CLADDING INSTALLATION SYSTEM

The present invention relates to a cladding installation system for buildings.

Cladding is an outer skin applied to a building with the purpose of providing weather protection, insulation, and/or desired aesthetics. There are many different known cladding systems, involving a range and combination of materials and styles. Some cladding systems use composite panels or glass to provide the cladding surface. However, it is often desirable for the cladding to provide the appearance of traditional brickwork. One reason for using cladding to provide the effect of traditional brickwork is that the number of skilled bricklayers is decreasing so it is becoming more difficult, and in some cases prohibitively expensive, to implement traditional bricklaying methods. However, the resulting cladding panels are heavy and unwieldy. Some panels are sized up to 6 metres tall and 3 metres wide and they are difficult to handle, expensive to transport and difficult to manage onsite, requiring a large workforce to oversee installation. In addition, due to the weight of the cladding panels, it is required to use many mounting points to ensure that the cladding panels are secured to the building, which again increases the installation time and materials required on site. One solution is to simply make the panels smaller in size, and it is known to provide 0.5 m²panels, however, the onsite assembly time is drastically increased with these panels as the workers are required to install significantly more panels to create the same finish as when using larger panels.

Brick-slip cladding systems are also known, wherein the outer surface is provided by thin sections of traditional brick (referred to as ‘brick slips’). In some known systems, the brick slips are glued to a panel, which is then in turn fixed to the building to provide the cladding. The problem with using adhesives is that they will fail over time, and further, in the event of a fire, when burned, the adhesives can release toxins which can travel throughout the building and intoxicate inhabitants distal to the source of the fire. It is therefore desirable to use an alternative solution to certain types of combustible toxic adhesives.

In known brick-slip cladding systems, the supporting framework which supports the cladding panels is assembled onsite and the panels are then in turn installed on the framework. The gap between the panels where the brick slips from adjacent panels meet is then pointed. Again, with these systems, the panels are small (approximately 0.5 m²), meaning that there is still a significant amount of pointing required onsite, and the onsite time is considerable due to the pointing requirements and the assembly of the framework.

In some known cladding systems, the arrangements used for mounting the cladding panels to the building structure often do not provide a sufficient cavity between the panel and the building structure. A minimum cavity of 50 mm is recommended, and this cannot be obtained by some known systems. There is also a problem with regards to adjustability of cladding panels during installation. Typically, installation involves fixing a bracket to the building and a further bracket to the panel which are configured to engage with one another. The panel is then installed such that the brackets engage. However, there are often fine margins of error because the panel must align with all adjacent panels, and the cavity spacing (between the cladding panel and the building structure) must be consistent across the panels. If the brackets are not fixed in the correct position, this can result in the panel not being correctly positioned when it is installed.

Another problem with mounting cladding panels into position on a building or structure is the utilisation of resources as the panels are being loaded from a delivery vehicle such as lorry with lifting gear. When the lifting gear of the lorry is holding the building panels in position to allow the installer to fix the panels to the building or structure, there are a number of workers on the lorry standing around waiting on the lifting gear to return to the back of the lorry. The lifting gear must stay engaged with each cladding panel until the panels have been fixed in place on the building or structure because the lifting gear is required to hold the cladding panels accurately in position until the fixings have been secured so as to lock the cladding panels securely in place. This means that operatives on the back of the lorry are standing around waiting on the mechanical securing of each panel to the building, often taking up to an hour per panel and so labour resource utilisation is extremely poor. Likewise, when the operatives fixing the panels have completely installed each panel, they must stand around waiting on the lifting gear to return with the next panel and so operatives on the lorry as well as operatives on the building have significant downtime waiting around for extended periods.

It is therefore an object of the invention to obviate or mitigate the problems outlined above in relation to cladding installation systems and particularly brick slip cladding installation systems.

According to an aspect of the invention there is provided a cladding installation system for a building, the cladding installation system comprising a cladding mounted assembly for aiding cladding installation and a building mounted assembly for aiding cladding installation, the cladding mounted assembly comprising means for locating the cladding onto the building mounted assembly and comprising means for guiding cladding into position relative to cladding or building structure below and/or above, the building mounted assembly comprising means for guiding and locating the cladding into a final in situ position on the building and for supporting the weight of the cladding in its final in situ position, the cladding installation system being adapted for guiding, locating and securely mounting the cladding to a building structure simply by lowering the cladding into its final in situ position.

Advantageously, the lifting gear for lifting the cladding from a delivery vehicle is no longer required after the panel is lowered into the final in situ position on the building as the cladding is then supported upon the building in its final permanent position, excluding final minor adjustments. This significantly reduces the operative down time waiting on lifting gear to return to the lorry to connect the next cladding panel in the process which is normally quite a long period of time as the lifting gear is currently required to hold the existing cladding panels in position for the entire duration of the panel fixing process. In the present invention, the cladding installation system is designed in such a way that the process of installation effectively creates the permanent fixing of each cladding panel in its correct final resting place on the building, except for some fine adjustments. This improved cladding installation system dramatically reduces the amount of time taken to install and finally fix the cladding panels into their correct permanent location on the building.

Preferably, the cladding installation system comprising drainage means for draining any moisture from the top of the building mounted assembly away from the building and preferably into a cavity between the cladding and the building.

Ideally, the means for locating the cladding onto the building mounted assembly comprises mechanical coupling means formed for mechanical coupling with the building mounted assembly.

Preferably, the building mounted assembly comprises correspondingly located mechanical coupling means for mechanical coupling with the locating means of the cladding.

Ideally, the correspondingly located mechanical coupling means of the locating means of the cladding mounted assembly and the building mounted assembly comprise male and female mechanical coupling means.

Ideally, the correspondingly located mechanical coupling means of the locating means of the cladding mounted assembly comprise female mechanical coupling means and the correspondingly located mechanical coupling means of the building mounted assembly comprise male mechanical coupling means.

Ideally, the female mechanical coupling means of the locating means of the cladding mounted assembly comprise protruding flanges having an aperture, most preferably elongate. Advantageously, the elongate aperture allows some relative positional tolerance between the male and female mechanical coupling members as the male mechanical coupling means can move along the elongate aperture during and after installation.

