Classifications

• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
  • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
  • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
  • E04B1/70—Drying or keeping dry, e.g. by air vents
  • E04B1/7069—Drying or keeping dry, e.g. by air vents by ventilating
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
  • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
  • E04B2/56—Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members
  • E04B2/70—Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members with elongated members of wood
  • E04B2/706—Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members with elongated members of wood with supporting function
  • E04B2/707—Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members with elongated members of wood with supporting function obturation by means of panels
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
  • E04F13/00—Coverings or linings, e.g. for walls or ceilings
  • E04F13/007—Outer coverings for walls with ventilating means
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
  • E04F13/00—Coverings or linings, e.g. for walls or ceilings
  • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
  • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
  • E04F13/0801—Separate fastening elements
  • E04F13/0803—Separate fastening elements with load-supporting elongated furring elements between wall and covering elements
  • E04F13/081—Separate fastening elements with load-supporting elongated furring elements between wall and covering elements with additional fastening elements between furring elements and covering elements
  • E04F13/0816—Separate fastening elements with load-supporting elongated furring elements between wall and covering elements with additional fastening elements between furring elements and covering elements the additional fastening elements extending into the back side of the covering elements
  • E04F13/0817—Separate fastening elements with load-supporting elongated furring elements between wall and covering elements with additional fastening elements between furring elements and covering elements the additional fastening elements extending into the back side of the covering elements extending completely through the covering elements
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
  • E04F13/00—Coverings or linings, e.g. for walls or ceilings
  • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
  • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
  • E04F13/0889—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements characterised by the joints between neighbouring elements, e.g. with joint fillings or with tongue and groove connections
  • E04F13/0894—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements characterised by the joints between neighbouring elements, e.g. with joint fillings or with tongue and groove connections with tongue and groove connections
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
  • E04F13/00—Coverings or linings, e.g. for walls or ceilings
  • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
  • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
  • E04F13/10—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements of wood or with an outer layer of wood

Definitions

• the present disclosure generally relates to building construction, and more particularly to ventilated cavity wall construction in residential buildings for managing water drainage and cavity ventilation in such construction, and an associated method of constructing such a ventilated cavity wall construction, particularly a wall section having vertically installed cladding elements.
• Cavity wall construction is a known building technique, originally developed for masonry wall construction, to prevent moisture migration into the interior of a building through a porous masonry material.
• two masonry walls were constructed with an air gap or cavity inbetween.
• the outer wall formed the exterior skin of the building and was exposed to the weather, and the inner wall formed the interior lining of the building. Any moisture that penetrated through the outer masonry wall was captured in the cavity and could not directly migrate into the interior of the building and affect the comfort levels of the building's inhabitants.
• cavity construction techniques were adapted for use in lightweight wall construction, particularly in residential construction methods.
• moisture management is necessary to prevent water accumulation in the cavity and drainage mechanisms should be provided to achieve this.
• Various techniques for moisture management have been used in lightweight cavity construction techniques, including using discontinuous batten sections to ensure there are gaps for any accumulated water to drain, or using moulded polymeric battens with channels formed into the body of the batten. Both approaches limit the battens to a non-structural role in the cavity wall construction.
• the vertically installed cladding is then indirectly attached to the frame via a direct connection to the battens supported on the noggins through fasteners of suitable strength, e.g., hand nailed fibre cement nails for a concealed fixation of or brad nails in the case of face fixation some interlocking fibre cement claddings.
• fasteners of suitable strength e.g., hand nailed fibre cement nails for a concealed fixation of or brad nails in the case of face fixation some interlocking fibre cement claddings.
• Provision of means for allowing efficient and cost-efficient vertical panel installation onto lightweight cavity wall frame systems would be welcomed by customers and building professionals.
• ventilated battens with structural capability and that provide an integral role in the strength of the wall, while accommodating in-service loadings such as wind loading, while in parallel providing a moisture management and cavity ventilation role would be desirable.
• the invention provides a ventilated cavity wall system with vertically installed cladding elements, the system comprising:
• the wall frame section comprises two or more battens joined together in an off-stud joining manner. More details of this embodiment are provided below.
• each ventilated structural cavity batten has a framing member (i.e., a rear face of the batten) contacting surface area arranged substantially parallel to the wall frame section having an associated through batten cross section plane which is substantially perpendicular to the wall frame section, wherein the framing member contacting surface has a surface area greater than a cross-sectional surface area of the through batten cross section plane.
• the ventilated structural cavity battens of the cavity wall system substantially provide, mainly provide, and in some cases exclusively provide horizontal structural support for the vertically installed cladding in the cavity wall system, preferably where the wall frame is a timber or a metal (e.g., aluminium or steel) frame.
• the wall frame is a timber or a metal (e.g., aluminium or steel) frame.
• existing structural noggins in a standard framing configuration support vertically installed cladding elements via horizontally disposed non-structural battens provided on the existing structural noggins, and/or, where additional structural noggins to support mounted non-structural battens for vertical cladding installation are added to a standard framing configuration via frame modification or retrofitting.
• the ventilated structural cavity battens described here mean that no additional structural noggins (added through standard frame modification or retrofitting) or at least substantially fewer additional (added through standard frame modification or retrofitting) structural noggins are required to support vertical installation of the cladding elements. This is due to the structural properties of the ventilated structural cavity battens described herein. As no, or at least reduced standard frame modification retrofitting with additional supporting noggins or other cladding supporting means is required to support vertical cladding installation, the system of the invention provides advantages in terms of efficiency improvements and cost reduction where vertically cladding installation is required for lightweight ventilated cavity wall frame systems.
• the framing member is a stud, such as metal stud or a timber stud, preferably a metal stud such as a steel stud or an aluminium, having a flange region onto which the batten is mounted.
• Steel studs are particularly preferred over aluminium studs, e.g., for cost reasons.
• the ventilated cavity wall system involves a lightweight cavity construction, e.g., timber frame or metal frame cavity walls.
