GB2410039A

GB2410039A - Timber wall with insulation panel

Info

Publication number: GB2410039A
Application number: GB0500845A
Authority: GB
Inventors: Stuart Harry Robertshaw
Original assignee: BLUE FLAG Ltd
Current assignee: BLUE FLAG Ltd
Priority date: 2004-01-17
Filing date: 2005-01-17
Publication date: 2005-07-20
Anticipated expiration: 2025-01-17
Also published as: GB0500845D0; GB2410039B; GB0401065D0

Abstract

A method of producing a structural unit which comprises taking a timber wall leaf 12 and bonding thereto an outer leaf of fibre reinforced composite plastics material 3 having thermal insulation properties. A structural unit comprising a timber wall leaf 12 and bonded thereto an outer leaf of fibre reinforced composite plastics material 3 having thermal insulation properties. A building system and a building relating to the structural unit.

Description

24 1 0039

BUILDING SYSTEM

This invention relates to a system for constructing buildings, in particular to a system for constructing houses from prefabricated units.

The system of the invention constitutes an improvement on the timber frame house s construction system. The latter, in brief, comprises the erection of a timber frame which can support a roof and which will constitute the inner leaf of a finished cavity wall construction, and thereafter the building of the outer leaf of the cavity wall by traditional wet trade building methods, i.e. bricks and mortar.

The method of the invention seeks to provide a building system in which a timber framed lo building can be partially prefabricated and then erected on site to the stage where it is waterproof in a very short period of time, e.g. a couple of days. , . ace .

According to a first aspect of the present invention, there is provided a method of producing a structural unit which comprises taking a conventional timber wall leaf and bonding thereto an outer leaf of fibre reinforced composite plastics material having thermal insulation ewe properties. . . .

According to a second aspect of the present invention, there is provided a structural unit comprising a timber wall leaf and bonded thereto an outer leaf of fibre reinforced composite plastics material having thermal insulation properties.

According to a third aspect of the present invention, there is provided a building system, comprising the steps of: producing one or more structural units according to the method of the first aspect of the present invention off site; pre-forming a foundation on site; attaching the or each structural unit to the foundation; and 2s affixing a roof.

According to a fourth aspect of the present invention, there is provided a building when produced by the building system of the third aspect of the present invention.

Preferably, the composite's outer leaf includes one or more insulating materials, for example, fibrous insulating matting or insulating granules. The composite outer leaf may also contain s one or more structural elements, for example, board such as orientated strand board.

The fibre reinforced composite plastics material may be any suitable plastics material and in particular may consist of glass reinforced plastics (GRP). The GRP preferably encapsulates the whole of the outer leaf unit bonded to the timber frame inner leaf. The bonding may be carried out using a separate bonding agent or adhesive but preferably the timber leaf is fused l o to the GRP as the latter cures. A mechanical fixing may also be employed.

The size and shape of the units manufactured will be determined according to the plan of the subsequent house to be built from the units, and suitable gaps or holes may be allowed for windows, doors, pipeways and the like.

In a typical house construction using the system of the invention, a bungalow may be built from four units according to the invention, together with four corner units. The units will be manufactured off site and then taken to the site where they will be bolted to a pre-formed foundation. The roof is then affixed and the building is thus waterproof at a very early stage in the construction. Traditional finishing of the inside only can be carried out as is known in the art, but the external surfaces are already pre-finished. Preferably, the roof is also prefabricated off site and assembled on site, removing the need for slating, tiling or the like.

Indeed the roof may be formed in the same way as the composite of the invention.

The units manufactured in accordance with the invention may have outer leaves of various thicknesses exhibiting different levels of insulation as will be described more fully hereinafter.

In the building system of the present invention, structural units may be disposed on top of other structural units in order to produce a multistorey building. Floors may be provided between consecutive storeys of the building. Stairs may be provided to connect consecutive storeys of the building.

s The roof may be prefabricated off site and assembled on site. Preferably, the roof is pre formed in two halves.

