Patent Application
20130239498
The present invention relates to a building system. More particularly the invention relates to stucco type cavity wall construction techniques and resultant consumables, subassemblies, assemblies, etc.
Exterior panels defined in situ in a plaster material in New Zealand have been restricted to a height no higher than about 2.4 meters high and 4 meters wide by building regulation. Larger cladding areas require movement control joints.
The present invention in one aspect is directed to a building system (eg. structures, methods, procedures, apparatus, etc) which would allow panels of greater than 2.4 meters in height to be created and/or greater than 4 meters width to be created without movement joints.
The present invention also or instead is directed to building envelopes being closed by a cavity wall plaster system which, with our without movement control joints (eg. vertical and/or horizontal control joints), can provide walls of considerable size and/or non-square or non-rectangular perimeter.
For a typical (nominal) 21 mm panel thickness in compliance with NZS3604, we envisage at least square or rectangular panels being created in situ that can achieve, without a movement control joint, a height of at least 4.85 meters and can be as wide as much as, for example, up to 12 meters, all without mandatory movement control joints. Smaller panel widths of 6 meters, 8 meters or other are also within the compass of the present invention. Likewise heights.
By way of example, and without in any way being limiting, we expect for an in situ panel, of say 21 mm thickness so as to be NZ compliant, a single level panel size of, say, 2.4×6 metres and a double level panel size of say, 5.2×8 metres without any mandatory movement control joint.
In other countries (eg. USA) a thicker panel of say, about 40 mm may find favour. We expect our system to cater similarly for such panels.
Irrespective of the dimensions of any resultant panel, its peripheral shape, etc any method of in situ formation of a reinforced plaster panel that allows that greater dimensional reach of a panel is also within the scope of the present invention. However a preferred system of plaster matrix will be described with respect to NZ requirements but in no way restricted to NZ regulatory constraints.
It is an aim or object of the present invention to provide a building and/or a building system, related assemblies, sub assemblies, procedures, methods, panels, flashings, reinforcements, cavity walls of part stucco construction, etc which will at least provide the public with a useful choice.
It is a further or alternative aim or object of the present invention to provide compliance with the plaster code NZS4251 in the provision of a building and/or a building system, related assemblies, subassemblies, procedures, methods, panels, flashings, reinforcements, cavity walls of part stucco construction etc, all which will at least provide the public with the useful choice.
It is a further or alternative aim or object of the present invention to provide compliance with the building code NZS3604 in the provision of a building and/or a building system, related assemblies, subassemblies, procedures, methods, panels, flashings, reinforcements, cavity walls of part stucco construction etc, all which will at least provide the public with the useful choice.
It is a further or alternative aim or object of the present invention to provide compliance with the building code NZS3604 and plaster code NZS4251 in the provision of a building and/or a building system, related assemblies, subassemblies, procedures, methods, panels, flashings, reinforcements, cavity walls of part stucco construction etc, all which will at least provide the public with the useful choice.
It is a further or alternative aim to provide stucco walled structures having panel rigidity and integrity.
It is a further or alternative aim or object of the present invention, or at least some embodiments, of the present invention to provide methods to meet what is expected to be allowable under NZ regulation.
In an aspect the invention is a building which has as a wall of its envelope, a wall of a size of at least 2.4 m high, at least 4 m wide and about 21 mm thick;
wherein the wall has
a frame or a substructure having studs at least some of which are spaced by a modular distance,
battens supported from and fixed to said frame or substructure, such battens fixed both on and between studs,
wherein the wall has at least one opening selected from a group consisting of door and window openings;
and wherein at least part of the periphery of each opening, within the matrix, has been further reinforced by one or more of
Preferably the studs are of minimum cross-section of 45 mm×90 mm.
Preferably there are dwangs at nominal 900 mm spacings between the studs.
Preferably the batten attached mesh is of a metal.
Preferably the batten attached mesh overlies a backing sheet.
Preferably the battens are of nominal 35 mm×40 mm cross-section.
Preferably the second mesh is non-metallic
Preferably regional reinforcement is by or includes metallic mesh.
Preferably the metallic mesh regional reinforcement has been attached prior to being embedded.
Preferably regional reinforcement is by or includes a non-metallic sheet material or mesh able to be embedded and penetrated by the matrix material.
Preferably panel boundaries include at least partially embedded lattice-like periphery defining members.