Preferably, the male mechanical coupling means of the building mounted assembly comprises a wall mounted bracket with an upwardly projecting locating spigot formed for passing through the aperture of the protruding flange. Advantageously, an upwardly projecting locating spigot allows an operator of lifting gear lowering the cladding toward the wall mounted bracket to visually align the aperture of the protruding flange with the spigot and once engaged, this interaction helps to steer the rest of the travel of the cladding panel being lowered into its final permanent resting place in situ on the building.

Ideally, the means for locating the cladding onto the building mounted assembly comprise mechanical coupling means formed for mechanical coupling with the building mounted assembly disposed at or about an upper portion of the cladding.

Preferably, the means for locating the cladding onto the building mounted assembly comprises a plurality of spaced apart mechanical coupling means formed for mechanical coupling with a plurality of spaced apart and correspondingly located mechanical coupling means of the building mounted assembly.

Ideally, the means for locating the cladding onto the building mounted assembly comprises a pair of spaced apart mechanical coupling means disposed along an upper portion of the cladding proximal to the lateral sides of the cladding formed for mechanical coupling with a pair of spaced apart and correspondingly located mechanical coupling means of the building mounted assembly.

Preferably, the means for guiding cladding into position relative to cladding or building structure below and/or above comprise at least one guide member on a lower portion and/or an upper portion of the cladding.

Ideally, the means for guiding cladding into position relative to cladding or building structure below and/or above comprise a plurality of guide members on a lower portion and/or an upper portion of the cladding.

Preferably, the means for guiding cladding into position relative to cladding or building structure below and/or above comprise a plurality of guide members projecting beyond the lower portion and/or the upper portion of the cladding in a plane parallel to the vertical plane of the cladding.

Ideally, the cladding has an external surface facing outwards from the building when in situ and an internal surface facing towards the building.

Preferably, the plurality of guide members projecting beyond the lower portion and/or the upper portion of the cladding in a plane parallel to the vertical plane of the cladding are located on the internal surface of the cladding.

Ideally, at least one of the guide members projecting beyond the upper portion of the cladding in a plane parallel to the vertical plane of the cladding has an end portion bent out of the vertical plane at an acute angle away from the cladding. Advantageously, this allows the cladding being lowered towards this guide member some locational tolerance and this angled guide member also acts as a guide to guide any wayward position of the lower part of the cladding being lowered back into alignment with the top of the cladding below.

Preferably, the means for guiding cladding into position relative to cladding or building structure below and/or above are adapted to align the vertical outer planes of cladding. Advantageously, this alignment functionality can be built into the cladding panels in a factory environment and can improve the efficiency of the installation process reducing extensive positional adjustment in situ as well as improving the overall aesthetic impression produced by the installed cladding panels.

Ideally, the means for guiding cladding into position relative to cladding or building structure below and/or above comprise means for aligning the lateral edges of cladding located one on top of the other.

Preferably, the means for aligning the lateral edges of cladding located one on top of the other comprises at least one guide member projecting beyond the upper portion of the lower cladding in a plane parallel to the vertical plane of the cladding, the guide member having a locating means formed for receiving a lateral edge alignment guide member disposed on a lower portion of cladding, the lateral edge alignment guide member being formed for engaging with the locating means of the cladding below.

Ideally, the building mounted assembly comprising drainage means for draining any moisture from the top of the building mounted assembly away from the building and preferably into a cavity between the cladding and the building.

Ideally, the cladding is a cladding panel.

Preferably, the cladding panel comprising a frame and a backing member mounted on the frame.

Ideally, the backing member is suitable for receiving covering elements thereto.

Ideally, the cladding panel is formed mostly or entirely from non-combustible materials.

Preferably, the building mounted assembly comprising means for allowing vertical adjustment of the building mounted assembly relative to the building. Advantageously, this allows an installer to precisely align the vertical height of a row of the brackets by using a laser level for example.

Ideally, the building mounted assembly comprising means for allowing horizontal or lateral adjustment of all or part of the building mounted assembly relative to the building. Advantageously, this allows adjustment of the width of the cavity between the cladding and the building and allows for alignment or levelling of the outer vertical surface plane of adjacent cladding panels.

Preferably, the building mounted assembly comprising means for allowing vertical adjustment of the cladding mounted assembly relative to the building mounted assembly and the building. Advantageously, this allows fine vertical adjustment of the corners of the cladding panel to adjust the gaps to be pointed between the cladding panels to ensure uniformity of gaps for aesthetic appearance.

Ideally, the cladding mounted assembly comprises means for allowing lateral adjustment of the cladding panels relative to the building and one another. Advantageously, this allows fine lateral or horizontal adjustment of the cladding panels again to adjust the gaps to be pointed between the cladding panels to ensure uniformity of gaps for aesthetic appearance.

Ideally, the building mounted assembly comprises a building engagement portion configured to engage with the building structure when the building mounted assembly is fixed to a building structure.

Preferably, the building engagement portion is adapted to engage with a flat surface of a building structure. Ideally, the building engagement portion can engage with a floor slab. Ideally, the building engagement portion is fixable to a building structure.

Preferably, the building engagement portion comprises one or more elongate apertures for receiving fixing elements such as bolts to fix the building engagement portion to a surface, such as the surface of a floor slab.

Ideally, the building mounted assembly comprises a projection that projects from the building engagement portion and which is configured to fix a building mounting component to an intermediate mounting component and ultimately to the cladding mounted assembly.

Ideally, there is a cavity located between the cladding panel and the building structure when the cladding panel is installed. The size of the projection and the intermediate mounting component, and the position of the connection between the two, defines the size of the cavity between the cladding panel and the building structure.

Ideally, the cavity is 50 mm or greater, but variations in this will be apparent to the skilled person.

Preferably, the building engagement portion is planar. Ideally, the projection is an angle bracket, most preferably a U-shaped angle bracket, arranged extending from the building engagement portion.

Ideally, the upper planar surface of the projection or U-shaped angle bracket is arranged so as to be inclined downwardly from the building engagement portion between 1° and approximately 10° from the horizontal towards the cavity. Advantageously, this downwardly inclined projection facilitates drainage of moisture away from the building.

