U.S. patent application number 12/995777 was filed with the patent office on 2011-07-07 for fibre cement lining board and uses thereof.
This patent application is currently assigned to JAMES HARDIE TECHNOLOGY LIMITED. Invention is credited to Damien Buongiorno, Craig Chetty, John Sydney Cottier, Milton O'Chee.
Application Number | 20110162295 12/995777 |
Document ID | / |
Family ID | 41397628 |
Filed Date | 2011-07-07 |
United States Patent
Application |
20110162295 |
Kind Code |
A1 |
Cottier; John Sydney ; et
al. |
July 7, 2011 |
FIBRE CEMENT LINING BOARD AND USES THEREOF
Abstract
The present invention relates in a first part to a fibre cement
lining board for use as a replacement to building wrap which can be
used to form a sub wall on the outer surface of a wall frame, and
to building wall structures and methods of constructing buildings
using these particular lining boards. The invention also relates to
a new method of constructing framed dual skin walls using the
lining boards, particularly brick or masonry veneer walls, and to
the wall structures formed by that method.
Inventors: |
Cottier; John Sydney; (New
South Wales, AU) ; O'Chee; Milton; (New South Wales,
AU) ; Buongiorno; Damien; (New South Wales, AU)
; Chetty; Craig; (Auckland, NZ) |
Assignee: |
JAMES HARDIE TECHNOLOGY
LIMITED
Dublin
IE
|
Family ID: |
41397628 |
Appl. No.: |
12/995777 |
Filed: |
May 29, 2009 |
PCT Filed: |
May 29, 2009 |
PCT NO: |
PCT/AU2009/000684 |
371 Date: |
February 23, 2011 |
Current U.S.
Class: |
52/105 ; 52/474;
52/745.09 |
Current CPC
Class: |
E04B 2001/268 20130101;
E04B 1/26 20130101; E04B 2/707 20130101; E04B 2002/565 20130101;
E04D 13/1478 20130101; E04C 2/06 20130101; E04D 3/405 20130101 |
Class at
Publication: |
52/105 ;
52/745.09; 52/474 |
International
Class: |
E04B 2/42 20060101
E04B002/42; E04C 2/04 20060101 E04C002/04; E04B 1/66 20060101
E04B001/66 |
Foreign Application Data
Date |
Code |
Application Number |
Jun 2, 2008 |
AU |
2008902779 |
Claims
1. An outer frame lining board for use as a lining board for an
outer frame structure comprising a fibre cement sheet having a
thickness of more than 3 mm but less than 4 mm, and at least two
major faces, the fibre cement which sheet is pre-sealed on at least
one major face prior to installation.
2. An outer frame lining board according to claim 1 wherein the
fibre cement sheet has a thickness of around 3.5 mm.
3. An outer frame lining board according to claim 1 wherein a
surface of the outer frame lining board includes markings to assist
with alignment of fasteners with standard stud spacings and the
like and/or to facilitate easy and accurate cutting and sizing of
the sheets.
4. An outer frame lining board according to claim 3 wherein the
markings are integrally formed.
5. An outer frame lining board according to claim 1 wherein the
board is distinguished at least in part by use of a coloured
coating.
6. A method of construction of a framed dual skin wall structure
comprising: erecting an internal structural wall frame in situ;
applying a plurality of fibre cement lining boards which are
pre-sealed on at least one major face prior to installation to
fully cover and seal the outside of the wall frame excluding window
and door openings and other designed penetrations to form a first
inner wall skin, applying a sealed roof or roof cover; and closing
off the designed penetrations to achieve a sufficiently sealed
building envelope to achieve "lock up" prior to subsequently
constructing a second outer wall skin in the form of an external
block wall or external cladding.
7. A method of construction of a framed wall structure according to
claim 6 wherein the wall structure is a brick or block style
masonry veneer structure.
8. A method of construction of a framed wall structure according to
claim 6 wherein the wall structure includes a second outer wall
skin in the form of panellised or plank style cladding.