In another aspect the invention is a building which has a wall that has
a frame or a substructure that includes studs substantially to a modularly spacing of about 600 mm where suitable,
battens supported from and fixed to said frame or substructure, said battens being fixed both to at least the modularly spaced studs and inbetween,
a first mesh attached to such battens,
a second mesh supported at least in part by a plaster matrix, and
one or more additional mesh as regional mesh reinforcement,
the plaster matrix applied as more than one layer, the plaster matrix penetrating the first mesh, embedding the second mesh, embedding the regional mesh or meshes.
Preferably the studs are of minimum cross-section of 45 mm×90 mm.
Preferably there are dwangs (preferably at nominal 900 mm spacings) between the studs.
Preferably the batten attached mesh is of a metal.
Preferably the batten attached mesh overlies a backing sheet.
Preferably the battens are of nominal 35 mm×40 mm cross-section.
Preferably the second mesh is non-metallic
Preferably regional reinforcement is by or includes metallic mesh.
Preferably the metallic mesh regional reinforcement has been attached prior to being embedded.
Preferably regional reinforcement is by or includes a non-metallic sheet material or mesh able to be embedded and penetrated by the matrix material.
Preferably panel boundaries include at least partially embedded lattice-like periphery defining members.
In still another aspect the invention is a stucco wall comprising or including
a stud including wall frame,
battens carried by the wall frame and in excess of the number of studs in the wall frame,
a mesh or the like perforate reinforcement sheet(s) carried by the battens,
a mesh or the like perforate reinforcement sheet(s) outwardly of and spaced from the batten carried sheet(s),
additional regional reinforcement mesh,
lattice and/or perforate reinforcement, and
a plaster or cementitious matrix, applied as at least a two layer application, that penetrates the batten carried sheet(s) and embeds or also embeds the other said reinforcement(s).
Preferably the studs are of minimum cross-section of 45 mm×90 mm.
Preferably there are dwangs (preferably at nominal 900 mm spacings) between the studs.
Preferably the batten attached mesh is of a metal.
Preferably the batten attached mesh overlies a backing sheet.
Preferably the battens are of nominal 35 mm×40 mm cross-section.
Preferably the second mesh is non-metallic
Preferably regional reinforcement is by or includes metallic mesh.
Preferably the metallic mesh regional reinforcement has been attached prior to being embedded.
Preferably regional reinforcement is by or includes a non-metallic sheet material or mesh able to be embedded and penetrated by the matrix material.
Preferably panel boundaries include at least partially embedded lattice-like periphery defining members.
In another aspect the invention is a building which has as a wall of its envelope, a wall of a size of at least 2.4 m high, at least 4 m wide and about 21 mm thick;
wherein the wall has
a frame or a substructure,
battens supported from and fixed to said frame or substructure,
a first mesh (“inner mesh”) attached to such battens,
a second (“outer”) mesh supported at least in part by a plaster matrix, and
the plaster matrix applied as more than one layer, the plaster matrix penetrating the first mesh, interposing both meshes, attaching to the second mesh and covering the second mesh;
wherein the wall has at least one opening selected from a group consisting of door and window openings;
and wherein the, or each, opening is positioned only as allowed and the, or each, opening is further reinforced in the plaster matrix at least substantially in accordance with the Rules as herein provided (preferably thereby to be NZS3604, or both NZS3604 and NZS4251, compliant, all as current June 2010).
Preferably the frame or substructure has studs that are of minimum cross-section of 45 mm×90 mm.
Preferably there are dwangs at nominal 900 mm spacings between the studs.
Preferably the batten attached mesh is of a metal.
Preferably the batten attached mesh overlies a backing sheet.
Preferably the battens are of nominal 35 mm×40 mm cross-section.
Preferably the second mesh is non-metallic
Preferably regional reinforcement is by or includes metallic mesh.
Preferably the metallic mesh regional reinforcement has been attached prior to being embedded.
Preferably regional reinforcement is by or includes a non-metallic sheet material or mesh able to be embedded and penetrated by the matrix material.
Preferably panel boundaries include at least partially embedded lattice-like periphery defining members.