Ideally, the upper planar surface of the projection or U-shaped angle bracket comprises one or more apertures to receive fixing elements to fix, most preferably to releasably fix, the building engagement portion to the intermediate mounting component and ultimately to the cladding-panel mounted assembly. The one or more apertures are elongate slots. Advantageously, use of an elongate slot provides adjustability along the length of the projection.

Ideally, the intermediate mounting component comprises a saddle for sitting across the top of the projection.

Ideally, the saddle comprises one or more apertures to receive fixing elements to fix, most preferably to releasably fix, the intermediate mounting component to the building engagement portion and ultimately to the cladding mounted assembly. The one or more apertures are elongate slots. Advantageously, use of an elongate slot provides lateral adjustability along the length of the projection.

Ideally, the saddle comprises the upwardly projecting locating spigot.

Ideally, the spigot is formed for passing through the aperture of the protruding flange.

Preferably, the spigot is threaded with a nut below the flange and a nut above the flange.

Ideally, the nut below the flange allows small vertical adjustments to the corner of the cladding panel to accurately align the position of the cladding panel relative to the surrounding cladding panels and/or to ensure uniformity of the mortar gap therebetween.

Ideally, the nut above the flange secures the cladding panel in place in a final fixed position on the saddle.

Preferably, the building mounted assembly comprises mounting means.

Preferably, the mounting means comprises a grip means to prevent relative movement between the different components of the cladding installation system such as the building mounted assembly, the cladding mounted assembly and/or the intermediate mounting component/saddle, when the cladding installation system or component parts thereof is assembled.

Ideally, the grip means comprises a surface of the building mounted assembly, most preferably a surface of the projection of the building mounted assembly, having a topography that can engage with the topography of a surface of the intermediate mounting component/saddle, or with the topography of a surface of the cladding mounted assembly, in more than one configuration. Advantageously, if during installation it is desired to adjust the relative position of the building mounted assembly and the intermediate mounting component/saddle, for example, the component topographies can be disengaged and re-engaged in a different configuration.

Ideally, the surface topography is provided by indentations, ridges, grooves, bumps, teeth, crenelations or other suitable formation or combination thereof.

Ideally, the indentations, ridges, grooves, bumps, teeth, crenelations or other suitable formation or combination thereof are provided around the aperture or apertures, preferably elongate of the projection and saddle of the building mounted assembly.

Ideally, the surface topography is provided by a series of ridges, most preferably arranged in parallel with respect to one another.

The indentations, ridges, grooves, bumps, teeth, crenelations or other suitable formation or combination thereof may be integrally formed with the projection and/or saddle of the building mounted assembly, or may be provided by a separate piece fixed to the projection and or saddle to provide the topography.

Preferably, the cladding mounted assembly comprising means for locating the cladding onto the building mounted assembly, the means for locating comprising a cladding-panel mounting component having a first part for engaging with the intermediate mounting component or saddle and a second part for engaging with the cladding panel joined by a connecting part.

Ideally, the first and/or second parts of the cladding-panel mounting component are planar parts. Preferably, the first part is arranged at 90° or approximately 90° to the connecting part and the connecting part is arranged at 90° or approximately 90° to the second part. Ideally, the first and second parts and the connecting part are provided by an S-shaped bracket.

Ideally, the cladding-panel mounting component, most preferably the first part of the cladding-panel mounting component, comprises one or more apertures to receive fixing elements to releasably fix the cladding-panel mounting component to the intermediate mounting component. Ideally, the one or more apertures are elongate slots.

Ideally, the longitudinal axis of the elongate slot of the first part of the cladding-panel mounting component extends in a horizontal plane in use along the length of the panel from side to side. Advantageously, this allows the panel to be adjusted laterally relative to the building during and after installation.

Preferably, the cladding-panel mounting component may be operable to provide a shelf on which a cladding panel can be mounted, and/or the cladding-panel mounting component may be operable to suspend a panel from the cladding-panel mounting component and therefore from the building structure.

Ideally, the perimeter of all or some of the elongate slot or slots of the cladding installation assembly comprises a series of teeth adapted to engage with a corresponding series of teeth on the outer boundary of a washer. Advantageously, a washer may be inserted into the elongate slot such that the teeth of the washer and the teeth of the perimeter of the elongate slot engage one another, and this prevents movement of the washer along the length of the slot. A bolt or other suitable fixing element can then be inserted through the washer and through the aperture on the corresponding part of the cladding installation assembly. To adjust the lateral position of the cladding panel with respect to the building structure, the washer can be removed from the elongate slot, repositioned, and reinserted as desired.

Ideally, the fixing elements used to fix the building mounted component to the intermediate mounting component, and to fix the intermediate mounting component to the cladding-panel mounting component may be a nut-and-bolt or other suitable fixing elements.

Ideally, the backing member is formed from a non-combustible material. Preferably, the backing member is formed from cementitious material such as calcium silicate fibre cement or magnesium oxide board. Advantageously, the backing member can readily receive mechanical fixings, such as screws or bolts, to mechanically fix a covering element thereto. Further advantageously, the backing member is relatively light in weight compared to other backing members, such as steel or concrete. The combination of a frame and lightweight backing member, rather than a concrete panel, means the cladding panel overall is much lighter and therefore easier to transport and install than known cladding panels. Ideally, the backing member is fitted to the frame before transportation. Advantageously, it is not required to assemble the frame onsite, and onsite installation times are reduced.

Preferably, one or more covering elements are fixed to the backing member.

Ideally, the one or more covering elements are mechanically fixed to the backing member.

Ideally, the one or more covering elements are masonry slips such as brick slips, block slips or stone slips, or composite slips such as glass-reinforced plastic (GRP) slips, or a combination thereof.

Ideally, the covering elements have a front face, a rear face, and side faces extending between the front face and the rear face. In use, the rear face engages with the backing member.

Ideally, the covering elements are fixed to the backing member by a covering-element fixing element which is in turn fixed to the covering element and backing member.

Adhesives may also be used with the mechanical fix to enhance the connection between the covering elements and the backing member.