• the invention provides a ventilated cavity wall system with vertically installed cladding elements, the system comprising:
• the invention provides a method of installing a ventilated cavity wall system, the method comprising the steps of:
• the invention provides a ventilated cavity wall system comprising:
• the invention provides a use of ventilated structural cavity battens as a substantial horizontal structural support for vertically installed cladding elements in stud wall frame section of a ventilated cavity wall system.
• the substantial, main and in some cases exclusive horizontal structural support provided by the ventilated structural cavity battens to the vertically installed cladding elements as described herein means minimal or at least reduced amounts of, and in some cases no additional framing modification (e.g. inclusion of structural horizontal noggins, and/or other vertically installed cladding supporting means) is required support vertically installed cladding elements.
• the cladding support is substantially, mainly and in some cases exclusively provided by the ventilated structural cavity battens.
• the wall frame section is a timber stud or a metal stud frame, preferably aluminium or steel stud frame.
• the framing member or stud contacting surface of the batten corresponds to a rear face (i.e., a frame directed face) of the batten when installed in the ventilated cavity wall system of the invention. This arrangement will be readily understood from the drawings provided herein.
• the term 'comprise' shall have an inclusive meaning. Thus, it is understood that it should be taken to mean an inclusion of not only the listed components it directly references, but also non specified components. Accordingly, the term 'comprise' is to be attributable with as broad an interpretation as possible and this rationale should also be used when the terms 'comprised' and/or 'comprising' are used.
• All dimensions stated in this disclosure should be read to include a normal machining or cutting tolerance of ⁇ 1 % of the maximum stated dimension is normal. For example, for dimensions under 50 mm, a ⁇ 0.5 mm normal process variation (tolerance) may occur. For dimensions between 50 mm and 500 mm that may be up to ⁇ 5 mm, and for dimensions of more than 1 metre a tolerance of ⁇ 10 mm per metre may be expected. These tolerances are intended when the term 'about' is used in respect of a stated dimension.
• the invention provides a ventilated cavity wall system with vertically installed cladding elements.
• the ventilated cavity wall system includes a wall frame section comprising two or more ventilated structural cavity battens affixed onto at least two vertical framing members of the wall frame section. It will be understood that for vertical installation of cladding elements, the ventilated structural cavity battens are positioned on the wall frame in a substantially horizontal orientation between base and header plates of the wall frame section. Two or more ventilated structural cavity battens can be affixed to the wall frame, depending on the dimensions of the frame, and local building regulations concerned with an applicable structural standard, for example, wind classification (e.g., AS4055 in Australia).
• Each ventilated structural cavity batten has a framing member or stud contacting surface located at the rear face of the ventilated structural cavity batten.
• the rear face of the ventilated structural cavity batten is arranged substantially parallel to the wall frame section.
• the ventilated structural cavity battens of the wall system substantially provides, mainly provides, and in some cases exclusively provide horizontal structural support for the vertically installed cladding elements in the ventilated cavity wall system of the invention.
• the ventilated structural cavity batten may further comprises a batten cross-sectional through plane which is a non-contacting surface (i.e., does not contact the frame / stud or the cladding) arranged substantially perpendicular to the framing member / stud wall frame section, wherein the framing member / stud contacting surface has a surface area greater than the cross-sectional surface area of the batten cross sectional through plane.
• the framing member / stud contacting surface has a surface area greater than the surface area of the non-contacting surface.
• the ventilated structural cavity battens are used to stably support two or more rectangular cladding elements, each affixed to each ventilated structural cavity batten present in the system in a vertically installed orientation.
• the framing member is a stud, such as metal stud or a timber stud, preferably a metal stud such as an aluminium or steel stud, having a flange region onto which the batten is mounted.
• Metal and in particular steel stud are desirable as the system of the invention operates in a way such that standard metal frame modification or retrofitting to include structural noggins or the like is not required, or alternatively, a reduced or less extensive modification or retrofit with fewer horizontal structural noggins is required, due to the structural performance of the battens described herein and the role of the battens as exclusive provider of horizontal structural support for the vertically installed cladding elements in the ventilated cavity wall system.
• a 'reduced modification or retrofit' means a limit of about only one or two additional horizonal structural noggins per stud bay of the wall frame section, e.g., one centrally disposed noggin per stud bay, or two noggins disposed towards the top and bottom regions of a stud bay.
• the non-structural batten supporting structural noggins would have to be provided at the required batten spaces for the application in question, such as batten spaces of 450 mm, 600 mm or 900 mm, that is, about three or four horizonal structural noggins per stud bay.
• Preferred application avoid the need for standard frame modification or retrofitting or provision of other and/or additional means for further supporting the cladding elements beyond the structural battens used herein.
• the wall frame section is a non-modified/non-retrofit or a reduced modification/retrofit wall frame system, which is substantially, mainly, or in some cases completely free of additional structural noggins.
• the reduced modification or retrofit frame will comprises less additional structural noggins members to be added to a conventionally / standard wall frame which meets building code regulations in order to structurally support vertical cladding installation.
• the cavity wall frame system of the invention is completely free of additional structural noggins and/or other vertically cladding supporting means, over those conventionally provided to produce a stable frame that meetings building code requirements.
• the wall frame is substantially, mainly and in some cases completely free of non-structural battens, particularly those supported on horizontal structural noggins. It will be understood that for a metal frame, horizontal structural noggins are equivalent to bracing elements.
• the ventilated structural cavity battens described herein are not required to be not mounted onto some or all of the structural noggins or additional structural noggins. That is, such a wall frame, to the extent structural horizontal noggins or additional structural horizontal noggins or other cladding supporting means are present, the wall frame may comprise ventilated structural cavity battens located in off noggin positions. Desirably, all ventilated structural cavity battens may be present in off noggin positions.
• the invention provides a ventilated cavity wall system with vertically installed cladding elements, the system comprising:
• a non-modified or non-retrofit frame is a conventional / standard form build to meet minimal building standard code / regulations for a particular application that has not had additional cladding supporting means supplied thereto.