In yet another aspect the invention is a building having at least one stucco wall, the stucco matrix having been layed up as plural settable layers, the wall being of at least 2.4 m high, at least 4 m wide and about 21 mm thick, the wall comprising or including
a frame or a substructure that includes studs of at least 45×90 mm cross-section, where appropriate, at about 600 mm centres,
battens of about 40 by 35 mm cross-section supported from the frame or substructure both on and in
between the studs,
reinforcement metal mesh attached to the battens and penetrated by a said layer of the stucco matrix,
reinforcement set out from the batten carried metal mesh and embedded in the stucco matrix,
regional extra embedded reinforcement, and
the stucco matrix
Preferably there are dwangs at nominal 900 mm spacings between the studs.
Preferably the batten attached mesh is of a metal.
Preferably the batten attached mesh overlies a backing sheet.
Preferably the second mesh is non-metallic
Preferably regional reinforcement is by or includes metallic mesh.
Preferably the metallic mesh regional reinforcement has been attached prior to being embedded.
Preferably regional reinforcement is by or includes a non-metallic sheet material or mesh able to be embedded and penetrated by the matrix material.
Preferably panel boundaries include at least partially embedded lattice-like periphery defining members.
In another aspect the invention consists in a building [or any kit, method or procedures which results in such a building] which has, or is to have, as part of its envelope and/or any wall,
wherein the panels (at least of said primary plaster matrix and the meshes has one or more of the following characteristics,
Preferably the first mesh is a metal mesh.
Preferably said first mesh “wraps” (as herein defined) the framing or substructure over the battens and to and/or substantially to any openings of the envelope.
Preferably prepared mesh sheet (preferably zinc coated) has been used as the inner mesh, paper side inwards.
Preferably the pre-papering provides, as if formwork, for first layer plaster application capture behind and to the inner mesh.
Preferably, or optionally, the inner mesh is of vertical and horizontal wire.
Optionally and preferably corners of openings have as additional reinforcement for and/or support for the plaster matrix (almost as if a patch), a zone a mesh with its wires running substantially at an angle with respect to the vertical and horizontal wires of the inner mesh “wrap”. These are outwards of each corner of any opening (e.g. doors or windows).
Preferably each corner is also further reinforced as additional reinforcement for, and/or support for, the plaster matrix, (almost as if a patch) a zone of a Rules mandated mesh between openings of close proximity (whether of same height or not). Preferably this is embedded in the base coat of the plaster system.
Preferably the first or inner mesh is a metal or wire mesh. It can be woven, forge knotted, welded or the like mesh or can be expanded perforate sheet material to define a “mesh”.
Preferably the outer or Rules mandated mesh is a non-metal mesh e.g. preferably fibreglass. Preferably that is a woven mesh.
Preferably external corners have a skeletal or lattice member embedded at least in part by the plaster matrix and embedded on both sides of the corner by the plaster matrix (eg. as if flanges).
Preferably the skeletal or lattice member is batten supported.
Preferably the external corner skeletal or lattice member is over the inner mesh.
Preferably the corner has acted as formwork.
Preferably said skeletal or lattice member is a corner moulding.
Preferably the external corner skeletal or lattice member is of a plastics material (eg. PVC).
Preferably window and/or door openings each have a head flashing to provide a canopy and that head flashing receives the inner mesh (ie. preferably holds the free ends of vertical wires of the mesh).
Preferably such flashings have end stopping (eg. flashing tape provided).
Preferably the flashings are of a plastics material (eg. PVC).
Preferably the head flashing is in part below the bottom ends of vertical battens and in part over a trim batten.
Preferably window and/or door openings have side jamb flashings.
Preferably each side jamb flashing locates a skeletal or lattice member (“side jamb skeletal or lattice member”) embedded at least in part by the plaster matrix.
Preferably each side jamb flashing is batten supported (at least in part).
Preferably each side jamb flashing is fixed to a trim batten or other batten.
Preferably window and/or door openings have a sill flange spanning between battens it is attached to.
Preferably a sill flashing (eg. of aluminium) overlays at least part of said sill flange.
Preferably the sill flashing is of “Z” section.
Preferably the sill flashing is of aluminium.
Preferably the sill flange has acted as a formwork periphery of the plaster matrix.
Preferably the top region of the sill flashing underlies the window frame (if opening is a window).
Preferably an inner mesh overlaps a flange of a wall bottom member (with preferably a drip edge).
Preferably the wall bottom member has two flanges, one to be positioned behind the bottom of vertical battens (and preferably to above any floor level) and one to be positioned over the same vertical battens and overlayed by the inner mesh.
Preferably the wall bottom member has acted as formwork for the plaster matrix.
Preferably the “Rules” hereafter described are or have been followed.
