IE20090481A1

IE20090481A1 - A facade system

Info

Publication number: IE20090481A1
Application number: IE20090481A
Authority: IE
Inventors: Ian Campbell
Original assignee: Kingspan Res And Dev Ltd
Priority date: 2008-06-20
Filing date: 2009-06-19
Publication date: 2009-12-23
Also published as: GB0910616D0; GB2460961B; WO2009153767A1; GB2460961A

Abstract

A facade system comprises a facade panel (1) of fibre reinforced cementitious material a support frame (2), and a plurality of fixings (5) for fixing the facade panel (1) to support frame (2). the fixings (5) comprise a facade anchor part (10) for fixing to the fixing to the facade panel (1) and extending therefrom, a frame part for fixing to the support frame (2), and an intermediate connection part between the facade part (10) and the frame part. The intermediate connection part facilities differential movement as a result of differential thermal expansion and contraction between the facade panel (1) and the support frame (2). The connection part comprises a bracket (20) which is of generally Z shape and comprises a first arm (21) having a fixing hole for mounting the facade panel fixing part (10) and a second arm (23) having a fixing hole for mounting the frame fixing part. <Figure 5>

Description

The invention relates to a facade panel of fibre-reinforced cemetilions material. In some cases the fibre is a glass fibre and the panels are referred to as GRC panels. More particularly, the invention relates to fixings for use in fixing such a facade panel to a support frame.

GRC panels are generally formed by casting GRC in a mould. A fixing or anchor is generally bonded to the GRC by applying a blob of GRC to the rear face of the panel.

This is done as part of a wet process to ensure that the bond between the panel and the anchor is homogenous. While this is very effective in terms of strength and bonding, it is a labour intensive, time consuming and dirty process.

There is also a significant amount of extra GRC material required to bond the anchors. This means extra cost and extra weight to be taken into account when designing panels. Another down side to the system is that it requires the frame to be removed after manufacture to fit an insulation board.

The invention is directed towards providing a facade system which will address at least some of these issues.

Statements of Invention According to the invention there is provided a facade system comprising a facade panel of fibre reinforced cementitious material, a support frame and a plurality of fixings for fixing the facade panel to the support frame, the fixing comprising a facade part for the facade panel and extending therefrom, a frame part lor fixing 9 0 4 81 -2lo the support frame, and an intermediate connection part between the facade and frame parts.

In one embodiment the facade panel comprises a plurality of undercut holes, each lor reception of an anchor therein, the facade part fixing being mounted to the anchor.

In one embodiment the intermediate connection part facilitates differential movement between the facade panel and the support frame. ln one case the connection part comprises a bracket. The bracket may have a first arm having a fixing hole for mounting the facade fixing part and a second arm having a fixing hole for mounting the frame fixing part. One of the fixing holes may be larger than the associated fixing part.

In one embodiment the system comprises a compressible washer which is interposed between the enlarged fixing hole and a fixing extending therethrough. In one case the washer has a hole which is approximately the same size as the fixing hole. The washer may have a lead in section for locating in the fixing hole. The washer surface may be at least partially curved for movement relative to the element in which the fixing hole is provided. In one embodiment there are two washers, one on either side of the fixing hole. In one case at least one of the washers provides a datum for insulation.

In one embodiment the first and second fixing arms are offset. The arms may be oppositely directed.

In one embodiment the bracket is of generally Z shape.

In one embodiment the facade panel comprises a main body of fibre-reinforced cementitious material and at least one mesh embedded within the fibre-reinforced cementitious material. There may be two meshes embedded within the fibre IE Ο 9 Ο 4 8 1 -3reinforced cementitious material. The meshes may be spaced - apart through the thickness of the panel.

The invention also provides a fixing for a facade panel of the invention.