• the wall frame section comprises two or more ventilated structural cavity battens joined together in an off-stud joining. More details of this embodiment are provided below.
• the invention provides a ventilated cavity wall system with vertically installed cladding elements, the system comprising:
• a standard / conventional timber wall frame is one fabricated to meet specification of a particular appliable building code or regulation.
• the timber wall frame section comprises two or more battens joined together via off-stud joining.
• the batten to frame fasteners are preferably those described in Tables 1 to 4 (face fixing fasteners), while the desired cladding element to frame fasteners are preferably those described in Table 5 and 6 (concealed face fixing).
• each ventilated structural cavity batten has a framing member (i.e., a rear face of the batten) contacting surface area arranged substantially parallel to the wall frame section having an associated through batten cross section plane which is substantially perpendicular to the wall frame section, wherein the framing member contacting surface has a surface area greater than a cross-sectional surface area of the through batten cross section plane.
• a preferred batten has a frame directed face (corresponding to the rear face in the accompanying figures) with a face height dimension which is which is 45 mm or greater, preferably 50 mm or greater, preferably 60 mm or greater, preferably 65 mm or greater, preferably 70 mm or greater.
• the face height dimension ranges from about 50 mm to about 90 mm, preferably, from about 60 mm to about 80 mm, more preferably from about 65 mm to about 75 mm, most preferably about 70 mm.
• a preferred batten has a cladding directed face (corresponding to the front face in the accompanying figures) with a face height dimension which is which is less than the face height dimension of the batten.
• the cladding directed face has a face height dimension of 35 mm or greater, preferably 40 mm or greater, preferably 50 mm or greater, preferably 55 mm or greater, preferably 60 mm or greater.
• the face height dimension ranges from about 40 mm to about 80 mm, preferably, from about 50 mm to about 70 mm, more preferably from about 55 mm to about 65 mm, more preferably about 60 mm, most preferably about 64 mm.
• Preferred batten face heights may be selected to provide an inclined / sloping top face having an angle of from about 70 to about 86 degrees (°), preferably from 73 to about 83 degrees, most preferably about 80 degrees.
• the inclined top face prevents water pooling.
• the ventilated structural cavity batten of the system of the invention has a depth (i.e., a thickness measured from edge to edge of the batten starting at an edge of the frame directed face) of from about 20 mm to about 50 mm, preferably about 20 mm to about 40 mm preferably from about 30 mm to about 40 mm thick, most preferably about 35 mm to about 45 mm thick, most preferably about 35 mm or about 40 mm.
• ventilated structural cavity battens have a frame directed face height dimension of about 70 mm, a cladding directed face height dimension of about 64 mm, and a depth / thickness of about 35 mm or about 40 mm.
• ventilated structural cavity battens having different frame directed face and cladding directed face height dimensions would provide a batten with differing frame member / stud and cladding contacting surface areas that are sufficient to support cladding installation in a vertical orientation. It would have been expected that substantially equal frame member / stud and cladding contacting surface areas would provide the necessary support / stability for vertically installed cladding.
• the ventilated structural cavity battens are formed from structurally graded timber.
• structural battens and indeed other structural / load carrying building component there are local, regional and/or national building standards and codes that may need to be adhered to.
• seasoned, kiln-dried radiata pine meeting at least the Australian F4 grading (or better) performance characteristics is a suitable material to ensure stable and safe vertical cladding installation when used in the system of the invention with the various system components and instructions provided herein.
• AS1730.1 includes details of, or references to, the relevant tests methods for assessing these properties. AS1730.1 is hereby incorporated by reference.
• the ventilated structural cavity battens may be formed from other materials including fibre cement, metal, polymers, polymer blends, or polymer composite materials, so long as the materials selected and in the dimensions provided exhibit equivalent flexural strength and Young's Modulus properties.
• the framing element / stud wall frame section comprises a metal stud wall frame or a timber stud wall frame, preferably a metal stud wall frame comprising metal vertical studs which are steel studs, preferably, wherein the steel is at least 0.5 mm thick.
• Thicker steel will be more expensive but may better support high density cladding elements. Thinner steel may better suit lower density cladding elements.
• the stud wall frame section comprises a metal stud wall frame with metal studs (e.g., aluminium or steel studs) having a flange region contacting a frame directed face of an affixed batten, wherein the batten contacting flange region of the metal stud has a horizontal width of from about 30 mm to about 70 mm, preferably from about 35 to about 50 mm.
• the steel is 0.55 BMT G550 steel or 0.75 BMT G550 steel.
• a minimum stud width of about 35 mm (batten contacting face of stud) may be used, but is less preferred in some embodiments as such narrow stud widths prohibits on-stud joining. It will be understood that for on-stud joining on timber, typically the minimum stud width is about 45 mm.
• the timber framing sections involve MPG10 grade timber, e.g., 90 ⁇ 45 mm MPG10 seasoned timber, graded in accordance with AS/NZS 1748.1.
• ventilated structural cavity batten may be formed from other materials such as fibre cement, metal, polymers, polymer blends, and polymer composite materials. It will be understood that these alternative materials should be of similar structural strength to the structurally graded timber battens described herein, and particularly in the examples.
• the cavity wall system of the invention is not strictly exclusive of conventional higher density cladding elements having a density of greater than 1.35 g/cm 3
• lower density cladding elements with a density of 1.35 g/cm 3 are used in some embodiments of the system of the invention.
• the cladding elements are formed from fibre cement, most preferably fiber cement having a density below 1.35 g/cm 3 .
• the system uses cladding elements having a depth (thickness) ranging from about 7.5 mm to about 20 mm.
• each cladding element is between 7.5 mm and 20 mm thick and each cladding element has a density below 1.34g/cm 3 .
• the cladding elements are provided in a plank or panel configuration, though combinations of same can be used if desired. Elongated plank or panel configurations are particularly preferred.
• each cladding element has a front face width of from about 200 mm to about 450 mm in the case of a plank, and from about >450 mm to about 1200 to 1800 mm in the case of a mini-panel or standard panel.
