U.S. patent application number 13/133451 was filed with the patent office on 2011-11-03 for cladding system with expressed joint.
This patent application is currently assigned to JAMES HARDIE TECHNOLOGY LIMITED. Invention is credited to Darren Southwell.
Application Number | 20110265416 13/133451 |
Document ID | / |
Family ID | 42242233 |
Filed Date | 2011-11-03 |
United States Patent
Application |
20110265416 |
Kind Code |
A1 |
Southwell; Darren |
November 3, 2011 |
Cladding System with Expressed Joint
Abstract
A cladding system based on a specially configured base sheet
profiled to provide a ship lap expressed joint with an adjacent
sheet, which is ideal for use with relatively low-build brushable
or rollable texture coatings. The ship lap expressed joint includes
within the visible portion of the joint between the outer surfaces
of the base sheets, an interface line defined by an inner
overlapping edge of one of the base sheets, whereby the interface
line is set in from the outer surface of the base sheets. This
arrangement enables coated walls, and in particular texture coated
masonry look walls, to be created at a much lower cost and using
less skilled operators, as it obviates the need to set and finish
the joints between adjacent sheets and the problems associated with
that process.
Inventors: |
Southwell; Darren; (Bella
Vista, AU) |
Assignee: |
JAMES HARDIE TECHNOLOGY
LIMITED
Dublin
IE
|
Family ID: |
42242233 |
Appl. No.: |
13/133451 |
Filed: |
December 4, 2009 |
PCT Filed: |
December 4, 2009 |
PCT NO: |
PCT/AU09/01582 |
371 Date: |
June 8, 2011 |
Current U.S.
Class: |
52/515 ;
52/588.1; 52/745.09 |
Current CPC
Class: |
E04B 2/707 20130101;
E04B 2001/2481 20130101; E04F 13/04 20130101 |
Class at
Publication: |
52/515 ;
52/588.1; 52/745.09 |
International
Class: |
E04B 2/32 20060101
E04B002/32; E04B 1/66 20060101 E04B001/66; E04C 2/38 20060101
E04C002/38 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 9, 2008 |
AU |
2008906360 |
Claims
1. A panelised masonry look wall cladding system incorporating
broad planar surfaces extending between vertical expressed joints,
the wall cladding system comprising: a plurality of broad
rectangular base sheets secured in a side by side vertical
orientation to an underlying structure; each of the base sheets
having an inner surface and a planar generally smooth unfinished
outer surface, each base sheet being profiled along at least one
longitudinal edge to provide, on installation with an adjacent
sheet, broad planar surfaces with an intermediate overlapping
vertical ship lap expressed joint, a portion of the joint being
clearly visible between the outer surfaces of the base sheets and
including an interface line defined by an inner overlapping edge of
one of the base sheets, the interface line thereby being set in
from the outer surfaces of the base sheets; and a relatively low
build brushable or rollable texture coating applied in situ to the
exposed unfinished outer surfaces of the installed base sheets.
2. A cladding system according to claim 1 wherein the visible
portion of the expressed joint is defined by a channel formation
between the outer surfaces of adjacent base sheets, the channel
having an outer width between the outer surfaces, and an inner
width at a depth set in from the outer surfaces.
3. A cladding system according to claim 2 wherein the interface
line is set in at the maximum depth of the channel.
4. A cladding system according to claim 2 wherein the profiled
edges of the base sheets includes some form of straight or curved
chamfer along the edges immediately adjacent the outer surface of
the base sheets, such that the outer width of the channel is wider
than the inner width of the channel.
5. A cladding system according to claim 4 wherein the channel has a
generally `V` shaped or truncated `V` shaped section.
6. A cladding system according to claim 2 wherein the outer width
of the channel is up to about 15 mm.
7. A cladding system according to claim 6 wherein the outer width
is from about 3 mm to about 9 mm.
8. A cladding system according to claim 7 wherein the outer width
is approximately 7 mm.
9. A cladding system according to claim 2 wherein the inner width
is up to about 10 mm.
10. A cladding system according to claim 9 wherein the inner width
is from about 3 mm to about 9 mm.