9. A method of construction of a framed wall structure according to
any one of claim 6 using a face sealed fibre cement lining board
with a thickness of more than 3 mm but less than 4 mm.
10. (canceled)
11. A framed dual skin wall structure comprising: an internal
structural wall frame; a plurality of fibre cement lining boards
which are pre-sealed on at least one major face prior to
installation fully covering and sealing the outside of the internal
structural wall frame, excluding window and door openings and other
designed penetrations, to form a first inner wall skin, a sealed
roof or roof cover over the internal structural wall frame; and the
internal structural wall frame, first inner wall skin and sealed
roof or roof cover being closed off at designed penetrations to
achieve a sufficiently sealed building envelope; and a second outer
wall skin around the internal structural wall frame and first inner
wall skin, the being in the form of an external block wall or
external cladding.
12. A framed dual skin wall structure according to claim 10 where
at least fibre cement lining board has a thickness of more than 3
mm but less than 4 mm.
Description
FIELD OF THE INVENTION
[0001] The present invention relates in a first part to a fibre
cement lining board for use as a replacement to building wrap which
can be used to form a sub wall or inner skin on the outer surface
of a wall frame, and to building wall structures and methods of
constructing buildings using these particular lining boards. The
invention also relates to a new method of constructing framed dual
skin walls using the lining boards, particularly brick or masonry
veneer walls and to the dual skin wall structures formed by that
method.
[0002] The inventions have been developed primarily for use in the
domestic building field and will be described hereafter in
reference to such applications. However, it will be appreciated
that the inventions could readily be adapted for use in commercial
building construction if required.
BACKGROUND OF THE INVENTION
[0003] One major limitation impacting on construction costs and
total construction times, particularly in the domestic dwelling
market in Australia and New Zealand, is the general need with all
conventional methods of dual skin framed building construction,
that is frame structure plus separate veneer or cladding, to fully
complete the external envelope of a building to a stage referred to
generally as "lock up", prior to commencing the internal lining
work and fit out.
[0004] For example, with a typical brick veneer structure, once the
foundation slab or blockwork is complete, the wall, floor and
roofing frames will first be erected. This may include the step of
applying structural bracing sheets, if the frame structure requires
strengthening of this form. The wall and the roof frames will
typically then be covered in an appropriate moisture management
barrier in the form of paper or foil building wrap or sarking
membrane prior to erecting the external brick wall and applying the
selected roof covering. As these membrane materials are not
particularly wind tolerant, they are generally only applied just
prior to the outer brick work being erected and immediately prior
to the roofing battens being applied to the roofing frame.
[0005] In some instances, the final roofing material, be it tile or
metal roofing sheets and the like, are not installed until the
outer brick work skin has been fully erected. Depending on the
availability of the brick layers and other relevant tradesmen, it
is not unusual to see building frames exposed to the elements for
fairly long periods, which can result in deterioration of the
structural frame. Even where the roof is installed shortly after
the building frames are erected, there can still be significant
delays before the protective outer brick wall is finished and "lock
up" can then be achieved.
[0006] Similar comments apply in relation to most of the more
commonly used domestic dwelling construction techniques for framed
structures that traditionally use weather resistant membranes which
are finished with an outer panelized or plank formed cladding
material.
[0007] It is object of the present invention to provide one or more
building solutions that overcome or ameliorate the above discussed
disadvantages, or which at least offer a useful alternative.
SUMMARY OF THE INVENTION
[0008] According to a first aspect of the invention there is
provided an outer frame lining board in the form of a fibre cement
sheet having a thickness of more than 3 mm but less than 4 mm,
which sheet is pre-sealed on at least one major face prior to
installation.
[0009] In one preferred form the thickness of the lining board is
around 3.5 mm.
[0010] Advantageously, it has been found that a fibre cement sheet
of this thickness offers a cost competitive alternative to building
membranes which is still easy to handle, yet strong enough to also
provide a weather barrier and security barrier sufficient to
achieve "lock up".