Preferably, the frame comprises a plurality of structural frame elements that are connected to one another and/or integrally formed with one another to define a frame.

Ideally, the cladding panel is arranged with the frame defining the rear of the cladding panel, with the backing member having a front surface for receiving covering elements. Ideally, no part of the frame is visible on the front surface. Preferably, no part of the frame extends to the front surface.

Ideally, the frame is mountable to the cladding-panel mounting component. The cladding-panel mounting component may be pre-mounted on the cladding panel before transport to the building site.

Ideally, the frame comprises one or more structural frame elements extending longitudinally in a first direction, and one or more structural frame elements extending longitudinally in a second direction. Ideally, the second direction is perpendicular or substantially perpendicular to the first direction.

Ideally, the frame comprises an upper frame element, arranged at or close to the upper edge of the backing member.

Ideally, the frame comprises a lower frame element, arranged at or close to the lower edge of the backing member.

Ideally, the upper and/or lower frame elements have apertures or openings that are configured to receive the fixing elements of the cladding-panel mounting component.

Preferably, the cladding panel may be mounted on the cladding-panel mounting component without having to secure the cladding panel thereto. Advantageously, this reduces complexity of the installation. The cladding panel can be installed by simply setting it onto a cladding-panel mounting component which is mounted on the building structure, such that the fixing elements of the cladding-panel mounting component extend through the apertures on the frame element. The cladding-panel mounting component can then be secured to the building.

Preferably, the frame comprises a side frame element, arranged at or close to the side of the backing member. Preferably, the frame comprises two side frame elements, one arranged at each side of the backing member.

Ideally, the side frame element extends between the upper and lower frame elements.

Ideally, the frame comprises one or more intermediate frame elements located extending partially or entirely between the upper and lower frame elements, and/or located extending partially or entirely between the two side frame elements. Advantageously, this strengthens the frame and the cladding panel.

Ideally, the frame is formed from a metal. Preferably, a majority of the frame is formed from steel and most preferably from light gauge steel. Ideally, at least 50%, 60%, 70%, 80%, 90%, 95%, 96%, 97%, 98% or 99% of the frame is formed from steel, most preferably light gauge steel. The entirety of the frame may be formed from steel, most preferably light gauge steel (with the possible exception of fixing elements or materials used to fix the structural frame elements together to form the frame, which may be formed from different materials to the frame elements). Light gauge steel is also known as cold-formed steel or cold-rolled steel. Use of light gauge steel ensures that the cladding panel is light in weight, and it can therefore be made to a larger size than known brick-slip cladding panels without becoming unwieldy and difficult to transport. Ideally, stainless steel is used. Advantageously, a panel spanning an entire floor may be made in this way.

The backing member may be provided by a single sheet of material, or it may be multiple sheets fixed to the frame and/or joined together.

Ideally, the panels are arrangeable extending between two floor slabs on a building, such that the panel extends from floor-to-floor.

Ideally, one panel is shaped to provide a flat outer surface of covering elements.

Ideally, a further panel is shaped to provide the appearance of a stepped column. In this panel, the frame is arranged to provide the frame of a stepped column, with the backing member fixed thereto.

Ideally, yet a further panel is arranged having both a fascia surface and a soffit surface. Advantageously, said panel can be used extending across openings such as windows, with the soffit surface extending in towards the building opening.

Combinations of the features of the stepped column and/or soffit surface may be integrated into a single panel and panels may be made with openings to accommodate windows, for example.

Ideally, the panel with the soffit surface has part of the backing member fixed to one part of the frame defining a fascia surface, and a further part of the backing member fixed to a further part of the frame defining a soffit surface, wherein the soffit surface is perpendicular or substantially perpendicular to the fascia surface.

Ideally, the frame of the panel with the soffit surface comprises a soffit frame element that extends along the rear of the backing member that defines the soffit surface. Ideally, the soffit frame element is a C-shaped beam. Ideally, one side of the C-shape beam extends along the rear of the soffit surface.

Ideally, the panel with the soffit surface is mountable to the intermediate mounting component. Ideally, the panel with the soffit surface is mounted by a cladding-panel mounting component for suspending the panel from the mounting means of the building mounted assembly. Ideally, the cladding-panel mounting component for suspending the panel is mounted in turn on the frame of the panel with the soffit surface. Ideally, the frame of the panel with the soffit surface is configured to receive the cladding-panel mounting component. Ideally, the frame comprises a surface, most preferably a planar surface, for receiving the cladding-panel mounting component. Ideally, the surface for receiving the cladding-panel mounting component comprises one or more apertures to receive the cladding-panel mounting component. Ideally, the surface for receiving the cladding-panel mounting component is located proximal to the side of the panel and preferably proximal to the upper part of the panel.

The cladding panel may extend for at least 1 m, at least 2 m, at least 3 m, at least 4 m, at least 5 m or at least 6 m in one direction. The cladding panel may have a surface area of at least 1 m², at least 4 m², at least 9 m², at least 16 m², or at least 25 m². Advantageously, despite large sizes, the cladding panel is not unwieldy due to being formed from lightweight materials.

According to a further aspect of the invention there is provided a cladding panel for a building, the cladding panel comprising a frame, and a backing member mounted on the frame, the backing member being suitable for receiving brick slips or other covering elements thereto, the panel comprising a cladding mounted assembly for aiding cladding installation onto a building mounted assembly, the cladding mounted assembly comprising means for locating the cladding onto the building mounted assembly and comprising means for guiding cladding into position relative to cladding or building structure below and/or above.

The cladding panel may comprise any features in any combination of any cladding panel described above in relation to the cladding system.

According to a further aspect of the invention there is provided a building, wherein the building is cladded using a cladding installation system.

The cladding installation system may comprise any features in any combination of the cladding system described above.

Ideally, the building comprises a flat surface provided by a cladding panel mounted extending between two spaced apart floor slabs. Ideally, wherein one floor slab is located above the other floor slab.

Ideally, the building comprises a stepped column provided by a cladding panel mounted extending between two spaced apart floor slabs. Ideally, wherein one floor slab is located above the other floor slab.