11. A cladding system according to claim 10 wherein the inner width
is about 3 mm.
12. A cladding system according to claim 2 wherein the maximum
depth of the channel is no more than about 6 mm.
13. A cladding system according to claim 12 wherein the maximum
depth of the channel is from about 3 mm to 4.5 mm.
14. A cladding system according to claim 1 wherein some or all of
the internal corners and edges are curved or chamfered.
15. A cladding system according to claim 1 wherein the base sheets
are pre-coated with an appropriate sealer.
16. A cladding system according to claim 1 wherein the relatively
low-build brushable or rollable texture coating has a thickness of
up to about 300 microns when applied.
17. A cladding system according to claim 1 further comprising a
back sealing tape adapted to span across the edges of the inner
surfaces of adjacent base sheets across the joint.
18. A cladding system according to claim 1 further comprising a
sealant for application between the overlapping surfaces of the
ship lap joint between adjoining base sheets.
19. A cladding system according to claim 1 wherein each base sheet
is profiled on two opposing longitudinal edges.
20. A cladding system according to claim 1 wherein the base sheets
are made from fibre cement.
21. A method of installing a panelised masonry look wall cladding
system, the method comprising the steps of: providing a plurality
of broad rectangular base sheets, each of the base sheets having an
inner surface and a planar generally smooth outer surface, each
base sheet being profiled along at least one edge such that on
installation with an adjacent sheet, an overlapping vertical ship
lap expressed joint is formed, a portion of the joint being clearly
visible between the outer surfaces of the base sheets and including
an interface line defined by an inner overlapping edge of one of
the base sheets which is thereby set in from the outer surfaces of
the base sheets; securing the base sheets to an underlying
structure in a side by side vertical orientation so as to form at
least one vertical ship lap expressed joint as described above; and
applying in situ a relatively low-build brushable or rollable
texture coating to the exposed unfinished outer surfaces of the
installed base sheets.
22. A method of installing a cladding system according to claim 21
wherein the base sheets are secured such that the visible portion
of the joint defines a channel between the outer surfaces of
adjacent base sheets, the channel having an outer width between the
outer surfaces, and an inner width at a depth set in from the outer
surfaces.
23. A method of installing a cladding system according to claim 22
wherein the base sheets are secured such that the interface line is
set in at the maximum depth of the channel.
24. A method of installing a cladding system according to claim 22
wherein the sheets are configured and selected such that on
installation, the cladding system defines a joint including a
channel with an outer width up to about 15 mm.
25. A method of installing a cladding system according to claim 21
further comprising applying a back sealing tape between the
underlying structure and the base sheets, such that the back
sealing tape spans across the inner edge surfaces of adjacent base
sheets.
26. A method of installing a cladding system according to claim 21
further comprising applying a sealant between the overlapping
surfaces of the ship lap joints between adjoining base sheets.
27. A method of installing a cladding system according to claim 21
wherein the relatively low-build brushable or rollable texture
coating is applied in two coats.
28. A method of installing a cladding system according to claim 21
wherein the relatively low-build brushable or rollable texture
coating is applied to a thickness of up to about 300 microns.
29. A method of installing a cladding system according to claim 21
wherein the base sheets are made from fibre cement.
Description
BACKGROUND OF THE INVENTION
[0001] The present invention relates to a cladding system,
particularly of the kind including base sheets which are secured to
an underlying structure such as a stud wall, with a thin finish
coating being applied to the outer surface of the base sheets. In
preferred forms the coating is a texture coating of a kind used to
achieve a masonary look finish.
[0002] The invention has been developed primarily for use with base
sheets made of fibre cement and will be described primarily with
reference to this particular form. However, it will be appreciated
that the cladding system of the invention is not limited for use
with the fibre cement base sheets and could readily be adapted for
use with base sheets made from other suitable materials.
[0003] Any discussion of the prior art throughout the specification
should in no way be considered as an admission that such prior art
is widely known or forms part of common general knowledge in the
field.