[0011] Preferably the fibre cement sheet forming the lining board
is configured by method of manufacture, composition, structure or
treatment, or any one or combination of these, to meet the local
applicable standards in respect of at least air and moisture
barriers. In other embodiments the fibre cement sheet may also be
configured to meet other standards requirements in relation to
bracing characteristics as would apply to rigid sheathing.
[0012] In one preferred form the outer frame lining board includes
integrally formed markings to assist with alignment of fasteners
with standard stud spacings and the like and/or to facilitate easy
and accurate cutting and sizing of the sheets. This marking may be
in the form of a grid pattern that is printed on or formed in the
surface of the board.
[0013] Ideally, the board is also marked to distinguish the lining
board as a product originating from the applicant or one of its
subsidiaries. In one form the board is distinguished at least in
part by use of a colored sealant that preferably results in a wash
of a green hue.
[0014] According to a second aspect of the invention there is
provided a method of construction of a framed dual skin wall
structure including the steps of:
[0015] erecting an internal structural wall frame in situ;
[0016] applying a plurality of fibre cement lining boards which are
pre-sealed on at least one major face prior to installation to
fully cover and seal the outside of the wall frame excluding window
and door openings and other designed penetrations to form a first
inner wall skin,
[0017] applying a sealed roof or roof cover; and
[0018] closing off the designed penetrations to achieve a
sufficiently sealed building envelope to achieve "lock up" prior to
subsequently constructing a second outer wall skin in the form of
an external block wall or external cladding.
[0019] Preferably, the fibre cement lining board has a thickness of
more than 3 mm and less than 4 mm.
[0020] In one form the framed wall structure is a brick or block
style masonry veneer structure. In other forms the framed wall
structure relates to walls having some form of panelised or plank
style outer cladding.
[0021] According to a third aspect of the invention there is
provided a framed wall structure made in accordance with the method
of the second aspect of the invention.
[0022] Preferably, the method of the second aspect of the invention
and/or the wall structure of the third aspect of the invention uses
the lining boards of the first aspect of the invention.
DESCRIPTION OF THE DRAWINGS
[0023] Preferred embodiments of the invention will now be
described, by way of example only, with reference to the
accompanying drawings in which:
[0024] FIG. 1 is a cut-away perspective view showing part of a
brick veneer wall structure in accordance with a third aspect of
the invention, incorporating the preferred outer frame lining board
in accordance with the first aspect of the invention.
[0025] FIG. 2 is a cut-away perspective view showing part of a
plank clad wall structure in accordance with a third aspect of the
invention, incorporating the preferred outer frame lining board in
accordance with the first aspect of the invention.
[0026] FIG. 3 is a perspective cut-away view showing a typical
outer frame lining board layout as applied to a timber frame.
[0027] FIG. 4 illustrates a typical lining board vertical on-stud
jointing arrangement on a timber frame.
[0028] FIG. 5 shows a typical lining board vertical off-stud
jointing arrangement on a timber frame.
[0029] FIG. 6 shows a typical lining board horizontal joint with
flashing arrangement on a timber frame.
[0030] FIG. 7 shows a typical lining of the board external corner
joint arrangement on a timber frame.
[0031] FIG. 8 shows a typical lining of the board internal corner
joint arrangement on a timber frame.
[0032] FIG. 9 is a perspective part view illustrating an outer
frame board external corner to horizontal joint arrangement.
[0033] FIG. 10 is a perspective part view illustrating a typical
pipe penetration through the outer frame lining board.
[0034] FIG. 11 illustrates preferred flashing tape arrangements
around window, door, meter box and other penetrations.
[0035] FIG. 12 is perspective part view illustrating a typical
apron flashing arrangement.
[0036] FIG. 13 is a perspective view illustrating a typical
flashing arrangement at a junction between a balustrade and a
wall.
[0037] FIGS. 14 and 15 are each cross-sectional views of the lining
board, frame and foundation detail.