In another aspect the invention consists in a cavity wall type structure comprising:
Preferably the plaster matrix is of at least a three layer application.
In an aspect the invention is an in situ formed type stucco (ie. plaster matrix) panel of a building structure supported from cavity providing battens;
wherein the panel is supported (at least in part) from the battens by an embedded metal mesh (optionally and preferably of two layers in some areas) and the plaster matrix embeds, more outwardly than the metal mesh, another mesh (eg. of fibreglass) [optionally and preferably of two layers] in some areas;
wherein [optionally but preferably] the panel is about 21 mm thick;
and wherein the panel has no movement control joints;
and wherein the panel is of perimeter larger than 2.4 mm×4 m.
Preferably outwardly of corners of opening there is two layers of the metal mesh.
Preferably “Rules” as hereinafter described mandate use of an extra layer of the mesh more outwardly of the metal mesh and embedded into the base coat.
In still a further aspect, the invention consists in a building envelope having battens that support part or all of an in situ formed panel (preferably of about 21 mm thick);
wherein there is
Preferably the Rules mandated mesh is of smaller opening size than the inner mesh.
In a further aspect the invention consists in a building envelope having battens that support part or all of an in situ formed panel (preferably of about 21 mm thick);
wherein there is
In a yet further aspect the invention consists in a building envelope having battens that support part or all of an in situ formed panel (preferably of about 21 mm thick);
wherein there is
In yet another further aspect, the invention consists in a building envelope having battens that support part or all of an in situ formed panel (preferably of about 21 mm thick);
wherein there is
an inner mesh attached to the battens
In another aspect the invention consists in any of the assemblies, procedures, structures, NZ regulatory authority satisfying cavity wall stucco panels or the like substantially as herein described with or without reference to the “Rules” and/or with or without reference to any one or more of the accompanying drawings.
In a further aspect the invention consists in a building envelope having battens that support, part or all of an in situ formed panel of about 21 mm thick;
wherein there is
Preferably an envelope is further characterised in that the battens are supported from framing or a substructure.
Preferably that framing or substructure includes studs of timber, metal or other material.
Preferably the battens are fixed by penetrative fixers with preferably no fixing of the wire mesh is fully through a batten.
Preferably the panel reinforced by overlays of one or both the inner and outer mesh with further mesh reinforcing.
In another aspect the invention consists in a method of in situ formation of a reinforced plaster panel as cladding of a support structure, (eg. thereby to define a stucco type cavity wall structure) said method comprising or including the steps of
Preferably a building, cavity wall type structure, or stucco panel, of any of the previously defined or preformed forms is a result of such method.
The invention is also any product of such a method.
The invention is also, in combination, components suitable for or of any such product produced by such a method.
In another aspect the invention is a building structure comprising or including
Preferably any one or more of the preferments herein referred to apply.
In still another aspect the invention is a building structure comprising or including:
Preferably any one or more of the preferments herein referred to apply.
In still another aspect the invention is a building structure of a stucco type comprising or including:
Preferably any one or more of the preferments herein referred to apply.
In yet another aspect the invention is a side jamb assembly of or for a peripherally framed glazed or glazable assembly of a stucco type structure, the side jamb assembly having:
Preferably any one or more of the preferments herein referred to apply.
wherein a “Z” type flashing has
Preferably any one or more of the preferments herein referred to apply.
In still a further aspect the invention is a head flashed window or door assembly of a building structure of a stucco type:
Preferably any one or more of the preferments herein referred to apply.
As used herein the term “and/or” means “and” or “or”. In some circumstances it can mean both.
As used herein the term “(s)” following a noun means one or both of the singular or plural forms.
As used herein “stucco” or “stucco panel(s)” includes (but is not limited to) any batten fixed mesh carrying a plaster matrix which itself embeds a mesh more outwardly of the batten fixed mesh, the panel(s) having been in situ formed to structure or frame carried battens.
Preferably regional reinforcement by one or both meshes being overlayed is provided.
As used herein the term “wrap” and related words) in respect of the first or inner mesh envisages, but is not limited to, discrete mesh expanses being placed (preferably with lapping) to provide an inner mesh support wheresoever there is to be the laying up of the plaster system.