[0004] In response to trends for affordable "monolithic" look
coated external wall styles, a number of coated wall cladding
systems have been developed. The most popular of these systems all
involve first applying planar base sheets or panels to fully clad
the outer surfaces of a new or existing external wall or wall
frame. After the cladding has been installed, it is then usually
coated with a relatively high-build trowel-applied texture coating
material which results in a monolithic solid textured stone like
appearance.
[0005] These systems have the advantage of providing the desired
monolithic type masonry appearance at relatively low cost and with
more design flexibility than an equivalent full masonry structure.
However, the need to carefully set the joints between adjacent
abutting base panels makes the installation of the base panels very
time consuming. This results in unduly high labour costs compared
to the component material costs and also slows the installation
process. Furthermore, in order to adequately hide the set joints, a
high build trowel applied texture coating needs to be used, which
can only be installed by highly trained coating application
specialists, again adding significantly to the overall system cost.
In addition, if there is movement between the base sheets due to,
for example, movement of the frame or poor installation, cracking
of the coating may occur along the set joints and repairs are not
practical without generally being noticeable.
[0006] It is an object of the present invention to provide a coated
or coatable cladding system that overcomes or ameliorates one or
more of the above disadvantages of the prior art, or which at least
provides a useful alternative
SUMMARY OF THE INVENTION
[0007] According to a first aspect of the invention, there is
provided a panelised masonry look wall cladding system
incorporating broad planar surfaces extending between vertical
expressed joints, the wall cladding system including:
[0008] a plurality of broad rectangular base sheets secured in a
side by side vertical orientation to an underlying structure;
[0009] each of the base sheets having an inner surface and a planar
generally smooth unfinished outer surface, each base sheet being
profiled along at least one longitudinal edge to provide, on
installation with an adjacent sheet, broad planar surfaces with an
intermediate overlapping vertical ship lap expressed joint, a
portion of the joint being clearly visible between the outer
surfaces of the base sheets and including an interface line defined
by an inner overlapping edge of one of the base sheets, the
interface line thereby being set in from the outer surfaces of the
base sheets; and
[0010] a relatively low build brushable or rollable texture coating
applied in situ to the exposed unfinished outer surfaces of the
installed base sheets.
[0011] The term `ship lap` joint is used herein to refer to any
sheet jointing structure in which a rebate is formed below the
outer surface of an edge of one sheet such that an overhang is
formed which is adapted to sit on or over a similar or dissimilar
rebate formed in the outer surface of an edge of an adjacent
joining sheet, whereby there is an overlap region and the outer
surfaces of the joined sheets remain in substantially the same
plane. The term `expressed` is used to refer to a joint finish and
structure which is intended to be a clearly visible feature, as
opposed to a minimal or incidental joint line.
[0012] It will be appreciated that the overlap provided by the ship
lap joint, in conjunction with the expressed sizing of the joint
with recessed interface line, obviates the need for joint setting
as was required with the prior art.
[0013] Preferably, the visible portion of the joint defines a
channel formation between the outer surfaces of adjacent base
sheets, the channel having an outer width between the outer
surfaces, and an inner width at a depth set in from the outer
surfaces. Preferably, the interface line is set in at the maximum
depth of the channel.
[0014] Preferably, the profiled edges of the base sheets include
some form of straight or curved chamfer along the edges immediately
adjacent the outer surface of the base sheets such that the outer
width of the channel is wider than the inner width of the channel.
In some preferred forms the channel has a generally `V` shaped or
truncated `V` shaped section. Desirably, some or all of the
internal corners and edges are curved or chamfered.
[0015] In preferred embodiments, the outer width is up to about 15
mm. Preferably, the outer width is from about 3 mm to about 9 mm.
It is preferred that the inner width is up to about 10 mm.
Preferably, the inner width is from about 3 mm to about 9 mm, with
the inner width, desirably, being less than the outer width.
Further, it is preferred that the maximum depth of the channel is
up to about 6 mm. Preferably, the maximum depth of the channel is
from about 3 mm to 4.5 mm.
[0016] In one particularly preferred form, the sheets are
approximately 8.5 mm thick and the channel is of a generally
truncated `V` shaped section having an outer width of approximately
7 mm, a depth of around 4 mm and an inner width of about 3 mm.