• An installed system may involve cladding elements of the same dimensions, or may involve classing elements of different dimensions of at least front face width which allows a broad range of cladding element design customisation.
• At least one cladding element may be formed from a different material to an adjacent cladding element.
• the cladding elements comprise complementary interlocking edge profiles and adjacent cladding elements are installed in an interlocked engagement.
• the cladding elements can involve concealed fixing and/or face fixing to the structural batten of wall system of the invention. Both methods can be useful for installation in high wind geographical regions. Likewise, more or less face fixing position may be utilised depending on where the system is geographically located.
• An example of concealed fixing may involve fastener placement through an outer lip or flange of the interlocking edge profile which is then covered over on placement of a complementary interlocking edge of an adjacent cladding element.
• cladding elements with plain edges may also be used. In such cases the cladding elements will involve face fixing to the structural batten of wall system of the invention.
• cladding elements include Hardie TM Stria TM Cladding and Hardie TM Oblique TM Cladding, both of which are shiplap boards. Hardie TM Stria TM Cladding has a choice of widths at 325 mm or 405 mm. Hardie TM Oblique TM Cladding has a width of 200 mm or 300 mm. Current non-structured battens are not suitable for vertically installation of these cladding elements without mounting the non-structured battens onto existing structural frame noggins and/or onto additional structural noggins provided to the frame during a standard frame modification or retrofit process.
• a barrier to moisture ingress through the joint is provided in the cladding envelope without the need for joint sealant.
• the cladding elements can support one or more surface features, that is, a front face of at least one cladding element of the wall system of the invention comprises one or more surface features, e.g., selected from patterns, textures, decorative images, and / or applied surface layers.
• a front face of at least one cladding element of the wall system of the invention comprises one or more surface features, e.g., selected from patterns, textures, decorative images, and / or applied surface layers.
• surface features are applied to fiber cement cladding elements having a fiber cement density of below 1.35 g/cm3.
• Such preferred fiber cement surface decorated low density cladding elements are particularly preferred in cavity walls systems involving metal (e.g. steel frames).
• suitable affixation of the ventilated structural cavity battens of the system of the invention to seasoned MPG10 timber framing could be achieved by at least the following fastener types: 1No 14-10 ⁇ 75 mm T17 Batten Screws, 1No 10 g 75 mm Treated Pine Screws, 2No 65 ⁇ 2.87 Galvanised Ring Shank Nail (limited to N3/C1 AS4055 Wind classification). See Tables below.
• a standard gun nailer may be used.
• the batten should be secured at right angles to the framing section with the fastener head flush with the surface of the batten. Fastener placed in vertical centre of the face of the batten.
• suitable affixation of the ventilated structural cavity battens of the system of the invention to steel framing could be achieved by at least the following fastener types: 2No 65 mm Iccons Super Shapy StructNail; 2No 14 - 10 ⁇ 75 mm Self Drilling Bugle Batten Screw; 2No 10-24 ⁇ 65 mm Fine Thread Countersunk Self-Drilling Screw (not suitable on N4/C2 wind category or greater.
• ventilated structured cavity batten spacing is 800 mm). See Tables below.
• predrilled bores can be used.
• the batten was secured at right angles to the framing section with the fastener head flush with the surface of the batten. Fastener placed in vertical centre of the face of the batten.
• suitable face fixing of Hardie TM Stria TM Cladding and Hardie TM Oblique TM Cladding elements to ventilated structural cavity battens of the system of the invention to seasoned MPG10 timber framing can be achieved by at least the following fastener types: 50 ⁇ 2.5 mm Ring Shank Coil Nails (single nail configuration N1, N2); ND 50 mm Stainless Steel Brad Nails (double nail configuration N1, N2), and Paslode 50 ⁇ 2.87 DekFast Nails (single nail configuration up to N3/C1). See Tables below.
• suitable concealed fixing of Hardie TM Stria TM Cladding and Hardie TM Oblique TM Cladding elements to ventilated structural cavity battens of the system of the invention to seasoned MPG10 timber framing can be achieved by at least the following fastener types: 40 ⁇ 2.8 mm Fibre Cement Nail, 50 ⁇ 2.5 mm Ring-Shank Coil Nail (up to N3/C1) or Paslode 45 ⁇ 2.5 mm Ring-Shank Nail (up to N1, N2).
• a standard gun nailer may be used. See Tables below.
• the ventilated structural cavity batten is affixed onto a metal flange of the vertical studs of a metal stud wall frame with a stud-to-batten fastener, preferably a power gun nail fastener. Therefore, batten thicknesses that support this conventional fastening method are particularly preferred.
• a ventilated structural cavity batten having a frame directed face height dimension of 75 mm and a ventilated structural cavity batten depth dimension of about 35 mm.
• one advantage of the invention is derived from the suitability of structural batten for off-stud joining which is described in more detail below.
• the ventilated structural cavity batten described herein are suitable to off-stud joining, timber or metal studs with horizontal widths (on batten contacting face of the stud) less than 45 mm are no longer less preferred for use. This is a significant improvement in the art, as smaller studs using less material can be successful used give off-stud structural batten joining is now possible. More detail is provided below.
• the flange / edge region of the stud provides the support for fixing of the ventilated structural cavity batten to the wall frame.
• the stability of the connection between the ventilated structural cavity batten and the stud is important, as forces (e.g. shear and/or rotational forces) arising from the dead weight of vertically installed cladding elements are transferred directly through the structural batten to the stud at the area of contact between the stud flange or edge. These forces are concentrated on the stud at the region where the affixing fastener is implanted into the stud.
• metal e.g., steel
• the flange region of the metal stud provides the support for the affixed structure batten.
• the forces arising from the dead weight of vertically installed cladding are transferred through the structural batten to the flange of the stud as before in the timber stud case, however, the metal flange thickness is much less than the timber stud thickness available for gripping the fastener.