Brief Description of the Drawings The invention will be more clearly understood from the following description of 10 an embodiment thereof, given by way of example only, with reference to the accompanying drawings, in which: Fig. I is an isometric view of a fixing according to the invention; Fig. 2 is an enlarged view of a detail of the fixing of Fig. I; Fig. 3 is an exploded isometric view of part of the fixing; Fig. 4 is a cross sectional view of part of the fixing; Fig. 5 is an elevational, partially cross sectional view of the fixing mounted to a panel, Fig. 6 is a view similar to Fig, 5 of a modified fixing mounted to another 25 panel which is thicker than the panel of Fig. 5; Fig. 7 is an elevational view of a facade system of the invention incorporating panels and fixings; Fig. 8 is a cross sectional view on the line A-A in Fig. 7; Fig. 9 is an enlarged view of a right hand comer detail of Fig. 8; IE Ο 9 ο 4 8 1 -4Fig. 10 is an enlarged view of detail X of Fig. 8; Fig. 1 I is a cross sectional view on the line B-B in Fig. 7; Fig. 12 is an enlarged view of detail Y of Fig. 11; and Fig. 13 is an isometric, partially cross sectional view of another fibre reinforced cementitions panel ofthe invention.

Detailed Description Referring to the drawings there is illustrated a manufactured facade system comprising a facade panel I of fibre reinforced cemetitious material {in this case GRC) a support frame 2, and a plurality of fixings 5 for fixing the facade panel I to the support frame 2. The facade system is manufactured entirely οίϊ-site so that il is readily erected when the assembly is delivered to a building site.

The fixings 5 according to the invention comprise a facade anchor part 10 for fixing to the facade panel 1 and extending therefrom, a frame part 11 tor fixing to the support frame 2, and an intermediate connection part 12 between the facade anchor 10 and the frame part 11. The intermediate connection part 12 facilitates differential movement as a result of differential thermal expansion and contraction between the facade panel 1 and the support frame 2. The connection part 11 comprises a bracket 20 which in this case is of generally L shape and comprises a first arm 21 having a fixing hole 22 for mounting the facade panel anchor part 10 and a second arm 23 having a fixing hole 24 for mounting the frame fixing part 11. The frame connection part 11 has a flattened end 50 with a hole 51 for fixing to a support frame 2 using a fixing 52.

It wilt be noted that the fixing hole 24 of the second arm 23 of the bracket 20 is oversize with respect to a threaded end 31 ofthe frame connection part 11. This facilitates relative movement between the facade panel 1 and the support frame 2.

IE Ο 9 ο 4 8 1 -5Washers 30 of plastics material are interposed between the threaded end 31 of the frame connection part 11 and the bracket arm 23. The plastic washers 30 are mounted on the threaded end 31 of the frame part 11 by washers 32 and nuts 33. The nuts 33 may be lock nuts for secure fixing. The restraint bar clement 11 is isolated from the Z bracket 20 by means of the plastic washers 30. This provides a region in the device where any movement can be accommodated. The washers 30 are partially compressible to accommodate varying loads. In addition, it will be noted that the face of each of the washers 30 that contacts the bracket arm 23 are curved so that movement can be accommodated. This avoids the problem of Ί0 prior art systems in which the facade panel is fixed to the support frame. In such prior art systems differential expansion due to temperature variations may result in undesirable deformation and consequent reduction in load bearing efficiency. Cold bridging through to the inner support frame 2 is also reduced. In one example, the diameter of the bracket arm hole 24 is about 8 mm. I'he diameter of the hole in the washers 30 is also about 8 mm. The threaded end 31 of the frame fixing part 11 is typically 6 mm. It will be noted that the washers 30 have lead-in projections 37 to aid location in the bracket arm hole 24.

I'he arrangement also provides a seating for an insulation board 35 ensuring that cavity width is maintained. The face of the insulation 35 is engaged against (he fiat face of the plastic washer 30 which acts as a datum for the insulation 35. This ensures that the depth of the insulation cavity 36 between the insulation 35 and the inner face of the facade panel 1 is uniform to provide optimum insulation efficiency.