[0017] There is also an overlap region of approximately 4 to 5 mm.
It will be appreciated that this could be varied. For example, in
order to increase weatherproofing capacity, it may be useful to
increase the overlap region.
[0018] In preferred forms the base sheets are pre-coated with an
appropriate sealer or primer to enable texture coating to commence
in accordance with the manufacturer's recommendations.
[0019] Preferably, the cladding system is part of a texture coated
cladding system. More preferably, using a relatively low build
brushable or rollable coating for application to the outer surfaces
of the installed base sheets.
[0020] Preferably, the relatively low-build brushable or rollable
texture coating is a roll-on coating for application by a paint
roller. Preferably, the relatively low-build brushable or rollable
texture coating has a thickness of up to about 300 microns when
applied.
[0021] Preferably, the system includes a back sealing tape adapted
to span across the inner edge surfaces of adjacent base sheets.
Preferably, the system also includes a sealant for application
between the overlapping rebated surfaces of the ship lap joints
between adjoining base sheets.
[0022] Preferably, each base sheet is profiled on a longitudinal
edge. More preferably, each base sheet is profiled on two opposing
longitudinal edges. Preferably, the longitudinal edges are
installed vertically when used in walling applications.
[0023] According to a second aspect of the invention, there is
provided a method of installing a panelised masonry look wall
cladding system, the method including the steps of:
[0024] providing a plurality of broad rectangular base sheets, each
of the base sheets having an inner surface and a planar generally
smooth outer surface, each base sheet being profiled along at least
one edge such that on installation with an adjacent sheet, an
overlapping vertical ship lap expressed joint is formed, a portion
of the joint being clearly visible between the outer surfaces of
the base sheets and including an interface line defined by an inner
overlapping edge of one of the base sheets which is thereby set in
from the outer surfaces of the base sheets;
[0025] securing the base sheets to an underlying structure in a
side by side vertical orientation so as to form at least one
vertical ship lap expressed joint as described above; and
[0026] applying in situ a relatively low-build brushable or
rollable texture coating to the exposed unfinished outer surfaces
of the installed base sheets.
[0027] Preferably, the base sheets are secured such that the
visible portion of the joint defines a channel between the outer
surfaces of adjacent base sheets, the channel having an outer width
between the outer surfaces, and an inner width at a depth set in
from the outer surfaces. Preferably, the base sheets are secured
such that the interface line is set in at the maximum depth of the
channel.
[0028] Preferably, where the profiled edges of the base sheets
include some form of straight or curved chamfer along the edges
immediately adjacent the outer surface of the base sheets, the base
sheets are secured such that the outer width of the channel is
wider than the inner width of the channel.
[0029] In preferred embodiments, the base sheets are secured such
that the outer width is up to about 15 mm. Preferably, the outer
width is from about 3 mm to about 9 mm. It is preferred that the
base sheets are secured such that the inner width is up to about 10
mm. Preferably, the inner width is from about 3 mm to about 9 mm,
with the inner width, desirably, being less than the outer width.
Further, it is preferred that the base sheets are secured such that
the maximum depth of the channel is up to about 6 mm. Preferably,
the maximum depth of the channel is from about 3 mm to 4.5 mm.
[0030] In one particularly preferred form, the sheets are
approximately 8.5 mm thick and the channel is of a generally
truncated `V` shaped section having an outer width of approximately
7 mm, a depth of around 4 mm and an inner width of about 3 mm.
[0031] There is also an overlap region of approximately 4 to 5 mm.
It will be appreciated that this could be varied. For example, in
order to increase weatherproofing capacity, it may be useful to
increase the overlap region.
[0032] In preferred forms the base sheets are pre-coated with an
appropriate sealer or primer to better enable texture coating to
commence in accordance with the manufacturer's recommendations.
[0033] In one example, the step of applying the relatively
low-build brushable or rollable texture coating is carried out by
rolling on the coating with a paint roller. Preferably, the
relatively low-build brushable or rollable texture coating is
applied in two coats. Preferably, the relatively low-build
brushable or rollable texture coating is applied to a thickness of
up to about 300 microns. In all cases, however, the coating must be
applied strictly in accordance with the manufacturer's
directions.
