The present invention relates to methods and apparatus for mounting cladding sheets over masonry or steel frame work. The invention has been developed primarily for use with fibre reinforced cement cladding sheets and will be described hereinafter with reference to this application. It will be appreciated, however, that the invention is also applicable to other cladding materials.
Battens have previously been used by the applicant in their facade and fascia cladding systems. These battens are sometimes referred to as “top hats” due to their inverted U-shaped cross-section and outwardly splayed edge flanges. The function of these battens or top hats is to provide a planar fixing frame for connection of cladding sheets. As will be appreciated by those skilled in the art, when applying cladding sheets over an uneven surface it is important that the frame on which the cladding sheets are mounted is planar. By the addition of packing materials, and spacers in conjunction with top hat battens, such a planar fixing frame can be obtained.
A known example of a conventional cladding system is shown in
The applicants have found that such top hat batten sections allow the main structural framing elements of the wall 10 to be spaced further apart, with the top hat battens spanning the structural elements to provide fixing points for the cladding sheets. It will be appreciated that this provides a substantial cost saving with regard to both the materials and labour required for framing.
Conventional top hat battens, however, have several drawbacks. Firstly, the generally require gaskets 31, backing strips 32 and sealants to provide adequate weatherproofing of the cladding system. Apart from the additional cost associated with such gaskets and backing strips, poor installation techniques may result in misalignment of the cladding sheets and damage to the sheets from over stressing along their edges, as well as inadequate waterproofing. The process is also labour intensive.
Additionally, the generally narrow width of the platform section 28 of the top hat battens requires fasteners to be located close to the sheet edges, as shown in
Lastly, in use it will be appreciated that stresses can be applied to the cladding sheet either internally or externally which can compromise the strength, weatherproofing or durability of conventional cladding systems. For example, external stress may be applied to a cladding sheet by wind loading or by thermal expansion or contraction of the sub-frame or battens themselves. Internal stresses may arise, for example, from within the fibre reinforced sheet due to moisture movement, carbonation shrinkage etc. In either case, such stresses can lead to premature wear, leakage, or even failure of various elements in the system.
The present invention seeks to overcome or substantially ameliorate one or more of these disadvantages of the prior art, or at least to provide a useful alternative.
In a broad aspect, the present invention provides a batten for mounting cladding sheets to a wall or frame, said batten comprising an elongate channel member having a pair of spaced apart side walls joined by an intermediate web, and a corresponding pair of mounting flanges spaced outwardly from the web and extending laterally from the side walls, the web being adapted for connection to the wall or frame, the flanges being adapted for connection to the cladding sheets, and the batten being configured such that stress applied to the cladding sheets in use results in preferential deformation of the batten.
The deformation is preferably elastic in mode, but may alternatively be plastic or a combination of both elastic and plastic deformation. The force required to displace one of the side walls of the batten, is preferably less than that which would normally induce failure in the cladding sheets due to expected movement or contraction as a result of changes in moisture content. In the preferred embodiment, the battens are configured such that the side walls flex by a predetermined amount, depending upon the stresses likely to be applied by corresponding cladding sheets of preselected size, thickness, material composition, moisture content and other specific characteristics. In this way, the battens can be individually tailored to the cladding sheets and their specific application.
Preferably, the channel member is generally U, omega (Ω) or V-shaped. Preferably, the side walls diverge outwardly from the web toward the mounting flanges, but in other embodiments may alternatively be generally parallel or converge inwardly. The side walls may optionally also be perforated or defined intermittently by spaced apart arms, tabs, fingers or lugs.
In the preferred embodiment, the present invention further provides a sealing strip which, in use, closes the open channel portion of the batten, intermediate the side walls. Also, in the preferred embodiment, the cladding sheets are connected to the mounting flanges by means of discrete fastening elements, ideally in the form of self-tapping screws.
Preferably, the mounting flanges are formed with respective longitudinally extending recessed channels configured, in use, to provide a clearance space between the cladding sheets and the mounting flanges. By extending through this clearance space, the mounting screws are preferably disposed to accommodate a limited degree of pivotal movement, thereby permitting a limited degree of relative lateral displacement in two dimensions between the cladding sheet and the batten, in the plane of the sheet. The recessed channels advantageously also facilitate drainage and thereby help to prevent ingress of water in adverse weather conditions.
According to a second aspect, the invention provides a method for mounting cladding sheets to a wall or frame using battens as previously defined, said method including the steps of positioning a plurality of said battens in spaced apart generally parallel relationship by fastening the web of each batten to the wall or frame, and securing the longitudinal edges of each cladding sheet to the respective mounting flanges of selected battens, such that stress applied to the cladding sheets results in preferential deformation of one or more of the battens.
In the preferred embodiment, the battens positioned between the outer edges of the sheets are adapted to be used in a reverse orientation, to provide intermediate internal support for the sheets. In this reverse orientation, the flanges are preferably connected to the frame or wall, and the cladding sheet is connected to the web.
The web preferably also includes a longitudinally extending recessed channel, configured to the normal orientation to provide a clearance space between the wall or frame and the web, and in the reverse orientation between the cladding sheet and the web. This arrangement allows pivotal movement of the mounting screws extending into the web, in the manner previously described, to permit a limited degree of relative lateral displacement in two dimensions, between the cladding sheet and the batten in the reverse orientation, or between the wall or frame and the batten in the normal orientation. Independently of the relative displacement accommodated by flexural deformation of the side walls.