Buildings produced in accordance with the building system of the present invention include single-storey buildings, such as bungalows, and multistorey buildings having two or more floors, such as detached, semidetached and terraced houses.

lo The invention will be described further, by way of example, with reference to the accompanying drawings, in which: Figure 1 is a plan view of a bungalow constructed in accordance with the invention; Figures 2a, b and c are respectively rear, side and front elevations of the bungalow of Figure ... . 1; ' Figure 3 is a section on line A-A of Figure 1 on an enlarged scale; : Figure 4 is a detail on an enlarged scale of the fixing of the wall unit to the foundation; Figure 5 is a cross-section through a wall unit manufactured in accordance with the invention; Figures 6a and 6b are plan views of the ground and first floors, respectively, of a two-storey house constructed in accordance with an embodiment of the invention; Figure 7 is a section on line A-A of Figures 6a and 6b; Figures 8a and 8b are front and rear elevations, respectively, of a semi-detached house constructed in accordance with an embodiment of the invention; and Figures 9a and 9b are rear and front elevations, respectively, of terraced houses constructed in accordance with an embodiment of the invention. s

Referring to the drawings, a timber frame wall leaf 12 of conventional construction is bonded at 14 to an outer leaf or "warm wall" 16 which comprises two fibre reinforced composite plastics material layers 1 and 6 encapsulating structural orientated strand boards 2 and 5 and insulating material 3 and 4. Structural orientated strand boards are made up of oriented wood 0 strands which are held together by resin (for example, phenol formaldehyde resin) and compressive bonds. As illustrated, the insulating material 3 is a fibrous matting insulation, em fibreglass, while the insulating material 4 is a particulate insulation, for example, "Optirock" clay granules. More or less insulation may be used according to requirements (see Figure 5) and other types of insulation may be employed. The warm wall 16 is completely sealed, i.e. s is completely encapsulated by the fibre reinforced composite layers 1 and 6 which seal the top side and bottom edges (not shown) to provide a fully sealed unit. The warm wall 16 is bonded - -- to the timber frame either with a separate adhesive or, preferably, by applying the timber frame to the fibre reinforced composite material before the latter has cured so that it adheres thereto on curing. The outer layer of composite l may carry on it suitable design or decoration so that it resembles conventional brick or render construction (see Figure 2).

It will be observed that there is no separate cavity as there would be in traditional construction, but that the timber wall 12 contains a cavity 8, in this case shown partially filled with insulation, and of course as described above the warm wall 16 also contains insulation. Thus, the composite wall unit 18 provides the entire wall for the finished building, no further 2s construction, cladding or the like being needed. It may be produced pre-finished, i.e. painted, or prepared for finishing on site.

The units 18 may also contain the necessary holes or gaps to receive doors, windows, main services and the like.

Figures 1 to 3 illustrate a typical two bedroom bungalow constructed using units produced in accordance with the invention. Four wall units 18 in accordance with the invention will be produced to form the front, rear and side elevations ofthe house and these will be joined using four corner units 20 produced in essentially the same manner as the wall units 18. As s illustrated in Figure 2, the corner units 20 have a different external finish from the wall units 18. On site, the units 18,20 are bolted to a pre-formed concrete foundation 22 as shown more clearly in Figure 4. The units 18 have a stepped lower end in which the timber wall 12 is slightly shorter than the warm wall 16. A sole plate 24, preferably formed of reconstituted plastics material which is water and damp proof, is bolted to the foundation 22 by means of 0 anchor bolts 26. The timber wall 12 sits on the sole plate 24 and is fixedly attached thereto by means of skewed coach screws 28.

As seen in Figure 1, where adjacent units 18,20 abut, the timber frame 12 is stepped at 30 so that the adjacent panels interlock and can be fixed together by means of suitable screws. The abutting edges of the panels are coated with a suitable mastic or sealant to ensure a watertight join. The abutting edges 31 can be made of a reconstituted plastics material similar to that of the sole plate 24 and may be secured together by angled coach screws in a similar fashion to the fixing to the sole plate also.

Once the four panels of the four wall units 18 and the four corner units 20 have been fixed in place and joined together, the roof 32 may be put on. As illustrated, this is pre-formed in the factory also in two halves 34 and 36. Each half 34,36 is formed by producing timber braces and trusses to which is attached a fibre reinforced composite roof unit formed in a similar manner to the warm wall 16 and carrying external figuring to resemble slates, tiles or the like.