PREFERRED EMBODIMENTS OF THE INVENTION
[0038] Referring to FIG. 1, there is shown a perspective cut-away
view of part of the brick veneer wall structure 1 according to the
invention. The wall structure incorporates an outer frame sub wall
2 formed from a series of lining boards 3 secured to the structural
frame 4.
[0039] In the preferred form, the outer frame lining board 3
comprises a fibre cement sheet having a typical thickness of
between 3 and 4 mm, which in the preferred form is around 3.5 mm,
and which is sealed on at least one major face 5. The fibre cement
sheet consists essentially of cement or a calcium silicate formed
by the chemical reaction of siliceous and a calcareous material,
reinforced by fibres. Process aids, fillers, and pigments which are
compatible with fibre-reinforced cement may be added. The exact
composition, method of manufacture and/or method of treatment or
coating of the fibre cement sheet will be selected to meet the
requisite performance characteristics of the final lining
board.
[0040] In the preferred form, it has been found, quite surprisingly
that a 3.5 mm thick cellulose fibre reinforced cement sheet coated
on the outer face and all edges with a Siloxane Sealer, which
reacts with the Fibre Cement board to form a Silicone resin seal on
the surface of the sheet, results in a lining board which is easily
handled and relatively inexpensive. It also readily meets with
various New Zealand standards relating to both sheathing boards and
to rigid air barriers, such as AS/NZS 2908, and the provisions of
the New Zealand Building Code Clause E2 External Moisture
(including the requirements of Table 23 of E2-AS1) and is suitable
for use in very high wind speed zones as specified in NZS 3604. In
this regard the preferred lining board of the applicant has been
tested to comply with the performance requirements of the New
Zealand Building Code (NZBC) and has been BRANZ appraised.
[0041] In a preferred form, the lining board 3 also includes
various markings on the sealed surface 6 to assist with alignment
and spacing of fasteners with standard stud spacings etc and/or to
facilitate easy and accurate cutting and sizing of the boards. The
markings may be printed on or formed into the surface of the board.
In one form the pattern may be in a grid form such as that shown in
the drawings, which includes vertically extending grooves that can
also assist in the drainage of moisture from the outer sealed
surface of the board.
[0042] Ideally, the board is also marked to distinguish the lining
board as a product originating from the applicant or one of its
subsidiaries. In the preferred form the board is distinguished at
least in part by use of a colored sealant. In the preferred form
the colour tint provides a wash of a green hue across at least a
portion of the board surface. A tint providing standard colour
readings on an L*a*b scale of DL-0.33; Da -0.46, Db 0.18 would
provide a suitable green hue.
[0043] Turning next to FIG. 2, there is shown a cut-away
perspective part view of an alternative clad wall structure 7 that
also uses the preferred lining boards 3 of the invention, to which
an exterior cladding in the form of weather board planking 8 is
applied. While FIG. 2 shows a structure whereby the cladding is
secured directly over the lining boards, in other structures
battens (not shown) are first applied over the lining boards and
the cladding is secured to the battens. Similarly, the cladding may
be in other forms such as panellised cladding rather than the
planking that is shown. Regardless, it will be appreciated that the
installation process for securing the lining boards 3 to the
underlying structural wall frame 3 is substantially the same for
all dual skin wall structures and this procedure is described in
more detail here after.
[0044] However, prior to describing detailed installation
procedures, it is worth providing an overview of the lining boards
and systems/methods of the inventions. In this regard, the
advantages of the lining boards and systems of the invention are
numerous. Firstly, the lining boards, when appropriately installed,
eliminate the need to apply any form of building wrap. Furthermore,
they can in many instances also simultaneously remove the need for
structural bracing boards or, alternatively, be used solely as a
highly durable but relatively low cost bracing boards. Whilst rigid
air barriers have been used in commercial buildings systems, these
have all been too heavy and expensive for use in the domestic
market, particularly when compared to the cost of using building
wrap. The fact that such a thin fibre cement based lining sheet can
be so versatile in terms of function and structural capabilities,
as well as handlability, has been surprising. Also, as alluded to
above, the new lining board also readily facilitates a radical
change to local domestic dual wall framed building construction
methods that can significantly reduce total construction times and
associated costs. It can also reduce the number of site inspections
required during the construction process.