According to a third aspect, the invention provides a batten for mounting cladding sheets to a wall or frame, said batten comprising an elongate channel member having a pair of spaced apart side walls joined by an intermediate web, and a pair of mounting flanges spaced outwardly from the web and extending laterally from the side walls, the web being adapted for connection too the wall or frame, and the flanges being adapted for connection to the cladding sheets by fastening elements, wherein at least one of the flanges includes a longitudinally extending recessed channel configured, in use, to provide a clearance space between the cladding sheet and the mounting flange such that a limited degree of relative lateral displacement in two dimensions between the cladding sheet and the batten is accommodated by pivotal movement of the fastening elements.
Preferably, both of the flanges include respective longitudinally extending recessed channels, and the fastening elements are preferably screws.
In the preferred embodiment, the web of the batten also includes a longitudinally extending recessed channel configured, in an analogous manner, to permit a limited degree of lateral displacement in two dimensions between the batten and the wall or frame in the normal orientation, or between the batten and the cladding sheets in the reverse orientation, by pivotal movement of the respective mounting screws.
Unless the context clearly requires otherwise, throughout the description and the claims, the words ‘comprise’, ‘comprising’, and the like are to be construed in an inclusive sense as opposed to an exclusive or exhaustive sense: that is to say, in the sense of “including, but not limited to”.
A preferred embodiment of the invention will now be described, by way of example only, with reference to the accompanying drawings in which:
Referring firstly to
The side walls diverge outwardly from the web, and terminate in corresponding flanges 125 and 145 extending laterally from their free edges. These flanges are adapted for connection to the cladding sheets as described below. In other embodiments, the side walls may be generally parallel, convergent, curved, V-shaped, omega (Ω) shaped, or be formed with any other suitable profile.
A detachable sealing strip 200, as shown in
As shown more clearly in
As shown in
An alternative batten is shown in
As will be clear to those skilled in the art, the battens 100 according to the present invention provide substantial advantages over the conventional prior art batten shown in
In addition to the above, the side walls 120 and 140 of the batten 100 are configured to deform preferentially over the cladding sheets, as a result of stress applied to or by the sheets. More particularly, the dimensions of cladding sheets such as fibre reinforced cement cladding sheets may alter over time. Some FRC sheets, for example, can expand or shrink due to moisture, carbonation etc. When the cladding sheet 300 shrinks, stress is applied to the edges 310 of the sheets via its connection with the supporting batten and frame. With known battens, this shrinkage can be sufficient to cause deformation, cracking or even failure of the cladding sheet 300 at its edges or elsewhere.
The present invention overcomes this problem by configuring the batten 100 to yield to such as applied stress in preference to deformation or failure of the cladding sheets 300. When the cladding sheets shrink, for example, the sides 120 and 140 of the supporting battens 100 would deform outwardly in response.
Similar deformation would result from external stresses. For example, the battens 100 will preferably yield to thermal expansion of frame or wall 50, wind loading, or the like within certain tolerances, thereby substantially isolating the cladding sheets from such stresses.
As shown in the drawings, it is also preferable that the cladding sheets 300 are connected directly to the battens 100 without packing, gaskets or the like. This saves material costs, reduces labour time, and avoids possible difficulties with over tightening the fastening screws. When connecting the cladding sheet to the batten by screwing, once the cladding sheet sits squarely on the flanges 125 and 145 no further tightening of the screws 325 is required. This contrasts with the prior art as shown in
The preferred configurations shown in
Such a configuration also provides two pressure equalized drainage channels 123 and 143 on either side of the sealing strip. Any moisture which does manage to migrate past the primary contact seals 122 and 142 can drain through the adjacent drainage channels. Further pairs of secondary contact seals 124 and 144 are provided by the corresponding flange portions 125 and 145 contacting the respective cladding sheets. In between these secondary pairs of contact seals, respective secondary drainage channels 126 and 146 are provided in much the same fashion as drainage channels 123 and 143.
It will there be clear to those skilled in the art that not only does the inventive batten 100 remove the need for additional packing, gaskets, and the like to provide a weatherproof seal, it does not rely only on one contact region to provide a weatherproof seal. Rather, it provides a series of primary and secondary contact seals with drainage channels disposed therebetween to virtually eliminate the prospect of moisture migrating behind the cladding sheets. It should also be recognised that the batten 100 provides a much simpler mechanism for installation over the conventional system shown in
A further advantage of the present invention relates to the ability of the batten 100 to permit movement of the fastening screws relative to the cladding sheets. As shown most clearly in
It will be also noted that the web of the batten incorporates a similar longitudinal recess or groove 150, which functions in an analogous manner to allow pivoting of the associated fastening screws extending therethrough. This is particularly advantageous in the case of those battens installed in intermediate locations in the reverse orientation, as shown in
It will be appreciated that by varying the gauge thickness, by using a higher or lower strength material, by using different materials, or by altering the cross sectional profile, the battens can be specifically tailored to match the stresses expected to be applied by or to the cladding sheets. Further, the shape of the recessed fixing grooves and drainage channels 126/146 may be altered such that the batten can accommodate additional shrinkage or swelling of the cladding sheet. In all these respects, the invention represents a practical and commercially significant improvement over the prior art.
Although the invention has been described with reference to specific examples, it will be appreciated by those skilled in the art that the invention may be embodied in many other forms. In particular, the sealing strips and battens can be constructed from any suitable materials including metal or plastic. Moreover, the battens can be configured to deform elastically or plastically depending upon requirements.
Number | Date | Country | Kind |
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PP9803 | Apr 1999 | AU | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
---|---|---|---|---|
PCT/AU00/00320 | 4/14/2000 | WO | 00 | 5/29/2002 |
Publishing Document | Publishing Date | Country | Kind |
---|---|---|---|
WO00/63506 | 10/26/2000 | WO | A |
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