[0034] Preferably, the method includes applying a back sealing tape
between the underlying structure and the base sheets such that the
back sealing tape spans across the inner edge surfaces of adjacent
base sheets. Desirably, the method includes applying a sealant
between the overlapping rebated surfaces of the ship lap joints
between adjoining base sheets.
[0035] Preferably, in walling applications, the base sheets are
secured such that the longitudinal edges of the base sheets run
vertically.
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] Preferred embodiments of the invention will now be
described, by way of example only, with reference to the
accompanying drawings in which:
[0037] FIG. 1 is a front elevation of a texture coated cladding
system in accordance with a preferred embodiment of the present
invention, with a base sheet shown cut away to reveal the
underlying timber stud wall structure;
[0038] FIG. 2 is a cross-sectional view of the texture coated
cladding system of FIG. 1 taken along section line A-A in FIG.
1;
[0039] FIG. 3 is a cross-sectional view of a texture coated
cladding system according to another preferred embodiment of the
invention, wherein the underlying structure is a steel frame;
[0040] FIG. 4a is a side elevation of two base sheets in an
installed configuration, in accordance with a first preferred
embodiment of the present invention;
[0041] FIG. 4b is a magnified fragmentary side elevation of the
ship lap joint between the two base sheets shown in FIG. 4a;
[0042] FIG. 5 is a side elevation of two base sheets in an
installed configuration, in accordance with a second preferred
embodiment of the present invention;
[0043] FIG. 6 is a side elevation of two base sheets in an
installed configuration, in accordance with a third preferred
embodiment of the present invention;
[0044] FIG. 7a is a perspective fragmentary view of a texture
coated cladding system according to the present invention, showing
a back sealing tape being applied over a vapour permeable
membrane;
[0045] FIG. 7b is a perspective fragmentary view of the texture
coated cladding system of FIG. 7a, showing the back sealing tape
applied over the vapour permeable membrane and between base sheets
and an underlying structure, and showing a sealant being applied to
the rebated surface of one of the base sheets in preparation for
the installation of a second base sheet; and
[0046] FIG. 7c is a perspective fragmentary view of the texture
coated cladding system of FIG. 7a, showing the installation of the
second base sheet.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0047] Referring to the drawings, each of the texture coated
cladding systems shown include a plurality of base sheets 1 for
securing to an underlying structure 2. In the embodiments shown in
FIGS. 2 and 3, the underlying structures are a timber stud wall
frame and a steel wall frame respectively. However, the underlying
structures are not limited to these, and in other embodiments can
be, for example, an existing wall structure with support battens,
or a floor frame.
[0048] Each of the base sheets 1 have an inner surface 3 and a
planar generally smooth outer surface 4, with each base sheet being
profiled along at least one edge 5 to provide, on installation, a
ship lap expressed joint 6 with an adjacent sheet. A portion 7 of
the joint is clearly visible between the outer surfaces 4 of the
base sheets and includes an interface line 8 defined by an inner
overlapping edge 9 of one of the base sheets, the interface line
thereby being set in from the outer surfaces of the base
sheets.
[0049] In the present embodiments, each base sheet is profiled on
two opposing longitudinal edges 5, with the longitudinal edges
preferably being installed vertically to assist drainage along the
joint, as best shown in FIG. 1. In other embodiments, some base
sheets may be profiled on only one edge, which suits situations
where the sheets are installed at the edges of the underlying
structure and are not required to join to other sheets in a
direction beyond the edges of the underlying structure. In other
embodiments, the base sheets may be profiled on more than two edges
in installations, for example, where horizontal joints as well as
vertical joints are desired. The longitudinal edges of the base
sheets may also be installed horizontally.
[0050] In the preferred forms, the base sheets are pre-coated prior
to installation with a suitable sealer or primer ready to receive a
finish coating or coatings in accordance with the coating
manufacturer's recommendations. If that is not the case, it may be
necessary to seal or prime the sheets in situ. Choice of sealer
will depend on the base sheet material--the type of texture coating
to be applied and the coating manufacturer's requirements.