As used herein “mesh” includes any lath or indeed alternatives such as any suitable perforate sheet. Preferably in respect of the batten fixed “inner” reinforcement it is of metal substantially as herein described. However in other variants it can be of, for example, stainless steel. The term “mesh” (or indeed the alternatives referred to) where not the batten fixed “inner” reinforcement or fixed regional reinforcement preferably is of a suitable glass or plastics fibre or at least derived from such materials (i.e. glass or plastics). In still other less preferred embodiments it can be of metal.
As used herein, the term “regional” means less than coextensive with the whole panel (minus openings). The preferred inner and outer reinforcements that are preferably so coextensive are “nonregional” in that sense.
As used herein “plaster” or “plaster matrix” can include (but is not restricted to) in the same panel, the same or different “plaster” for different layers of application.
For example MCL® Stucco Rite® System plaster mixes. Such as, in sequence, NZ660 Multicoat cement plaster (pumped, and trowelled only after outer mesh placement) and top coat layer NZ660 Multicoat cement plaster (hand skimmed) and sponge finish.
Alternatively, a water repellent plaster sealer may be applied as a seal to the second layer and a top coat of a finishing plaster applied [e.g. MCL® Stucco Rite® AL40 SP Polymer Modified Finishing Plaster.
A water repellent plaster sealer may be applied prior to full set. A final waterproof coating can be applied post set.
To those skilled in the art to which the invention relates, many changes in construction and widely differing embodiments and applications of the invention will suggest themselves without departing from the scope of the invention as defined in the appended claims. The disclosures and the descriptions herein are purely illustrative and are not intended to be in any sense limiting.
One preferred form of the present invention will now be described with reference to the accompanying drawings in which
FIGS. 58A through 58MMM show diagrams and detail (herein incorporated as text hereof by reference) appropriate for application of certain rules (“Rules”) as to movement control joint (“MCJ”) location and extra fibreglass mesh reinforcement placement, such extra fibreglass being insertable by, for example, trowelling of it into an unset plaster layer, preferably the base coat layer.
The existing MCL StuccoRite® Cavity Wall Cavity System is a masonry cladding system incorporating a 35 mm vented cavity, comprising of special pre-papered steel mesh fixed to H3.1 treated timber battens, incorporating flashings for openings and penetrations, control joints, H3.1 treated fixing blocks, plus a proprietary cementitious render. The cladding system is installed on timber framing that complies with NZS3604 protected by a building wrap and protected by a building wrap and pre-qualified window sealing tape that complies with Table 23 of E2/AS1 and BQI interim Performance Standard BQI C4021*. The render is protected from the weather with a coating system complying with BQI interim Performance Standard C5031*.
In the opinion of BEAL, the MCL StuccoRite® Cavity Wall Cavity System (known as MCL StuccoRite®) and when installed according to the MCL StuccoRite Technical Manual dated January 2006, will meet the following performance requirements of the Building Code:
The present invention is an evolution of that system.
The current system of the invention comprises proprietary plaster, reinforced with pre-papered hot dipped galvanised zinc steel wire MCL® StuccoRite® Mesh Sheet and other reinforcement, to achieve a nominal thickness of 21 mm with a standard sponge or plastic float finish. The plaster is applied by MCL® StuccoRite® Mortar Pumps over the mesh which is stapled to 35 mm×40 mm nominal sized H3.1 or H3.2 treated vertical timber battens providing a ventilated and drained cavity.
The proprietary plaster is applied in three coats; a base coat, a levelling coat, and the top coat. The base coat encapsulates the pre-papered MCL® StuccoRite® Mesh Sheet reinforcement as well as additional reinforcement at corners and around joinery. The levelling and mesh coat contains further reinforcement in the form of fibreglass mesh (MCL® Fibreglass Mesh).
The final skim coat is sponge or plastic float finish.
The MCL® StuccoRite® Mesh Sheet is fabricated from copper bearing cold drawn hot dipped galvanised zinc vertical face wires and horizontal back wires, electrically welded at all points of intersection. The zinc coating is not less than 27.9 g/m2.
The face and back wires are 1.5 mm diameter with openings not exceeding 51 mm. A layer of absorptive, slot perforated paper is placed between the face and back wires. The mesh is self furring by being fabricated horizontally into the lath at 152 mm centres with a 6.5 mm crimp in each face wire at its intersection with double back wires. A layer of Type 1, Grade D, Style 2 black building paper in compliance with UBC Standard No. 17-1 is strip glued to the back of the high absorbent slot perforated paper and is extended 100 mm beyond the lath at the left end of the sheet and 100 mm beyond the upper long edge of the sheet.