• This means that the applied forces resulting from the dead weight of vertically installed cladding elements are entirely concentrated at the fastener piercing regions of the relatively thin steel frame. This effect makes vertically cladding installation onto steel wall frames particularly challenging. Modification or retrofitting a standard steel frame with horizontal noggins which could support the vertically installed cladding elements could assist but is time consuming and adds expense to the build.
• the structural properties of the ventilated structural cavity battens described herein ensures the batten does not splinter, fracture and/or otherwise suffer from damage to a degree that would cause failure of transfer of the load to the vertical stud through the connection with the fastening means used. This level of performance is not possible with existing ventilated non-structed battens without being mounted on standard structural noggins or additional noggins added to a modified frame.
• the typical dimensions of the ventilated structural cavity battens height and depth are described above, as have the typical dimensions of metal (e.g., steel) flanges and timber edges onto which the ventilated structural cavity battens are affixed.
• metal e.g., steel
• the surface area of the region of contact between the stud and the ventilated structural cavity batten will vary.
• a surface area of contact between the metal flange / timber edge of the stud and the stud contacting surface of the ventilated structural cavity batten made be determined by multiplication of height of the frame directed face of the batten with the horizontal width of the flange / edge of the stud.
• the contacting surface area is up to 3,500 mm 2 .
• a 90 mm flange / edge of stud and a 70 mm high ventilated structural cavity batten provides a potential contacting surface area of 6,300 mm 2 .
• the contacting surface areas achievable may be greater than those achieved with typical prior art non-structured ventilated battens which have a typical batten height (when installed) of around 20 mm.
• the contacting surface area is potentially up to just 1,000 mm 2 for a 50 mm flange / timber edge, and up to 1,800 mm 2 for a 90 mm flange / timber edge.
• An advantage of system of the invention is that contacting surface area between the ventilated structural cavity batten and the stud flange / edge efficiently spreads out / better distributes the forces (e.g., shear and/or rotational forces) produced by the drag / dead weight of the cladding on the fastener / stud intersection point. Spreading out / better distribution of these forces across the stud flange / edge greatly reduce the magnitude of forces experienced by the stud at the fastener / steel or timber intersection point. The benefits are particularly pronounced in the case of metal studs (e.g. steel).
• a steel stud flange has a typical thickness of only from 0.55 mm and 1.6 mm, which does not provide a great depth of material for a secure grip around the fastener. If the forces are not mitigated, the dead weigh drag from vertically installed cladding results in significant concentrated forces at the fastener / stud intersection point on the metal. This can result in an unacceptably high fixation failure risk and poor cladding support on the frame.
• the cladding element can then pull away from frame / wall under its own weight and sub-optimal fixation to the cavity wall frame. Wind damage from wind accessing underneath loose cladding may exacerbate the problem, and severe wall damage may occur. Modifying and/or retrofitting standard wall frames to address these issues is costly and burdensome. These issues hinder the uptake of vertically installed cladding on cavity wall frame systems.
• the ventilated cavity wall system provides secure and safe vertical cladding installation on cavity wall frames, and depending on the frame substrate, without the need for standard frame modification and/or retrofit or at least a reduction in the number of additional horizontal structural noggins that would be conventionally required for a vertical cladding installation involving mounting non-structural battens onto structural battens on a conventional frame.
• These benefits are provided via the combination of use of a structurally graded ventilation batten as described herein, together with batten height and depth dimensions.
• the batten rear face height dimensions support higher surface area contact between the studs and the batten which better distributes / reduces the concentration of forces (e.g., shear and/or rotational forces) produced by the drag / dead weight of the cladding on the fastener / stud intersection point.
• forces e.g., shear and/or rotational forces
• These advantages are particularly applicable to steel stud wall frames where the fastening point on the flange of the steel is particularly susceptible to shear and/or rotational or twisting forces from the vertical orientation of the cladding elements.
• the minimum strength properties of the batten required to impact the required structural functionality are described elsewhere herein.
• cladding element may be utilised in the ventilated cavity wall system of the invention having vertically installed cladding elements.
• Typical cladding used will be generally rectangular in shape, such as rectangular / elongated planks or rectangular / elongated panels or the like. Due to the vertical orientation and as a result of the rectangular general shape, the weight of the cladding elements exerts significant downward forces on the metal frame. While any cladding type can in principle be used, lower density cladding elements are preferred as thicker / deeper cladding elements can securely and stably fit to the stud of the cavity wall frame.
• thinner cladding elements e.g., higher density cladding
• thinner cladding member are likely required. In such cases, surface features on thinner cladding members is not desired due to the described risks around negative impact on the integrity / robustness of the cladding element.
• a further advantage of the invention is the ability to include vertically installed cladding elements in the wall system of the invention, where the cladding elements have one or more surface features, e.g., selected from patterns, textures, decorative images, and / or applied surface layers. This is particularly the case for steel frame cavity wall systems.
• a further advantage of the invention relates to the ability to use a wider selection of conventional fasteners, both ventilation structural batten-to-stud fasteners, and cladding element-to-ventilation structural batten fasteners.
• a further still advantage is the ability to utilise off stud joining without compromising the structural properties of the cavity batten and performance in the cavity wall system in terms of stable and safe support of vertically installed cladding elements.
• Battens are generally produced in lengths suited to use in local building practices. They can be cut to required lengths on the building site, by any suitable standard industry cutting method. Typical lengths are in the 2 m to 4 m range. While there is no strict limit to the length of batten supplied for installation of the system of the invention, in practice, a ventilated structural cavity batten may be supplied in a range of commonly used practical lengths such as 2.5 m, 2.75 m, 3 m, 3.5 m, 4 m and various other lengths such as may be practical for use in construction of ventilated structural cavity wall system.
• One example of a commonly used length is 2.75 m, which spans across several stud bays of a framed construction type building substrate, but is still easy for a single person installer to manage.
• the number of joins between adjacent ventilated structural cavity battens will be determined by the lengths selected by the installer, and the width of the desired wall section to be constructed.