[0051] The texture coated cladding systems shown also include a
relatively low-build brushable or rollable texture coating 10 for
application to the outer surfaces 4 of the installed base sheets 1.
Advantageously, these coatings include roll-on texture coatings
that are readily available to end consumers and do not require the
skills of specialist tradespeople to apply. The present embodiments
include a coating of this type for application by a paint roller,
which when applied has a preferred thickness of up to about 300
microns. Examples of suitable brushable or rollable texture
coatings suitable for this application include Dulux.RTM. Fine
Texture, Wattyl Granotex.RTM. Roll On, and Taubmans.TM. Armawall
Ultrasand. In all cases, it is important that the coatings be
applied strictly in accordance with the coating manufacturer's
instructions.
[0052] As best shown in FIG. 4b, the visible portion 6 of the joint
defines a channel 11 between the outer surfaces 4 of adjacent base
sheets 1, the channel having an outer width 12 between the outer
surfaces, and an inner width 13 at a depth set in from the outer
surfaces. The interface line is set in at the maximum depth 14 of
the channel.
[0053] The profiled edges 5 of the base sheets 1 include some form
of straight or curved chamfer along the edges 15 immediately
adjacent the outer surface 4 of the base sheets 1 such that the
outer width 12 of the channel is wider than the inner width 13 of
the channel. The inner overlapping edge 9 of the one base sheet and
the inside corner 16 of the rebate of the other base sheet are also
curved. In the present embodiments, the various dimensions of these
features are as follows:
TABLE-US-00001 TABLE 1 Approximate channel dimensions in preferred
embodiments Embodiment Outer width Inner width Maximum depth FIG. 4
7.0 mm 3.0 mm 4.0 mm FIG. 5 14.0 mm 8.0 mm 4.3 mm FIG. 6 4.4 mm 1.0
mm 4.1 mm
[0054] In preferred embodiments, the outer width is up to about 15
mm. Preferably, the outer width is from about 3 mm to about 9 mm.
It is preferred that the inner width is up to about 10 mm.
Preferably, the inner width is from about 3 mm to about 9 mm, with
the inner width, desirably, being less than the outer width.
Further, it is preferred that the maximum depth of the channel is
up to about 6 mm. Preferably, the maximum depth of the channel is
from about 3 mm to 4.5 mm. It will be appreciated, however, that a
variety of dimensions and combinations of dimensions can be
achieved depending on the desired appearance of the installed
system.
[0055] The presently preferred embodiment is that shown in FIG. 4,
preferably made from fibre cement, having a sheet thickness of
around 8.5 mm (although this could vary), the channel having an
outer width of approximately 7 mm, a depth of around 4 mm and an
inner width of about 3 mm. Preferably all internal corners and
edges are slightly curved as shown. There is also an overlap region
of approximately 4 to 5 mm. It will be appreciated that this could
be varied. For example, in order to increase weatherproofing
capacity, it may be useful to increase the overlap region.
[0056] The base sheets can be made of any suitable material such
as, but not limited to, fibre cement, oriented strandboard,
engineered wood, plywood, and masonite. In preferred forms, the
base sheets are made of a nailable cellulose fibre reinforced
cement. The currently preferred base sheet is a medium density
fibre cement board designed for an exterior cladding
application.
[0057] In preferred forms the base sheets are pre-coated with an
appropriate sealant or primer ready to receive a finish coating or
coatings in accordance with the manufacturer's instructions. For
fibre cement sheets of the preferred kind mentioned above an
acrylic sealer is suitable.
[0058] The preferred fibre cement sheets have the edges formed
during manufacture by continuous milling, cutting, machining,
pressing, extrusion, embossing, or any other suitable processes.
The simple rebated profiles contemplated by the present invention
are well suited to continuous manufacturing processes, especially
where longitudinal edges are profiled. Hence, base sheets with
these profiled edges can be manufactured relatively easily and cost
effectively. The presently preferred method of forming the edges is
cutting.