Reinforcement at all external corners is provided by MCL® uPVC Kwik corners being a 55 mm×55 mm angle with nosing and MCL®uPVC Kwik flanges, being 65 mm×15 mm angles with nosing, provide reinforcement at window and door openings.
MCL®Fibreglass Mesh is contained locally at certain openings in the base coat and continuously in the levelling and mesh coat. The MCL®Fibreglass Mesh is alkali resistant and woven with a 4 mm×4 mm aperture weighing not less than 165 grams per square mere.
The edges of the plaster are formed and supported by a number of uPVC mouldings. The MCL® Bottom J-Mould with Drip Edge and the MCL® Window/Door head with Drip Edge also provide vermin proofing and allow for drainage and ventilation to the cavity.
Movement is accommodated by providing physical breaks in the plaster. This is achieved with a uPVC moulding for the vertical movement control joint (VMCJ) and with a uPVC window head moulding and Z flashing for the horizontal movement control joint (HMCL).
Joinery shall comply with the requirements of E2/AS1 and be flashed with head and sill Z flashings as described in this Appraisal.
To provide a moisture resistant surface the completed plaster is sealed with the MCL® Water Repellent Plaster Sealer. The MCL® StuccoRite® System is completed by being waterproofed with the application of not less than a 2 coat paint system in accordance with Paragraph 9.3.7 of E2/AS1.
Components and consumables of the new system are preferably:
Battens—No. 1 framing, rough sawn or gauged 35 mm×40 mm Radiata Pine treated to H3.1 or H3.2.
Tolerance shall be + or −3 mm on both dimensions.
No. 1 framing Radiata Pine dwangs treated to H3.1 or H3.2. Minimum gauged 45 mm×90 mm.
Wall wrap complying with Table 23 of E2/AS1.
Flashing tape complying with Paragraph 4.3.11 of E2/AS!.
Powder Coated Aluminium Z flashings at head and sill of joinery.
Plain Aluminium Z flashing at garage door heads.
Mesh staples to the battens shall not be less than 1.6 mm diameter, 38 mm×9.5 mm or wider type 304 stainless steel gundriven divergent point staples.
Batten nails shall be not less than 75 mm long×2.8 mm diameter ring grip 304 stainless steel gun driven nail.
20 mm×2.8 mm diameter hot dipped galvanised round head nails.
Sealant to soffit, window/door jambs, HMCJ jointers and corners, meter box and all penetrations as per Paragraph 4.5.2 (g) of E2/AS1 which is a neutral cure silicone sealant.
At meter boxes 20 mm×20 mm×0.75 mm aluminium angle.
At decks:
M12 bolt with nut and washers; all Type 304 stainless steel length to suit.
50 mm×50 mmsq.×3 mm washer with 14 mm diameter hole, Type 304 stainless steel. 50 mm×50 mm sq.×3 mm EPDM washer.
10DN PVC Sleeve 22 mm long.
Saddle flashings as described in NZS 3604 and E2/AS1 can be used but to the dimensions described herein. Flashing material shall comply with Clause 4.10.2 of NZS 3604 or the ‘50 year’ requirement of Table 20 in E2/AS1.
Proprietary Type 304 Stainless Steel Joist Hanger minimum shear strength half span x spacing×3.35 kn (for 2.0 kpa Deck) or 4.85 kpa (for 3.0 kpa Deck)
140 mm×140 mm sq.×13 mm fibre cement board with 14 mm diameter hole.
Aluminium Z Flashings and uPVC Mouldings
MCL® Plain Aluminium deck and HMCJ Z flashings including uPVC Jointers and Corners to the HMCJ Z flashings all as described in the Technical Manual.
MCL® uPVC Bottom J-Mould with Drip Edge
MCL® uPVC Window/Door head with Drip Edge
MCL® uPVC Soffit/Sill Flange
MCL® uPVC Side Jamb Flashing
MCL® uPVC Vertical Movement Control Joint
MCL® StuccoRite® NZ 660 Multicoat Cement Plaster (25 kg bags)
MCL® StuccoRite® AL 40 SP Polymer Modified Finishing Plaster (25 kg bags and pre-mixed in plastic buckets).
MCL® Water Repellent Plaster Sealer in plastic container.