The roof halves are then mounted on site and attached to one another and to the wall units 18 in a conventional manner using connectors, e.g. bolts and screws.

As illustrated in Figure 5, the warm wall 16 can be of various thicknesses containing greater amounts of insulation, as shown in wall types A to F. The corresponding U-values, in watts per square metro, are also illustrated for the various thicknesses. Building regulations being phased in over the next few years will mean that conventional brick and block cavity walls will not bc able to meet the necessary insulation requirements with an equivalent thickness of wall, whereas the wall units of the present invention will do so.

Figures 6 to 9 illustrate different types of two-story houses constructed using structural units 18 produced in accordance with the invention. Figures 6a and 6b are plan views of the ground s and first floors, respectively, of a two-storey house constructed in accordance with the invention. As for the bungalow of figures 1 to 3, wall units 18 in accordance with the invention are produced to form the front, rear and side elevations ofthe house. One set of wall units 18 form the ground floor 38, as shown in Figure 6a, and another set of wall units 18 form the first floor 40, as shown in Figure 6b. The wall units are joined by corner units 20. On site, 0 the units 18,20 of the ground floor 38 are bolted to a pre-formed concrete foundation 22, as shown in Figure 7. The method is the same as that hereinbefore described with reference to the bungalow of Figures I to 3.

As shown in Figure 7, first floor 40 is attached to the top of the wall units 18 making up the ground floor 38. Additional columns/pillars may be erected in order to provide further structural support for the first floor 40. The wall units 18 making up the first floor 40 are then attached to the floor 40. The various attachments may be achieved by means of bolting, as previously described in relation to Figures I to 4. The wall units 18 are joined by corner units 20, as shown in Figures 8a and 8b. As already described in relation to Figure 1, adjacent panels of the units 18,20 making up the ground 38 and first floor 40 interlock and are fixed together by means of suitable screws. As shown in Figure 7, a staircase 42 connects the ground 38 and first 40 floors.

Figures 8a,b and 9a,b illustrate semi-detached and terraced housing, respectively, constructed according to the present invention. Figures 8a and 8b are front and rear elevations, respectively, of a semi-detached house in accordance with an embodiment of the invention.

2s Figures 9a and 9b are rear and front elevations, respectively, of terraced houses constructed in accordance with an embodiment of the invention. Thus, detached, semi-detached and terraced housing may be produced in accordance with the present invention. The housing may be single storey or multi-storey.

The windows and doors shown in the various types of houses illustrated in Figures 1 to 3 and 6 to 9 may be fitted on site, the relevant orifices having been formed in the wall units 18, or they may be pre-fitted in the factory, as desired.

The system of the invention enables the construction ol houses to be carried out quickly and economically and, moreover, enables the high levels of insulation required by incoming building regulations to be achieved without excessive wall thickness.

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Claims

CLAIMS: I. A method of producing a structural unit which comprises taking

a timber wall leaf and bonding thereto an outer leaf of fibre reinforced composite plastics material having thermal insulation properties.
2. A method according to claim 1, wherein the composite's outer leaf includes one or more insulating materials.
3. A method according to claim 1 or 2, wherein the insulating material is a fibrous matting insulation.
4. A method according to claim 3, wherein the fibrous matting insulation is fibreglass.

lo
5. A method according to any preceding claim, wherein the insulating material is a .

particulate insulation. .. A.-:.
6. A method according to claim 5, wherein the insulating material is insulating granules. . . .
7. A method according to any preceding claim, wherein the thickness of the outer leaf varies and exhibits different levels of insulation.
8. A method according to any preceding claim, wherein the composite outer leaf contains one or more structural elements.
9. A method according to claim 8, wherein the one or more structural elements is orientated strand board.
10. A method according to any preceding claim, wherein the fibre reinforced composite plastics material consists of glass reinforced plastics. -9 -
11. A method according to any preceding claim, wherein the fibre reinforced composite plastics material encapsulates the whole of the outer leaf bonded to the timber wall leaf.
12. A method according to any preceding claim, wherein the bonding is carried out using a separate bonding agent or adhesive.
13. A method according to any of claims 1 to l 1, wherein the timber wall leaf is fused to the fibre reinforced composite plastics material as the latter cures.
14. A method according to any of claims 1 to l 1, wherein the timber wall leaf is fixed to the outer leaf by means of a mechanical fixing.
15. A method according to any preceding claim, wherein the structural unit has gaps or lo holes. :.,.:.
16. A method according to any preceding claim, wherein the outer leaf carries on it a suitable design or decoration so that it resembles conventional brick or render construction. . :.
17. A method according to any preceding claim, wherein the structural unit has a.