• each ventilated structural cavity batten spans at least two framing members, that is, spans at least two studs.
• each ventilated structural cavity batten should span, and be fixed to, at least two framing members of the ventilated cavity wall system. This arrangement should ensure the maximum structural strength of ventilated cavity wall system, particularly near corners or edges of the wall section.
• one or more ventilated structural cavity batten may be joined together to increase the length of a single batten.
• the ventilated structural cavity battens when joined together, must retain sufficient structural strength to support the weight of the vertically installed cladding elements that together form an exterior cladding envelope in the ventilated cavity wall system of the invention.
• battens are supplied in finite lengths, it is often necessary to install adjacent battens with their ends butted against each other in order to span a desired wall section length.
• single framing members such as timber studs may be wide enough to accommodate fixing of adjacent batten ends side by side (on-stud joining), or additional framing members such as studs or noggings can be installed to accommodate supporting adjacent batten ends (on-stud joining).
• off-stud joining the ends of adjacent battens to be joined are not directly supported by studs or nogging of a building frame, instead they are located in between stud locations. In some embodiments, ends of a pair of battens to be joined together will be positioned to meet within approximately the centre 1/3 of the spacing between adjacent studs.
• a further desirable and advantageous feature of the system of the invention is the ability for adjacent ventilated structural cavity battens to be joined together off-stud, while retaining sufficient structural strength to support the weight of the vertically installed cladding elements.
• This feature assists in the ability of the ventilated structural cavity battens described herein to be used in a wall frame as a structural component, in a way that if desired, can reduce or at least lessen the need for standard frame modification or retrofitting to include additional horizontally orientated structural components such as noggins or the like, as is required for conventional vertical cladding installation which uses non-structured battens mounted onto structural noggins of the wall frame.
• adjacent ventilated structural cavity battens are joined off-stud, they should be positioned so that end faces of adjacent battens are in contact.
• the structural strength of the off-stud join should at least match that of the material from which ventilated structural cavity batten is made.
• a pair of adjacent ventilated structural cavity battens can be joined together off-stud using suitable fastening means including, nail plates, strapping, support noggings, or the like.
• a nail plate is used as the joining means.
• Nail plates are metal plates that have been punched to form an array of apertures with small prongs attached at one end of each aperture. When the nail plate is positioned onto a substrate, these prongs can be hammered down so that they extend through their respective apertures and fix into the substrate. They provide a convenient method of mechanically fastening adjacent elements together.
• a first nail plate is applied to angled top face adjacent ventilated structural cavity battens, so the nail plate spans across the adjacent ends of both battens and is fixed in place by hammering down the integrally formed prongs that provide joining strip fastener.
• a second nail plate may be applied to a bottom face (floor directed face) of the adjacent ventilated structural cavity batten and fixed in place. Attaching nail plates to the front and/or rear face of the batten is preferably avoided to limit issues with cladding misalignment.
• metal strapping is used to join adjacent ventilated structural cavity battens together off-stud.
• a first metal strapping piece of suitable length and width may be applied to angled top face of adjacent ventilated structural cavity battens so the strap that it spans across the adjacent ends of both and is fixed in place by joining strip fasteners, such as suitable mechanical fasteners like nails or screws.
• a minimum of two screws on each side of the join are preferred to meet the required mechanical strength of the join.
• An equivalent second metal strapping piece may then be similarly applied to bottom face of adjacent ventilated structural cavity battens and fixed in place using joining strip fasteners.
• a metal strapping piece may be formed from hoop iron, which is commonly used for bracing timber construction and bonding masonry. It is available in 30m long rolls, and may be 25 mm wide ⁇ 0.8 mm thick. It is commonly made of steel and may be galvanised.
• a support nogging e.g., a horizontal noggin, formed from a material with sufficient structural strength to match that of the ventilated structural cavity batten, such as an appropriate grade and thickness of structural timber or steel, is positioned in contact with rear face (stud directed face) of adjacent ventilated structural cavity battens, in a manner evenly spanning the join.
• a noggin can be attached to the studs either side of the join.
• Each ventilated structural cavity batten is then fastened to the support nogging by nogging fasteners of an appropriate strength.
• a feature of the invention relates to the ability of the wall system of the invention to be sufficiently ventilated. Good ventilation is supported through provision of spaced apart castellations in the structural batten of the invention.
• the structural ventilated batten comprises a series of spaced apart castellations. The castellations are provided to the stud directed face of the structural cavity batten and form a ventilation plane.
• the castellations comprise alternating embrasures or recesses and merlons as morphological features.
• the castellations comprise embrasures / recesses that are about 20 mm to about 30mm wide, preferably approximately 22 mm wide.
• the depth of individual recesses may range from about 2 mm to 10 mm in depth, preferably about 4 mm to 8 mm in depth, and most preferably about 5 mm deep. Good results in terms of cavity ventilation have been achieved for a batten with castellation having a recess of about 20 mm to about 30 mm width, preferably approximately 22 mm, in combination with about 5 mm depth.
• the castellations comprise merlons which are spaced apart by about 75 mm, measured from mid width of a recess of about 22 mm.
• the recesses / embrasures of the castellations are substantially rectangular, i.e., are formed at 90 degrees to the long axis of ventilated structural cavity batten. This shape of recess / embrasure to maximises air flow opportunity in a cavity wall construction when battens are installed with their long axis oriented horizontally. Installation in this orientation results in the castellations being oriented vertically and providing the maximum unrestricted air flow path possible for ventilating the cavity.
• the castellation features may be formed into timber battens by machining techniques like cutting, sawing, routing, and the like. In any mechanical process, there is some natural variability that occurs. Tolerances for such variations are described elsewhere herein.
• the face (or 'cladding directed face') of the ventilated structural cavity batten is provided with a drainage plane, through provision of a series of spaced apart grooves formed in front face. In some embodiments, all grooves are all the same dimensions and are evenly spaced apart along the length of ventilated structural cavity batten.