MCL® StuccoRite® Mesh Sheets by K-Lath Division of Tree Island Steel Inc, Monrovia California Fed. Spec. QQ-L-10c. (2.180 m×0.7 m)
MCL® uPVC Kwik Corner Reinforcing
MCL® uPVC Kwik Flange Reinforcing
MCL® Fibreglass Mesh with 4 mm×4 mm apertures and weighing 160 g/sqm (1 m×50 m rolls).
The MCL® plaster shall be mixed with potable water and applied to walls by a MCL® StuccoRite® Mortar Pump. These electric powered rotor/stator pumps are as shown in the Technical Manual and are supplied for purchase or hire by MCL®.
Materials for use as the plaster system are available from Mineral Coatings (NZ) Limited.
The MCL® StuccoRite® System requires a continuous concrete foundation or slab edge thickening under all walls.
The MCL® StuccoRite® System is intended to be fixed to timber walls with studs at 600 mm centres, heights up to 4.8 m and dwangs spaced at up to 900 mm centres. An additional dwang is required at soffit level as described in the Technical Manual.
The system is able to resist wind face loading up to and including those associated with VH wind speed zones.
The weight of the total system is 41 kg/m2 and does not contribute to the building lateral bracing.
The system may be fixed to wet timber framing provided the interior lining and insulation is not installed until the framing moisture content is less than 18%.
The location of Movement Control Joints (VMCJs) shall be shown on the consented building elevations in compliance with the Rules.
Vertical Movement Control Joints (VCNJ's) shall be provided at changes in elevation, at openings and to break the length of a wall into sections no wider than 8 meters or 2.75 times the panel's height all as required by the Rules hereafter. Where VMCJ's are required they shall not be located any closer than 175 mm to any penetrations including those for windows or doors.
Horizontal Movement Control Joints (MMCJ's) shall be provided at intermediate floor level where the moisture content of flooring timbers or wall plates abutting the intermediate floor is greater than 18%. Checks on moisture content shall be conducted prior to plastering commencing to ensure this requirement is met.
Where battens extend continuously past an intermediate floor (i.e. with no provision for a HMCJ) and checks before plastering reveal a moisture content higher than 18% then either the wall shall be re-battened allowing for the provision of a HMCJ at intermediate floor level or plastering operations shall be delayed until such time as the moisture content has dropped to 18% or less.
In addition to any HNCJ that may be required at the intermediate floor level, HMCJ's shall be provided at horizontal steps and to break the height of the wall into panels with a maximum average height of 5 meters except at gable ends and other certain narrow panels all as required by the Rules hereafter. Where HMCJ's are required to limit height they shall be located at an intermediate floor as shown herein.
The MCL® Stucco Rite® System allows for the construction of decks, simply supported or cantilevered. The requirements of NZS 3604 must be followed except to extent required to account for the junction.
Whilst specific materials have been specified for various employments herein, various consumables in so far as the reinforcement attachment and building up the matrix, a person skilled in the art will appreciate other alternatives that might exist Likewise in respect of any weather proofing of the plaster matrix other options to those described or described in the aforementioned website can be used.
The same mesh, without the paper backing shown in
Preferably the studs are at 600 mm centres or less.
Preferably the gaps between bottom plates and dwangs and between dwangs is a maximum of 900 mm.
The underlying frame as shown in
Battens 8 are then applied over the surface. These battens are shown over the wrap as shown in
The batten fixing with nails 10 is shown in
The construction method is preferably as previously stated. This results in a bottom panel near a foundation or concrete slab 18 having a batten 8 nailed by nails 10 into a floor plate on the slab 18 with building paper 14 interposed. A bottom member 1 as in
In
In
With reference to
Incidentally
Later drawings show other preparative arrangements and the resultant stucco panels.
A feature that enables the satisfying of likely regulatory requirements for such larger size panels (albeit nominally of 21 mm thickness) is all as shown. A major requirement is not to take panels beyond an approved size without moving control joints or by satisfying the reinforcement requirements (that preferably involves the use of an extra amount of mesh as dictated by the Rules hereinafter described) and the movement control joint requires (also as dictated by the Rules).
The bevelling of battens 8 can be seen in a number of locations to accommodate flashing taped flashings.
The usual method of construction can be seen by reference to our website mentioned previously.
Shown, by way of example, in
The second layer B is being shown applied in
Any extra mesh material (e.g. of preferably a similar type to 19) mandated by the Rules is positioned on or applied into the base layer A (e.g. by a similar technique to that shown for mesh being positioned into layer B). This is in addition to the mesh 23 requirements.