Ideally, the building comprises a soffit surface and fascia surface provided by a cladding panel.

Ideally, the majority of the building is cladded in the cladding system. Most preferably, at least 80%, 85%, 90% or 95% of the building is cladded in the cladding system.

According to a further aspect of the invention there is provided a method for cladding a building using a cladding installation system, the method comprising using a cladding mounted assembly for aiding cladding installation and using a building mounted assembly for aiding cladding installation, the cladding mounted assembly comprising means for locating the cladding onto the building mounted assembly and comprising means for guiding cladding into position relative to cladding or building structure below and/or above, the building mounted assembly comprising means for guiding and locating the cladding into a final in situ position on the building and for supporting the weight of the cladding in its final in situ position, the method comprising lowering the cladding and cladding mounted assembly towards the building mounted assembly so that the locating means of the cladding mounted assembly engages with the guiding and locating means of the building mounted assembly and so that the cladding guiding means of the cladding mounted assembly engages with the cladding or building structure below so that the cladding installation system guides, locates and securely mounts the cladding to a building structure simply by lowering the cladding towards the building mounted assembly into its final in situ position.

Ideally, the method comprises fixing the building mounted assembly to a building structure, such as a floor slab.

Preferably, the method comprises fixing a cladding installation assembly to a cladding panel.

Ideally, the method comprises the step of installing a single panel extending from one floor to the floor directly above or below said floor. The method may comprise installing a plurality of panels adjacent to each other to clad the majority or entirety of a building. Ideally, the method comprises the step of installing a panel suspended from the mounting means of the building mounted assembly.

The method may comprise the step of fitting waterproof membranes and/or insulation between and/or around the panels.

The method comprising the step of adding waterproof seals between and/or around the panels.

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

FIG. 1 is a perspective of a cladding panel according to the invention;

FIG. 2 is a vertical cross section view of the cladding installation system between the two cladding panels and a floor slab;

FIG. 3 is a section view of cladding installation system;

FIG. 4 is an elevation view of the cladding installation system of FIG. 3; and

FIG. 5 is a plan view of the cladding installation system of FIGS. 3 and 4.

FIG. 6 is a perspective of view of the cladding installation system 1 according to the invention.

FIG. 7 is a section view of the cladding installation system of FIG. 6.

FIG. 8 is a section view of the cladding installation system of FIG. 6.

FIG. 9 is a front view of an arrangement for aligning the lateral edges of cladding according to the invention.

FIG. 10 is a perspective view of an arrangement for guiding cladding into position relative to cladding or building structure.

FIG. 11 is a side view of an arrangement for guiding cladding into position relative to cladding or building structure of FIG. 10.

In the drawings there is shown a cladding installation system for a building, the cladding installation system being indicated generally by reference numeral 1.

The cladding installation system 1 for a building 2 see FIG. 2, has a cladding mounted assembly 3 for aiding cladding installation and a building mounted assembly 4 for aiding cladding installation. The cladding mounted assembly 3 having an arrangement 6 for locating the cladding 5 onto the building mounted assembly 4 and having an arrangement 50 for guiding cladding 5 into position relative to cladding 5 or building structure below and/or above. The building mounted assembly 4 having an arrangement 7 for guiding and locating the cladding 5 into a final in situ position on the building 2 and for supporting the weight of the cladding 5 in its final in situ position. The cladding installation system 1 being adapted for guiding, locating and securely mounting the cladding 5 to a building structure 2 simply by lowering the cladding 5 into its final in situ position.

Advantageously, the lifting gear not shown for lifting the cladding 5 from a delivery vehicle is no longer required after the cladding panel 5 is lowered into the final in situ position on the building 2 as the cladding 5 is then supported upon the building 2 in its final permanent position, excluding final minor adjustments. This significantly reduces the operative down time waiting on lifting gear to return to the lorry to connect the next cladding panel 5 in the process which is normally quite a long period of time as the lifting gear is currently required to hold the existing cladding panels 5 in position for the entire duration of the panel fixing process. In the present invention, the cladding installation system 1 is designed in such a way that the process of installation effectively creates the permanent fixing of each cladding panel 5 in its correct final resting place on the building 2, except for some fine adjustments. This improved cladding installation system 1 dramatically reduces the amount of time taken to install and finally fix the cladding panels 5 into their correct permanent location on the building 2.

The cladding installation system 1 comprising a drainage arrangement 8 see FIG. 2 for draining any moisture from the top of the building mounted assembly 4 away from the building 2 and preferably into a cavity 11, see FIG. 2 between the cladding 5 and the building 2. The arrangement 6 for locating the cladding 5 onto the building mounted assembly 4 is a mechanical coupling arrangement 6 formed for mechanical coupling with the building mounted assembly 4. The building mounted assembly 4 has correspondingly located mechanical coupling arrangement 7 for mechanical coupling with the locating arrangement 6 of the cladding 5. The correspondingly located mechanical coupling arrangement 6 of the locating arrangement 6 of the cladding 5 and the building mounted assembly 4 comprise male 7 and female 6 mechanical coupling arrangements 7, 6. The correspondingly located mechanical coupling arrangement 6 of the locating arrangement 6 of the cladding 5 comprise female mechanical coupling arrangements 6 and the correspondingly located mechanical coupling arrangements 7 of the building mounted assembly 4 comprise male mechanical coupling arrangements 7. The female mechanical coupling arrangement 6 of the locating arrangement 6 of the cladding 5 comprises protruding flanges 12 having an elongate aperture 6. Advantageously, the elongate aperture 6 allows some relative positional tolerance between the male and female mechanical coupling members 6, 7 as the male mechanical coupling member 7 can move along the elongate aperture 6 during and after installation.

The male mechanical coupling arrangement 7 of the building mounted assembly 4 comprises a wall mounted bracket 14 with an upwardly projecting locating spigot 7 formed for passing through the aperture 6 of the protruding flange 12. Advantageously, an upwardly projecting locating spigot 7 allows an operator of lifting gear lowering the cladding 5 toward the wall mounted bracket 14 to visually align the aperture 6 of the protruding flange 12 with the spigot 7 and once engaged, this interaction helps to steer the rest of the travel of the cladding panel 5 being lowered into its final permanent resting place in situ on the building 2.

