side stud forms one of a tongue or a groove.

13. An exterior wall panel according to claim 1 , wherein of the wall panel is in the form of a corner panel comprising of vertically extending corner, a first vertically extending end and a second vertically extending end, wherein the respective ends of the corner are at an angle to each other.

14. An exterior wall panel according to claim 1 , wherein of the stud frame comprises a horizontal first bottom beam. 15. An exterior wall panel according to claim 14, wherein the first bottom beam is recessed inwardly from a lower edge of the aerated concrete.

15. An exterior wall panel according to claim 1 , wherein the first bottom beam is recessed inwardly from the bottom of the thermal installation layer.

16. An exterior wall panel according to claim 1 , wherein of the lower edge of the thermal insulation layer extends lower than lower edge of the aerated concrete layer.

17. An exterior wall panel according to claim 1 , wherein the stud frame comprises a horizontal top beam.

18. An exterior wall panel according to claim 17, wherein the wall panel comprises a wall plate beam fixed to the horizontal top beam so as to form a structural ring beam.

19. An exterior wall panel according to claim 1 , wherein the wall panel comprises a plurality of tie down rods projecting from a second bottom beam for insertion into corresponding holes in a slab. In an embodiment the first bottom beam is fixed onto the second bottom beam.

20. A building formed with one or more of the panels according to any one of claims 1 to 19.

21 . A method of fixing a wall panel to a concrete slab, comprising:

providing a concrete slab;

forming a plurality of holes along a periphery of a top surface of the slab;

22. A building formed by the method of claim 21 .