[0059] As best shown in FIGS. 7a to 7c, the texture coated cladding
systems of the present embodiments include a back sealing tape 17
adapted to span across the edges of the inner surfaces 3 of
adjacent base sheets 1. The back sealing tape is a 50 mm EPDM foam
tape fixed between the studs 18 of the underlying timber frame
structure and the ship lap joints 6 that coincide with the studs.
The systems also include a sealant 19 for application between the
overlapping rebated surfaces 20 of the ship lap joints 6 between
adjoining base sheets 1. The sealant in these embodiments is
preferably a continuous 3 mm diameter bead of fluid joint sealant
that sets to form a seal between the rebated surfaces 20.
[0060] The present embodiments also include a vapour permeable
membrane 21 between the base sheets 1 and the underlying structure
2, as best shown in FIGS. 7a to 7c. In embodiments such as these,
where a back sealing tape 17 is included, the vapour permeable
membrane is between the underlying structure 2 and the back sealing
tape 17. The vapour permeable membrane is pliable and serves to
prevent moisture ingress, by acting as a drainage plane, whilst
allowing water vapour build up from the underlying structure to
escape.
[0061] The present invention also provides a method of installing
texture coated cladding. A preferred embodiment of the method
involves installing the texture coated cladding systems described
above.
[0062] This preferred method includes the steps of: providing the
plurality of base sheets 1 described above; securing the base
sheets 1 to the underlying structure 2 such that each or at least
one base sheet forms a ship lap joint 6 with an adjoining sheet,
whereby, on installation, the portion 7 of the joint is visible
between the outer surfaces 4 of the base sheets and includes the
interface line 8 defined by the inner overlapping edge 9 of one of
the base sheets, the interface line thereby being set in from the
outer surfaces of the base sheets; and then applying the relatively
low-build brushable or rollable texture coating 10 to the outer
surfaces 4 of the installed base sheets 1.
[0063] The base sheets 1 are secured such that the visible portion
7 of the joint 6 defines the channel 11 between the outer surfaces
4 of adjacent base sheets, the channel having the outer width 12
between the outer surfaces, and the inner width 13 at a depth set
in from the outer surfaces. The base sheets are also secured such
that the interface line 8 is set in at the maximum depth 14 of the
channel. Further, the base sheets 1 are configured and secured
whereby the outer width 12 of the channel is wider than the inner
width 13 of the channel.
[0064] Furthermore, the base sheets 1 are preferably secured such
that the longitudinal edges 5 of the base sheets run vertically. In
other embodiments, the base sheets are secured whereby the
longitudinal edges run horizontally, or any other orientation
depending on the requirements of the installation. For example, the
base sheets may be installed with edges running at oblique angles,
especially where the sheets meet wall penetrations such as windows,
or terminations such as rooflines.
[0065] In all cases, it will be important to also ensure that
installation complies with locally applicable building codes and
regulations which may dictate certain spacings from ground surfaces
and eaves and/or frame fixing requirements etc.
[0066] In the present embodiments, the base sheets are configured
and secured to achieve the dimensions detailed in Table 1 above. In
other preferred embodiments, the base sheets are secured to achieve
the preferred dimensions described above. In most cases the
configuration of the ship lap expressed joint is such that adjacent
sheets can be fixed with the edge most surfaces in a generally
abutting relationship.
[0067] The step in preferred form of the invention of applying the
relatively low-build brushable or rollable texture coating 10 is
preferably carried out by rolling on the coating with a paint
roller. The relatively low-build brushable or rollable texture
coating must be applied in accordance with the coating
manufacturer's recommendations. In one form, the coating may be
applied in two coats to a thickness of about 300 microns, but may
also be applied in any number of coats to a variety of thicknesses
according to the requirements of the particular installation and
the recommendations of the coating manufacturer. If appropriately
pre-sealed or primed base sheets are used, then, subject to the
coating manufacturer's requirements, no other under coating may be
required before the texture coating is applied.
[0068] Rolling on or brush applying low-build texture coatings that
are readily available to end consumers has the particular advantage
of dispensing with the need for specialist relatively high-build
trowel-applied texture coatings that require specialist
tradespeople to install.