The arrangement 6 for locating the cladding 5 onto the building mounted assembly 4 is a pair of mechanical coupling arrangements 6 formed for mechanical coupling with the building mounted assembly 4 disposed at or about an upper portion of the cladding 5. The arrangement 6 for locating the cladding 5 onto the building mounted assembly 4 has a pair of spaced apart mechanical coupling arrangements 12 disposed along an upper portion of the cladding 5 proximal to the lateral sides of the cladding 5 formed for mechanical coupling with a pair of spaced apart and correspondingly located mechanical coupling arrangements 7 of the building mounted assembly 4.

The arrangement for guiding cladding 50 into position relative to cladding 5 or building structure below and/or above comprise at least one and preferably a plurality of guide members 51 on a lower portion 5′ and/or an upper portion 5″ of the cladding 5. The arrangement for guiding cladding 50 into position relative to cladding 5 or building structure below and/or above comprise a plurality of guide members 51 projecting beyond the lower portion 5′ and/or the upper portion 5″ of the cladding 5 in a plane parallel to the vertical plane of the cladding 5. The cladding 5 has an external surface 15 facing outwards from the building 2 when in situ and an internal surface 16 facing towards the building 2. The plurality of guide members 51 projecting beyond the lower portion 5′ and/or the upper portion 5″ of the cladding 5 in a plane parallel to the vertical plane of the cladding 5 are located on the internal surface 16 of the cladding 5.

At least one of the guide members 51 projecting beyond the upper portion 5″ of the cladding 5 in a plane parallel to the vertical plane of the cladding 5 has an end portion 52 bent out of the vertical plane at an acute angle away from the cladding 5. Advantageously, this allows the cladding 5 being lowered towards this guide member 51 some tolerance for initial locational inaccuracy and this angled guide member 51 also acts as a guide to guide any wayward position of the lower part of the cladding 5 being lowered back into alignment with the top of the cladding below.

The guiding arrangement for guiding cladding 5 into position relative to cladding 5 or building structure below and/or above are adapted to align the vertical outer planes of cladding 5. Advantageously, this alignment functionality can be built into the cladding panels 5 in a factory environment and can improve the efficiency of the installation process reducing extensive positional adjustment in situ as well as improving the overall aesthetic impression produced by the installed cladding panels 5. The arrangement for guiding cladding into position relative to cladding or building structure below and/or above comprises an arrangement 60 for aligning the lateral edges 17′, 17″ of cladding 5 located one on top of the other. The arrangement for aligning the lateral edges 17′, 17″ of cladding 5 located one on top of the other comprises at least one guide member 61 projecting beyond the upper portion of the lower cladding 5 in a plane parallel to the vertical plane of the cladding, the guide member 61 having a locating arrangement 62 formed for receiving a lateral edge alignment guide member 63 disposed on a lower portion of cladding 5, the lateral edge alignment guide member 63 being formed for engaging with the locating arrangement 62 of the cladding below.

The building mounted assembly 4 has a drainage arrangement 8 for draining any moisture from the top of the building mounted assembly 4 away from the building 2 and preferably into the cavity 11 between the cladding panel 5 and the building 2. The cladding 5 is a cladding panel 5. The cladding panel 5 has a frame 17 and a backing member 18 mounted on the frame 17. The backing member 18 is provided with covering elements 19 in the form of slips such as brick slips.

The cladding panel 5 is formed mostly or entirely from non-combustible materials. The building mounted assembly 4 has an arrangement 21 for allowing vertical adjustment of the building mounted assembly 4 relative to the building 2. Advantageously, this allows an installer to precisely align the vertical height of a row of brackets by using a laser level for example. The building mounted assembly 4 also has an arrangement 22 for allowing horizontal or lateral adjustment of part of the building mounted assembly 4 relative to the building 2. Advantageously, this allows adjustment of the width of the cavity 11 between the cladding 5 and the building 2 and allows for alignment or levelling of the outer vertical surface plane of adjacent cladding panels 5. The building mounted assembly 4 also has an arrangement 23 for allowing vertical adjustment of the cladding mounted assembly 3 relative to the building mounted assembly 4 and the building 2. Advantageously, this allows fine vertical adjustment of the corners of the cladding panel 5 to adjust the gaps to be pointed between the cladding panels 5 to ensure uniformity of pointing gaps for aesthetic appearance. The cladding mounted assembly 3 also has an arrangement 24 for allowing lateral adjustment of the cladding panels relative to the building 2 and one another. Advantageously, this allows fine lateral or horizontal adjustment of the cladding panels 5 again to adjust the gaps to be pointed between the cladding panels 5 to ensure uniformity of gaps for aesthetic appearance.

The building mounted assembly 4 has a building engagement portion 25 configured to engage with the building structure 2 when the building mounted assembly 4 is fixed to a building structure 2. The building engagement portion 25 is adapted to engage with a flat surface of a building structure 2. The building engagement portion 25 can engage with a floor slab 26. The building engagement portion 25 is fixed to the building structure 2. The building engagement portion 25 has an elongate aperture 27 for receiving a fixing elements such as bolts 28 to fix the building engagement portion 4 to a surface, such as the surface of a floor slab 26.

The building mounted assembly 4 has a projection 29 that projects from the building engagement portion 25 and which is configured to fix the building mounting component 4 to an intermediate mounting component 31 and ultimately to the cladding mounted assembly 3. Cavity 11 is located between the cladding panel 5 and the building structure 2 when the cladding panel 5 is installed. The size of the projection 29 and the intermediate mounting component 31, and the position of the connection between the two, defines the size of the cavity 11 between the cladding panel 5 and the building structure 2. Ideally, the cavity 11 is 50 mm or greater, but variations in this will be apparent to the skilled person.

The building engagement portion 25 is planar. The projection 29 is an angle bracket, most preferably a U-shaped angle bracket, arranged extending from the building engagement portion 25. Ideally, the upper planar surface of the projection 29 or U-shaped angle bracket is arranged so as to be inclined downwardly from the building engagement portion 25 between 1° and approximately 10° from the horizontal towards the cavity 11, best illustrated in FIG. 3. Advantageously, this downwardly inclined projection 29 facilitates drainage of moisture away from the building 2 into the cavity 11.