[0045] In this regard, the new lining board enables a builder to
erect a cost effective sub-wall directly on to the frame which, in
combination with the installation of doors, windows, penetration
covers and appropriate flooring and/or roofing, is capable of fully
protecting the outside envelope of a dwelling. This means that a
building can reach an effective "lock-up" stage early in the
construction process, so that work on the interior can commence
before the outer wall, be it cladding or brick etc, is even
started. This also means that a single building inspection can be
booked for both final internal and external sign off. In New
Zealand, the product and method of the invention proposed for
launch has been appraised by the relevant authorities and approved
to allow exposure of the installed lining sheets to external
elements for 90 days. This means that delays in installation of the
final outer wall structure will not in turn delay interior fit out
work. In addition the product is resistant to fire and damage from
moisture, particularly when installed as prescribed. It is also
rated for very high wind speed zones.
[0046] What is important in the construction method of the
invention is that the lining board meets the relevant air barrier
standards and is installed in a manner whereby the building
envelope around the frame is appropriately sealed and secured. To
this end each of the panels must be adequately sealed at adjacent
edges and at boundaries with various wall openings and
penetrations.
[0047] While there may be a number of ways in which this can be
achieved, preferred methods of installing the lining panels 3 will
now be described with reference to FIGS. 3 to 16.
[0048] Firstly, a structural wall frame 4 must be provided in
accordance with the relevant local standards or comply with a
specific engineering design requirements. For example, for the New
Zealand market for which the products and systems have originally
been designed, the stud spacing and nogs spacing must not exceed
600 mm centres and 1200 mm centres respectively. A minimum of 45 mm
wide stud is required at the lining board vertical joints for
jointing on stud. The framing will of course also need to be
suitable for installing the selected exterior cladding in the event
that a cladding material is to form the final outer wall skin.
[0049] The lining boards 3 will then need to be selected and, if
required, cut to fit the wall or fit around a wall opening. In the
preferred form, the lining boards have a grid formed into the
surface of the boards which makes it easier to accurately cut the
boards using a score and snap knife. It is important that the
lining boards be fitted with the sealed grid marked surface facing
away from the frame 4. Fixing and sealing then follows as described
below.
[0050] FIG. 3 shows the general board to frame layout with the
numbered arrows indicating the Figure reference where various
features are shown in more detail. Where the lining board is
intended for use as a general rigid air barrier to replace flexible
building wrap material, there is an option to form vertical joints
on or off the stud and methods for doing this will be described
hereafter. However, where the product is used to achieve structural
bracing, or edges of the lining board must be supported and fixed
to the framing. In this regard, any vertical joints must be formed
on the studs ideally with a gap of 1-2 mm maximum between the
lining boards.
[0051] As indicated above, there are two options for vertical
jointing of the lining board in general applications, on stud
jointing and off stud jointing.
[0052] The on stud jointing is achieved by forming the joint on a
stud 10 as shown in FIG. 4. As indicated a gap 11 is provided
between the two lining boards 3 and the lining boards are
preferably nailed to the stud with nails 12 as shown. A tape 13 is
then applied to cover the nails 12 and gap 11 along the full length
of the board edges.
[0053] Off stud jointing is preferably achieved by using a uPVC
jointer 15 to form the lining board vertical joint away from the
stud as shown in FIG. 5. The jointer 15 is then fixed to the bottom
and top plates and to the nogs/dwangs.
[0054] Horizontal joints may be flashed using a uPVC horizontal
flashing 16 of the kind shown in FIG. 6. Typically, a minimum gap
of 15 mm is left at the floor joist or is specified by the project
engineer. When jointing in the middle of a floor height, a 10 mm
minimum gap is usually recommended. In this regard, the horizontal
edges of the lining board 3 should not be fixed into the solid
timber floor joists 17. The flashing should ideally be lapped by 35
mm minimum on both sides of the joint as shown in the drawings.