• each groove may independently be from about 3 to about 10 mm wide, preferably about 6 mm wide. In some embodiments, each groove may independently be from about 3 to about 10 mm deep, preferably about 5 mm deep. In a preferred embodiment, the drainage plane comprises a series of grooves that are about 6 mm wide and about 5 mm deep. In some embodiments, adjacent grooves are spaced from about 100 mm to about 200 mm apart, preferably approximately 150 mm apart. Such groove features have been found to enable good moisture drainage through the batten.
• spacing between each end of each ventilated structural cavity batten and the first groove is approximately 1 ⁇ 2 of that between adjacent grooves along the length of the batten so that, when two battens are installed with the ends adjacent, the spacing between adjacent grooves will be similar to that along the body of the batten. Normal tolerances, as described above, also apply to these dimensions.
• the structural ventilated batten comprises an inclining top face which slopes away from a frame directed face to a cladding element directed face of the batten, preferably wherein the slope of the inclining top face is angled at a value ranging about 70 to about 86 degrees (°), preferably from 73 to about 83 degrees, most preferably about 80 degrees.
• the incline aids in rapid movement of accumulated moisture on a top face of the batten to moisture draining recesses or embrasures when present.
• any water that ingresses into cavity may be effectively directed to drainage plane to ensure that ventilation plane remains dry and/or resists water pooling.
• Particularly preferred walls systems of the invention comprise a combination of ventilation castellations and moisture drainage castellations and an inclined top surface to aid in rapid drainage of moisture down to toward a base of the wall system.
• the ventilated structural cavity batten comprises ventilation castellations having 5 mm recesses or embrasures and adjacent 75 mm wide merlons on the frame directed face, and at the same time, 22 mm channels, and adjacent merlons of width of about 144 mm.
• the system further comprises a cavity vent strip adjacent to the base plate of the wall frame section.
• the cavity vent strip located at a base level of the cavity wall system provides for drainage of moisture from the cavity wall, assists in ventilation, and provides vermin proofing.
• the cavity vent strip is an elongate member that can be cut to a desired size to match the cavity wall section dimensions.
• the cavity vent strip has a generally L shape with a vertical flange or lip on the horizontal part of the L shaped member.
• the cavity vent strip has a depth which is substantially corresponds to the depth / width of the ventilated structural cavity batten used in the system. During use the vent strip captures moisture drained through the castellations provided in the batten at the back of the installed cladding. It will be understood that in the use, ventilated structural cavity batten are not installed into the cavity vent strip to ensure suitable moisture drainage and ventilation function.
• the cavity vent strip is formed from PVC, preferably extruded PVC.
• the stud wall frame section further includes a building wrap applied to one or more frame section surfaces to form a moisture resistant barrier layer.
• the invention also relates to a method of installing a ventilated cavity wall system, the method comprising the steps of:
• the framing member or stud contacting surface of the batten corresponds to a rear face (i.e., a frame directed face) of the batten when installed in the ventilated cavity wall system of the invention. This arrangement will be readily understood from the drawings provided herein.
• the invention thus relates to a method of installing a ventilated cavity wall system, the method comprising the steps of:
• the method further comprises the step of off-stud joining of ends of a pair of ventilated structural cavity batten, for example, via nail plate, strapping, or support noggin.
• the ventilated structural cavity batten comprises one or more features as described in accordance with the first aspect of ventilated cavity wall system with vertically installed cladding elements of the invention.
• the frame element or stud wall frame section is as described in accordance with the first aspect of ventilated cavity wall system with vertically installed cladding elements of the invention.
• the cladding elements are as described as described in accordance with the first aspect of ventilated cavity wall system with vertically installed cladding elements of the invention.
• the method involves affixing the ventilated structural cavity batten onto the vertical framing member/stud with a stud-to-batten fastener, preferably a power gun nail fastener, most preferably a power gun nail fastener suitable for affixing the ventilated structural cavity batten to a metal stud, for example, a flange of a steel stud.
• a power gun nail fastener preferably a power gun nail fastener suitable for affixing the ventilated structural cavity batten to a metal stud, for example, a flange of a steel stud.
• the ability to use a power gun nail fasteners to affix component is desirable because due to speed and efficiency of instal.
• the method also involves the step of joining together terminating ends of provided adjacent ventilated structural cavity battens in an on-stud or an off-stud manner, most preferably in an off-stuff manner, for example, using nail plates, strapping, or support noggings. Advantages of off-stud joining are described above.
• the cladding affixing step of the method involving affixing a cladding element to a ventilated structural cavity batten at a predetermined location using prescribed cladding-to-batten fasteners at predetermined spacings. See Tables herein for more details.
• the cladding affixing step of the method further comprises positioning a further cladding element adjacent to an affixed cladding element and affixing the further cladding element to the ventilated structural cavity batten using cladding-to-batten fasteners, optionally wherein the positioning step includes interlocking mating features of adjacent cladding elements.
• FIG. 1 shows a ventilated cavity wall system according to the present disclosure comprising a building frame
• a building frame can include at least one framing member 112 (e.g., metal such as steel or timber), one or more noggings (not shown), bracing (not shown) as well as other elements that provide internal linings, insulation and the like (not shown for the sake of clarity).
• framing member 112 e.g., metal such as steel or timber
• noggings not shown
• bracing not shown
• Other elements that provide internal linings, insulation and the like not shown for the sake of clarity
• Multiple framing members 112, also called studs are generally aligned so that they are co-planar and form surface (not shown) to which other structural and non-structural elements, such as building wrap 118, are fixed.
• metal e.g.
• At least two ventilated structural cavity battens 120 are each fixed to surface of building substrate 110 in a predetermined position though affixation onto at least two vertical studs / framing members.
• Each ventilated structural cavity batten 120 has rear face 123 ( ⁇ stud directed face'), front face 127 ( ⁇ cladding directed face'), body thickness ( ⁇ batten depth / thickness') 130 between rear face 123 and front face 127, angled or inclined top face 132 and bottom face 134.