The upper planar surface of the projection 29 or U-shaped angle bracket 29 has one elongate aperture 22 to receive fixing element 33 to fix, most preferably to releasably fix, the building engagement portion 25 and projection 29 to the intermediate mounting component 31 and ultimately to the cladding-panel mounted assembly 3. Advantageously, use of an elongate slot 22 provides adjustability along the length of the projection 29. The intermediate mounting component 31 is a saddle 31 for sitting across the top of the projection 29. The saddle 31 also has one elongate aperture 22 to receive fixing element 33 to fix, most preferably to releasably fix, the intermediate mounting component 31 to the building engagement portion 25 and ultimately to the cladding mounted assembly 3. Advantageously, use of an elongate slot 22 provides lateral adjustability along the length of the projection 29. The saddle 31 has the upwardly projecting locating spigot 7. The spigot 7 is formed for passing through the aperture 6 of the protruding flange 12. The spigot 7 is threaded with a nut 35 below the flange 12 and a nut 36 above the flange 12, see FIG. 2. The nut 35 below the flange 12 allows small vertical adjustments to the corner of the cladding panel 5 to accurately align the position of the cladding panel 5 relative to the surrounding cladding panels 5 and/or to ensure uniformity of the mortar gap therebetween. The nut 36 above the flange 12 secures the cladding panel in place in a final fixed position on the saddle 31.

The cladding installation system has a grip arrangement to prevent relative movement between the different components of the cladding installation system such as the building mounted assembly 4, the cladding mounted assembly 3 and/or the intermediate mounting component/saddle 31, when the cladding installation assembly 3 or component parts thereof is assembled. The grip arrangement has a surface of the building mounted assembly 4, most preferably a surface of the projection 29 of the building mounted assembly 4, having a topography that can engage with the topography of a surface of the intermediate mounting component/saddle 31, or with the topography of a surface of the cladding mounted assembly 3, in more than one configuration. Advantageously, if during installation it is desired to adjust the relative position of the building mounted assembly 4 and the intermediate mounting component/saddle 31, for example, the component topographies can be disengaged and re-engaged in a different configuration. The surface topography is provided by indentations, ridges, grooves, bumps, teeth, crenelations or other suitable formation or combination thereof. The indentations, ridges, grooves, bumps, teeth, crenelations or other suitable formation or combination thereof are provided around the elongate apertures 22 of the projection 29 and saddle 31 of the building mounted assembly 4. The surface topography is provided by a series of ridges, most preferably arranged in parallel with respect to one another. These indentations, ridges, grooves, bumps, teeth, crenelations or other suitable formation or combination thereof may be integrally formed with the projection 29 and/or saddle 31 of the building mounted assembly 4, or may be provided by a separate piece fixed to the projection and or saddle to provide the topography.

The cladding mounted assembly 3 has an arrangement for locating the cladding onto the building mounted assembly 4, the locating arrangement having a cladding-panel mounting component 38 having a first part for engaging with the intermediate mounting component 31 or saddle 31 and a second part for engaging with the cladding panel 5 joined by a connecting part. The first and/or second parts of the cladding-panel mounting component 38 are planar parts. The first part is arranged at 90° or approximately 90° to the connecting part and the connecting part is arranged at 90° or approximately 90° to the second part. The first and second parts and the connecting part are provided by an S-shaped bracket 38. The cladding-panel mounting component 38 and the first part of the cladding-panel mounting component, comprises an elongate aperture 6 to receive fixing element/spigot 7 to releasably fix the cladding-panel mounting component 38 to the intermediate mounting component 31. The longitudinal axis of the elongate slot 6 of the first part of the cladding-panel mounting component 38 extends in a horizontal plane in use along the length of the panel 5 from lateral side to side. Advantageously, this allows the panel 5 to be adjusted laterally relative to the building 2 during and after installation.

The cladding-panel mounting component 38 is operable to provide a shelf on which a cladding panel 5 is mounted, and/or the cladding-panel mounting component 38 is operable to suspend a panel 5 from the cladding-panel mounting component 38 and therefore from the building structure 2.

The perimeter of all or some of the elongate slot or slots 6, 21, 22, 24 of the cladding installation assembly 1 have a series of teeth adapted to engage with a corresponding series of teeth on the outer boundary of a washer. Advantageously, a washer may be inserted into the elongate slot such that the teeth of the washer and the teeth of the perimeter of the elongate slot engage one another, and this prevents movement of the washer along the length of the slot. A bolt 7, 28, 33 or other suitable fixing element can then be inserted through the washer and through the aperture on the corresponding part of the cladding installation assembly 1. To adjust the lateral position of the cladding panel 5 with respect to the building structure 2, the washer can be removed from the elongate slot, repositioned, and reinserted as desired.

The fixing elements used to fix the building mounted component 4 to the intermediate mounting component 31, and to fix the intermediate mounting component 31 to the cladding-panel mounting component 38 is a nut-and-bolt or other suitable fixing elements. The backing member 18 is formed from a non-combustible material. Preferably, the backing member 18 is formed from cementitious material such as calcium silicate fibre cement or magnesium oxide board. Advantageously, the backing member 18 can readily receive mechanical fixings, such as screws or bolts, to mechanically fix a covering element 19 thereto. Further advantageously, the backing member 18 is relatively light in weight compared to other backing members, such as steel or concrete. The combination of a frame 17 and lightweight backing member 18, rather than a concrete panel, means the cladding panel 5 overall is much lighter and therefore easier to transport and install than known cladding panels. The backing member 18 is fitted to the frame 17 before transportation. Advantageously, it is not required to assemble the frame 17 onsite, and onsite installation times are reduced. The covering elements 19 are mechanically fixed to the backing member 18. The covering elements 19 are masonry slips such as brick slips, block slips or stone slips, or composite slips such as glass-reinforced plastic (GRP) slips, or a combination thereof. The covering elements 19 have a front face, a rear face, and side faces extending between the front face and the rear face. In use, the rear face engages with the backing member 18. The covering elements 19 are fixed to the backing member by a covering-element fixing element which is in turn fixed to the covering element 19 and backing member 18. Adhesives may also be used with the mechanical fix to enhance the connection between the covering elements 19 and the backing member 18.