[0055] Internal and external corner joints can be sealed using a 75
mm wide sealing tape as shown in FIGS. 7 and 8. Furthermore, when
using uPVC horizontal flashing 16, the internal and external corner
flushing joints must also be sealed using a 75 mm minimum width
joint sealing tape 18 as shown in FIG. 9. All penetrations such as
pipe penetrations through the installed lining boards 3 must also
be properly sealed using a flexible flashing tape or sheet 19 as
shown in FIG. 10. Ideally, a 100 mm minimum cover flashing is
maintained over the lining board 3 around the penetration with a
minimum of 25 mm of flashing tape 19 extending over the pipe
20.
[0056] To achieve an adequate seal at the junction with a soffit,
the lining board ideally needs to extend up to the top of the top
plate or go past the top plate.
[0057] In order to provide full weatherproof sealing to the
finished building envelope, it is important that exposed timber
framing around the window, door, meter box and other penetrations
be covered with a suitable flashing such as a 100 mm wide flashing
or sealing tape 21 as shown in FIG. 11. Furthermore, the flashing
tapes around the window, door, meter box and other penetrations
must be lapped over the lining board 3 by, ideally, at least 50
mm.
[0058] An appropriate apron flashing arrangement is shown in FIG.
12. In this configuration, a flashing tape 19 is applied to the
apron upstand 23 of the apron flashing 24 over the lining board
3.
[0059] Similarly, junctions between ballustrades and walls need to
be appropriately flashed and an example of how this can be achieved
is shown in FIG. 13. In the illustrated example, flexible flashing
tape 19 is dressed up and adhered to the lining board 3 behind the
battens 26.
[0060] In most installations, the lining boards will be required to
extend below the bottom plate 28 by around 15 mm minimum to form a
drip edge. In certain applications, it is recommended that the
lining board maintain a 100 mm minimum clearance between the bottom
edge of the board and finished ground as shown in FIGS. 14 and 15.
It is also recommended that when the bottom edge of the panel 3 is
cut on site to suit the site requirements, the cut edge should be
sealed with an appropriate primer or sealer. Naturally, the
adjacent finished ground site must slope away from the building in
accordance with the relevant building code requirements. It is
important that the lining board is not installed in such a way that
it may remain with contact with standing water. In structures where
the lining boards 3 are being installed as bracing, all board edges
must be supported by the underlying framing. The particular
installation requirements will depend on relevant local building
codes and the particular form of lining boards. In preferred forms,
the lining board, the outer face will be marked to indicate
appropriate fixing centres.
[0061] While the examples discussed above all relate to timber
framed wall structures, it will be appreciated that the inventive
concepts can also be applied to steel frame structures with
appropriate adaptations with lining board fasteners and spacings as
may be required.
[0062] Once the lining boards have been installed as discussed
above, the builder has the option of sealing the roof or applying a
roof covering and taking required further steps necessary to
achieve "lock up" without needing to start on the outer brick
veneer or cladding skin. This enables early commencement of the
internal fit out which leads to the advantages discussed above. The
external skin, be it brick or cladding etc, can then be erected in
the usual manner and in accordance with site specific
conditions.
[0063] The numerous advantages of the preferred fibre cement lining
board are discussed in detail above, but can be summarised as being
cost effective, light and easy to handle, multi-purpose (air
barrier, bracing, moisture control, structured sub-wall etc), easy
to cut and fix and easily identified by the selected colour which
is distinctive in the local market.
[0064] Similarly, the advantages of the new method of dual skin
framed wall construction, whether using the preferred lining board
or an alternative, are clear and represent a very significant move
forward over local prior art construction methods.
[0065] While the invention has been described with reference to
specific examples, it will be appreciated by those skilled in the
art that the invention may be embodied in many other forms.
* * * * *