[0069] It will also be appreciated that the cladding structure also
enables a wider range of coatings to be applied, which of course do
not need to be textured.
[0070] The present embodiment of the method includes the step of
applying the back sealing tape 17 between the underlying structure
2 and the base sheets 1 such that the back sealing tape spans
across the inner edge surfaces 3 of adjacent base sheets. The
present embodiment also includes the step of applying the sealant
19 between the overlapping rebated surfaces 20 of the ship lap
joints 6 between adjoining base sheets 1, as best shown in FIG.
7b.
[0071] The present embodiment also includes the step of installing
the vapour permeable membrane 21 to the underlying structure 2
before installing the back sealing tape 17, and then installing the
base sheets 1 over the back sealing tape.
[0072] In one preferred form, the vapour permeable membrane 21 is
fixed to the underlying structure 2 first, by means such as
nailing, stapling, or gluing. The back sealing tape 17 is then
positioned over the vapour permeable membrane 21 along the studs
18. The sealing tape 17 can be glued into place or can have an
adhesive coating on the back surface that adheres the sealing tape
to the vapour permeable membrane 21, as shown in FIG. 7a. The next
step is to secure the base sheets 1 to the underlying structure
1.
[0073] At the studs 18, the base sheets 1 are positioned such that
suitable fasteners 22, such as galvanised fibre cement nails,
stainless steel brad nails, or screws, can be driven through the
base sheets inboard of the profiled edges 5, through the back
sealing tape 17, and into the stud 18 to secure the base sheets to
the underlying structure 2. The fasteners 22 are driven through
until the fastener heads are flush with the outer surfaces 4 of the
sheets. Thus, the fasteners 22 pass through the full thickness of
the base sheets, and not through the reduced thickness rebated edge
5.
[0074] As shown in FIG. 7b, a bead of the fluid joint sealant 19 is
then applied to the outwardly facing rebated surfaces 20 of the
profiled edges 5 of the base sheets already secured onto the stud
18. Next, further base sheets 1 are positioned onto the underlying
structure 2 such that the inwardly facing rebated surface 20 of the
profiled edges 5 of the further base sheets sit over the outwardly
facing rebated surface 20 of the base sheets already secured onto
the stud 18, with the edge most surfaces of each sheet in, or close
to, abutment with each other. Thus, the sealant 19 is sandwiched
between the rebated surfaces 20 of the adjoining sheets, sealing
the ship lap joint 6 formed between the sheets.
[0075] The newly positioned base sheets 1 are then secured to the
underlying structure 2 by means of fasteners 22 driven through the
sheets at positions inboard of the profiled edges 5, through the
back sealing tape 17, and into the stud 18, until the fastener
heads are flush with the outer surfaces 4 of the sheets, similar to
the previously secured base sheets, and as shown in FIG. 7c. Excess
sealant 19 is then wiped away from the visible portions 7 of the
ship lap joints 6. The relatively low-build brushable or rollable
texture coating 10 is then applied as described above.
[0076] The described embodiments exemplify the various advantages
of the present invention. Having a portion of the joints between
base sheets that are deliberately designed to be clearly visible,
and in particular, having a recessed interface line between the
sheets, eliminates or ameliorates the prior art problems of needing
to hide joints effectively prior to coating, at the same time
enabling a wider range of coating types to be used.
[0077] The configuration of the ship lap joints contemplated by the
present invention, and in particular, the configuration of the
rebates in the profiled longitudinal edges, are well suited to
large scale continuous manufacturing processes. This results in
cost-effective manufacture of the base sheets, decreasing the
material costs.
[0078] Furthermore, for texture coated applications the present
invention allows the use of relatively low-build brushable or
rollable texture coatings that are readily available to end
consumers. These are typically rolled-on in a convention manner
dispensing with the need for specialist tradespeople applying
specialist relatively high-build trowel-applied texture coatings.
This results in significantly decreased installation costs and
time, particularly decreased specialist labour costs and further
savings in material costs.
[0079] Finally, it will be appreciated that further variations are
possible without departing from the scope of the invention or
inventions described herein.
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