The frame 17 comprises a plurality of structural frame elements that are connected to one another and/or integrally formed with one another to define a frame. The cladding panel 5 is arranged with the frame defining the rear of the cladding panel 5, with the backing member 18 having a front surface for receiving covering elements 19. No part of the frame 17 is visible on the front surface and no part of the frame 17 extends to the front surface. The frame 17 is mountable to the cladding-panel mounting component 38. The cladding-panel mounting component 38 is pre-mounted via welding for example on the cladding panel 5 before transport to the building site. The frame 17 has structural frame elements 17 extending longitudinally in a first direction, and one or more structural frame elements extending longitudinally in a second direction perpendicular or substantially perpendicular to the first direction. The frame 17 has an upper frame element, arranged at or close to the upper edge of the backing member 18. The frame 17 has a lower frame element, arranged at or close to the lower edge of the backing member 18. The frame 17 has a side frame element, arranged at or close to the side of the backing member 18. The frame 17 has two side frame elements, one arranged at each side of the backing member 18. The side frame element extends between the upper and lower frame elements. The frame 17 has one or more intermediate frame elements located extending partially or entirely between the upper and lower frame elements, and/or located extending partially or entirely between the two side frame elements. Advantageously, this strengthens the frame 17 and the cladding panel 5. The frame 17 is formed from a metal. A majority of the frame is formed from steel and most preferably from light gauge steel. Ideally, at least 50%, 60%, 70%, 80%, 90%, 95%, 96%, 97%, 98% or 99% of the frame is formed from steel, most preferably light gauge steel. The entirety of the frame 17 may be formed from steel, most preferably light gauge steel (with the possible exception of fixing elements or materials used to fix the structural frame elements together to form the frame, which may be formed from different materials to the frame elements). Light gauge steel is also known as cold-formed steel or cold-rolled steel. Use of light gauge steel ensures that the cladding panel is light in weight, and it can therefore be made to a larger size than known brick-slip cladding panels without becoming unwieldy and difficult to transport. Stainless steel is used. Advantageously, a panel spanning an entire floor may be made in this way.

The backing member 18 may be provided by a single sheet of material, or it may be multiple sheets fixed to the frame and/or joined together. The panels 5 are arrangeable extending between two floor slabs 26 on a building 2, such that the panel extends from floor-to-floor. One panel 5 is shaped to provide a flat outer surface of covering elements 19. A further panel 5 is shaped to provide the appearance of a stepped column. In this panel, the frame 17 is arranged to provide the frame of a stepped column, with the backing member 18 fixed thereto. Yet a further panel 5 is arranged having both a fascia surface and a soffit surface. Advantageously, said panel 5 can be used extending across openings such as windows, with the soffit surface extending in towards the building opening.

Combinations of the features of the stepped column and/or soffit surface may be integrated into a single panel and panels may be made with openings to accommodate windows, for example. The panel with the soffit surface has part of the backing member fixed to one part of the frame defining a fascia surface, and a further part of the backing member fixed to a further part of the frame defining a soffit surface, wherein the soffit surface is perpendicular or substantially perpendicular to the fascia surface. The frame of the panel with the soffit surface comprises a soffit frame element that extends along the rear of the backing member that defines the soffit surface. The soffit frame element is a C-shaped beam. One side of the C-shape beam extends along the rear of the soffit surface. The panel with the soffit surface is mountable to the intermediate mounting component. The panel with the soffit surface is mounted by a cladding-panel mounting component for suspending the panel from the mounting arrangement of the building mounted assembly. The cladding-panel mounting component for suspending the panel is mounted in turn on the frame of the panel with the soffit surface. The frame of the panel with the soffit surface is configured to receive the cladding-panel mounting component. The frame comprises a surface, most preferably a planar surface, for receiving the cladding-panel mounting component. The surface for receiving the cladding-panel mounting component comprises one or more apertures to receive the cladding-panel mounting component. The surface for receiving the cladding-panel mounting component is located proximal to the side of the panel and preferably proximal to the upper part of the panel.

The cladding panel 5 may extend for at least 1 m, at least 2 m, at least 3 m, at least 4 m, at least 5 m or at least 6 m in one direction. The cladding panel may have a surface area of at least 1 m², at least 4 m², at least 9 m², at least 16 m², or at least 25 m². Advantageously, despite large sizes, the cladding panel 5 is not unwieldy due to being formed from lightweight materials. Seals 40 are provided along the vertical and horizontal joints between the panels. An EPDM D seal is installed in the factory along the horizontal and vertical joints in combination with a backing rod and a mastic sealant along the horizontal joint. A cavity fire barrier 41 is disposed below the projection 29 on the insulation and the panel 5. The cavity fire barrier has a cassette on the panel 5 for receiving an expanding intumescent strip fixed to the insulation.

The skilled person will appreciate that all preferred or optional features of the invention described with reference to only some aspects or embodiments of the invention may be applied to all aspects of the invention.

It will be appreciated that optional features applicable to one aspect of the invention can be used in any combination, and in any number. Moreover, they can also be used with any of the other aspects of the invention in any combination and in any number. This includes, but is not limited to, the dependent claims from any claim being used as dependent claims for any other claim in the claims of this application.

In relation to the detailed description of the different embodiments of the invention, it will be understood that one or more technical features of one embodiment can be used in combination with one or more technical features of any other embodiment where the transferred use of the one or more technical features would be immediately apparent to a person of ordinary skill in the art to carry out a similar function in a similar way on the other embodiment.

The features disclosed in the foregoing description or the following drawings, expressed in their specific forms or in terms of a means for performing a disclosed function, or a method or a process of attaining the disclosed result, as appropriate, may separately, or in any combination of such features be utilised for realising the invention in diverse forms thereof.

CLADDING INSTALLATION SYSTEM

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CPC

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Abstract

Description

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Priority Claims (1)