In the invention, a GRC panel is moulded in a conventional manner but without anchors being attached by means of blobs of GRC. The panel is moulded and allowed to cure. Undercut holes 40 are made in the rear of the GRC panel I and the anchors 10 can be efficiently inserted using a gun which is quick and efficient. The undercuts 40 can be drilled by an automated CNC machine which makes it easy to quality control the attachments and inspect the anchors 10 alter they arc inserted. The bracket arm 21 is mounted to a threaded bar part 41 of the facade anchor 40. The bar 41 has a washer 42 and a nut, usually a lock nut 43.

IE 0 9 0 4 8 1 -6The undercut hole 40 may have an enlarged lead-in entrance 45 to accommodate manufacturing tolerances in the thickness of the panel.

Referring to Fig. 12 there is illustrated a facade panel 60 comprising a main body 5 61 ol'fibre-reinforced cementitious material, a facing 62 of cementitious material and at least two fibre meshes 63, 64 embedded within the panel. The meshes 63, arc transversely spaced-apart across the thickness of the panel. The panel may be used in association with the anchor system described. The inclusion of the meshes 63, 64 strengthens the panel and reduces the fibre content ol' the GRC used. lhe invention is not limited to the embodiments hereinbefore described, which may be varied in construction and detail.

Claims

1.I. A facade system comprising a facade panel of fibre reinforced cementitious material, a support frame and a plurality of fixings lor fixing 5 the facade panel to the support frame, the fixing comprising a facade part for the facade panel and extending therefrom, a frame part for fixing to the support frame, and an intermediate connection part between the facade and frame parts. 10

2. A facade system as claimed in claim 1 wherein the facade panel comprises a plurality of undercut holes each for reception of an anchor therein, fhe facade part fixing being mounted to the anchor.

3. A system as claimed in claim I or 2 wherein the intermediate connection 15 part facilitates differential movement between the facade panel and the support frame.

4. A system as claimed in any of claims I to 3 wherein the connection part comprises a bracket.

5. A system as claimed in claim 4 wherein the bracket has a first arm having a fixing hole for mounting the facade fixing part and a second arm having a fixing hole for mounting the frame fixing part. 25

6. A system as claimed in claim 5 wherein one of the fixing holes is larger than the associated fixing part.

7. Λ facade system as claimed in claim 6 comprising a compressible washer which is interposed between the enlarged fixing hole and a fixing 30 extending therethrough.

8. A facade system as claimed in claim 7 wherein the washer has a hole which is approximately the same size as the fixing hole. /f Ο 9Ο4 βι -89. A facade system as claimed in claim 8 wherein the washer has a lead in section for locating in the fixing hole. 5 10. A facade system as claimed in any of claims 7 to

9. Wherein the washer surface is at least partially curved for movement relative to the element in which the fixing hole is provided. I 1. A facade system as claimed in any of claims 7 to 10 wherein there are two

10. Washers, one on either side of the fixing hole.

11. 12. A facade system as claimed in claim 11 wherein at least one of the washers provides a datum for insulation. 3. A system as claimed in any of claims 5 to 12 wherein the first and second fixing arms are offset.

12. 14. A system as claimed in claim 13 wherein the arms are oppositely directed.

13. 15. A system as claimed in any of claims 5 to 14 wherein the bracket is ot' generally Z shape.

14. 16. A system as claimed in any of claims 1 to 15 wherein the panel comprises a glass fibre reinforced cementitious material.

15. 17. A system as claimed in any of claims 1 to 16 wherein the facade panel comprises a main body of' fibre-reinfoced cementitious material and at least one mesh embedded within the fibre-reinforced cementitious material.

16. 18. A system as claimed in claim 17 wherein there are two meshes embedded within the fibre - reinforced cementitious material. IE 0 9 0 4 81 - 9

17. 19. A system as claimed in claim 18 wherein the meshes are spaced-apart through the thickness ofthe panel.

18. 20. A facade system substantially as hereinbefore described with reference lo 5 the accompanying drawings.

19. 21. A fixing for a facade panel as claimed in any of claims 1 to