Once the mesh impregnated layer B has been smoothed the third coat can then be applied thereby to leave the plaster matrix ready for finishing in a manner as previously described. For example any suitable preset/post set water repellent/resistance coating system.
For the purpose of these Rules the alphanumeric and numeric content of the appended drawings is here included by reference.
The location of movement control joints, both vertical (VMCJ) and horizontal (HMCJ), and additional Fibreglass Mesh into the basecoat, all is required by these Rules, shall be shown on plans and specifications.
With stucco extending vertically from the base of the wall (i.e. bottom member of
The width and average height of a wall panel shall be measured between the control joints or the stucco edges (base soffit or internal/external corners) that bound the wall panel.
For the purposes of these Rules the locations and dimensions of the “openings” shall be measured to the plasters' edge.
Rule 1 A VMCJ, as required by these Rules, shall extend from the bottom member of
Rule 2 A VMCJ is required:
Rule 3 Install a HMCJ at any horizontal step in a wall panel where the width of the step is wider than 600 mm. For steps less than 600 mm embed a 400 mm square of fibreglass mesh in the basecoat diagonally across the step.
Rule 4 HMCJs shall be provided at intermediate floor level where, at the time of plastering, the moisture content of flooring timbers or wall plates abutting the intermediate floor is greater than 18%. In addition, HMCJs at intermediate floor level shall be provided where necessary to ensure the requirements on panel height are met.
The maximum average height of a MCL® Stucco Rite® wall panel shall be 5.2 m except in the following situations where the maximum height of the wall panel shall be 7 m:
Rule 5 Not withstanding the above Rules, the maximum width (L) of a wall panel shall not be greater than 2.75 times its height or 8 m.
Rule 6 A minimum separation distance of 175 mm shall be provided between the following:
In all situations above where the separation distance is less than 300 mm provide a layer of fibreglass mesh in the basecoat over the full length of the separation distance. Where the separation distance is at an opening extend the mesh 300 mm beyond each end of the opening. See
If the separation between openings is not horizontal or vertical but instead at some angle then the layer of fibreglass mesh in the basecoat shall extend out perpendicular to that angle, in both directions, over the full width of the separation for a distance of at least twice the separation distance. See
Rule 7 When the sum of the opening heights (Σh) in a wall panel exceeds 40% of the wall panel's average height (H) then reduce the wall panel's width to not greater than 6 m. When determining the sum, openings separated horizontally by 900 mm or less shall be included as shown in
Rule 8 When the ratio Σh/H as determined by Rule 7 exceeds 80% of the wall panel average height then in addition to meeting the Rule 7 a VMCJ shall be provided no further than 300 mm from each side of all openings. A VMCJ is not required if the opening is closer than 600 mm from an internal or external corner or when Rule 10 applies. See
Rule 9 When the sum of the opening widths (Σb) exceeds 60% of wall panel width (L) then a layer of fibreglass mesh embedded in to the basecoat, shall be provided between all openings between openings and the panels edges extending from 300 mm above to 300 mm below he openings. When determining the sum, openings separated vertically by 900 mm or less shall be included as shown in
Rule 10 If the distance between two openings is 1.2 m or less than two MVCJ's between the openings may be replaced by one centrally located VMCJ.
In respect of
In FIGS. 58N to 58KK are shown examples for MCJ and mesh location on single level buildings. In these drawings the key is as follows:
In FIGS. 58LL to 58MM are shown examples for MCJ and mesh location on two level buildings. In these drawings the key is as follows:
The present invention has been described by reference to the drawings and requirements that might satisfy New Zealand regulatory approvals. Whilst the description is in respect of a wooden framed structure having a cavity depth of about 35 mm clad by a reinforced and weather sealed plaster matrix of about 21 mm thick, variations that might satisfy requirements in other countries are within the scope of the present invention. Reference is drawn to our website www.mineral.co.nz/stuccorite.cfm which discloses details of the existing MCL StuccoRite cavity wall cladding system described in our Technical Manual dated January 2006.
Some features of note in the new system include:
VMCJ
Compliance with the Rules as set out we believe will enable compliance with both building code NZS3604 and plaster code NZS4251.
| Number | Date | Country | Kind |
|---|---|---|---|
| 586092 | Jun 2010 | NZ | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/IB11/52485 | 6/8/2011 | WO | 00 | 6/3/2013 |