stepped lower end in which the timber wall leaf is shorter than the outer leaf. .,
18. A method substantially as hereinbefore described with reference to any of the accompanying drawings.
19. A structural unit comprising a timber wall leaf and bonded thereto an outer leaf of fibre reinforced composite plastics material having thermal insulation properties.
20. A structural unit according to claim 19, wherein the composite's outer leaf includes one or more insulating materials.
21. A structural unit according to claim 19 or 20, wherein the insulating material is a fibrous matting insulation.
22. A structural unit according to claim 21, wherein the fibrous matting insulation is fibreglass.
23. A structural unit according to any of claims 19 to 22, wherein the insulating material is a particulate insulation.

s
24. A structural unit according to claim 23, wherein the insulating material is insulating granules.
25. A structural unit according to any of claims 19 to 24, wherein the thickness of the outer leaf varies and exhibits different levels of insulation.
26. A structural unit according to any of claims 19 to 25, wherein the composite outer lo leaf contains one or more structural elements.
27. A structural unit according to claim 26, wherein the one or more structural elements is orientated strand board. -,.
28. A structural unit according to any of claims 19 to 27, wherein the Abbe reinforced...

composite plastics material consists of glass reinforced plastics. . ;
29. A structural unit according to any of claims 19 to 28, wherein the fibre reinforced composite plastics material encapsulates the whole of the outer leaf bonded to the timber wall leaf.
30. A structural unit according to any of claims 19 to 29, wherein the outer leaf of fibre reinforced composite plastics material is bonded to the timber wall leaf by a bonding agent or adhesive.
31. A structural unit according to any of claims 19 to 29, wherein the timber wall leaf is fused to the fibre reinforced composite plastics material. -1 1
32. A structural unit according to any of claims 19 to 29, wherein the timber wall leaf is fixed to the outer leaf by means of a mechanical fixing.
33. A structural unit according to any of claims 19 to 32, wherein the structural unit has gaps or holes.
34. A structural unit according to any of claims 19 to 33, wherein the outer leaf carries on it a suitable design or decoration so that it resembles conventional brick or render construction.
35. A structural unit according to any of claims 19 to 34, wherein the units have a stepped lower end in which the timber wall leaf is shorter than the outer leaf.

lo
36. A building system, comprising the steps of: . , . producing one or more structural units according to any of method claims l to 18 off site; pre-forming a foundation on site; attaching the or each structural unit to the foundation; and -.^ . affixing a roof. c .
37. A building system according to claim 36, wherein adjacent structural units are.

joined together by a corner unit.
38. A building system according to claim 36 or 37 when dependent on claim 17, wherein a sole plate is attached to the foundation and the timber wall leaf is attached to the sole plate.
39. A building system according to any of claims 36 to 38, wherein the timber wall leaf is stepped where adjacent units abut so that adjacent panels interlock.
40. A building system according to any of claims 36 to 39, wherein structural units are 2s disposed on top of other structural units in order to produce a multi- storey building.
41. A building system according to claim 40, wherein floors are provided between consecutive storeys of the building.
42. A building system according to claim 41, wherein stairs are provided to connect consecutive storeys of the building.
43. A building system according to any of claims 36 to 42, wherein the roof is prefabricated off site and assembled on site.
44. A building system according to claim 43, wherein the roof is preformed in two halves.
45. A building system according to claim 44, wherein each roof half is formed by lo producing timber braces and trusses to which is attached a fibre reinforced composite roof unit formed in a similar manner to the outer leaf of the structural unit. ;
46. A building system substantially as hereinbefore described with reference to any of A. the accompanying drawings.
47. A building when produced by any of the building systems of claims 36 to 46.
48. A building substantially as hereinbefore described with reference to any of the accompanying drawings.