• each ventilated structural cavity batten 120 incudes castellations in the form of a series of spaced apart the form of substantially rectangular recesses ('embrasures') 124 and adjacent merlons which together form a ventilation plane 122.
• ventilated structural cavity batten 120 is shown with an intermediate break line to indicate that it is of indefinite length, that is, it can be provided or formed into any particular length as may be required.
• ventilated structural cavity batten 120 may be supplied in a range of commonly used practical lengths such as 2.5 m, 2.75 m, 3 m, 3.5 m, 4 m and various other lengths such as may be practical for use in construction of ventilated structural cavity wall section 100.
• the number of joins between adjacent ventilated structural cavity battens will be determined by the lengths selected by the installer, and the width of the desired wall section to be constructed.
• Front face (or 'cladding directed face') 127 of each ventilated structural cavity batten 120 includes a series of spaced apart grooves or channels 128 to form drainage plane 126.
• ventilated structural cavity batten 120 is shown in cross sectional view with ventilation plane 122, drainage plane 126 and angled top face 132.
• ventilation plane 122 By separating ventilation of cavity 170 through ventilation plane 122 from drainage of water through drainage plane 126, optimum effectiveness of each plane can be achieved.
• By providing an angle of approximately 80 degrees on angled top face 132 any water that ingresses into cavity 170 may be effectively directed to drainage plane 126 to ensure that ventilation plane 122 remains dry.
• each cladding element 160, 160' When in use, as shown in FIG. 2C , at least two rectangular cladding elements 160, 160', are each fixed in a vertical orientation to the front face (or 'cladding directed face') 127 at least two ventilated structural cavity battens 120 (only one is visible in this cross-sectional top view and with respect to this figure, only visible features will be described), each cladding element 160 comprising rear face, front face 164, and a pair of opposing profiled side edges supporting complementary interlocking edge profiles 168, 168'.
• a ventilated cavity is formed between surface of building substrate and rear face of cladding element 160, the cavity depth being defined by the body thickness ( ⁇ batten depth / thickness') 130 of ventilated structural cavity batten 120.
• ventilated structural cavity battens 120 is fixed to building substrate such that ventilation plane 122 is in contacting engagement with surface of building substrate 110 and recesses ('embrasures') 124 124 of ventilation plane 122 allow air flow to ventilate cavity.
• Rear face 162 of each of at least two rectangular cladding elements 160 are fixed to front face (or 'cladding directed face') 127 of ventilated structural cavity batten 120.
• Angled top face 132 of ventilated structural cavity batten 120 is oriented for directing any accumulated water towards the rear face 162 of an attached cladding element 160 and allowing the water to drain through grooves 128 of drainage plane 126.
• Ventilated structural cavity battens 120 together have sufficient structural strength to support the weight of the cladding elements 160 that together form an exterior cladding envelope in the ventilated cavity wall construction.
• the frame section may be a metal frame section, with metal framing members generally in the form of C-channel studs. Any suitable metal framing may be used, but steel framing is most commonly used. Steel framing used in residential construction is at least 0.5 mm thick. For example, Australian supplier Bluescope Steel's G550 Grade steel is a typical grade used in residential steel framing with a published guaranteed minimum yield strength of 550 MPa and controlled ductility. Thicknesses can be between 0.55 mm and 1.6 mm, but a typical thickness would be in the 0.65-mm-1.2 mm range. Steel framing may have a protective coating applied to decrease the occurrence of corrosion. For example, G550 is hot-dip coated with an aluminium-zinc alloy, but other grades and steel framing from other suppliers may have other coatings or surface treatments applied.
• Fastener selection for construction of ventilated cavity wall system 100 on a steel frame building substrate 110 requires a selection of fasteners for the installation steps of different components.
• Installation of ventilated structural cavity batten 120 to steel framing member (or 'stud') 112, with sufficient mechanical strength required for use with a cladding up to 16mm thick and having density of up to 1.35g/cm 3 can be achieved by using, for example, 2 No 65mm Gripshank Supersharpy from Iccons (AU), or 2 No 14-10 ⁇ 75 mm Self drilling Bugle batten screws, or 2 No 10-24 ⁇ 65 mm fine thread countersunk self-drilling screws, or as equivalent in terms of holding capacities from other manufacturers.
• Fastener manufactures provide guidance on suitability for various applications and such recommendations should be considered together with, e.g., cladding type and frame configuration (e.g. stud width, metal frame thickness, grade, gauge, flange width, etc.), batten width / depth used and stud spaces. Care should be taken to understand any restrictions in the number and type of fasteners that are suitable for use in a given location due to wind zone classification such as Australia's AS4055 Wind Classification. For example, No 10-24 ⁇ 65mm fine thread countersunk self-drilling screws may not be suitable for use with some cladding types in an N4/C2 or greater Wind Classification zone. Selection of appropriate alternative fasteners and frame components, configuration etc., relative to the above mentioned examples is well with the remit of the skilled builder's knowledge and capability.
• cladding type and frame configuration e.g. stud width, metal frame thickness, grade, gauge, flange width, etc.
• batten width / depth used and stud spaces e.g.
• Table 1 below provides a guide to the maximum spacings horizontally between adjacent framing members (or 'studs') 112, and vertically between adjacent ventilated structural cavity battens 120, as recommended for different Wind Classification zones, when using the fastener types recommended above and cladding elements 160 are to be face fixed to ventilated structural cavity battens 120.
• TABLE 1 AS4055 Wind Classification Framing Member spacing (mm) Ventilated Structural Cavity Batten Spacing (mm) General Edges General Edges N1 600 600 900 900 N2 600 600 900 900 N3/C1 600 600 900 900 N4/C2 600 450 900 900 N5/C3 600 450 900 600 N6/C4 450 400 900 450
• cladding element 160 such as James Hardie's 14 mm thick fibre cement Stria TM or Oblique TM cladding plank product onto ventilated structural cavity batten 120
• cladding fasteners 150 there are recommended numbers and types of cladding fasteners 150 depending on the width of each cladding element 160. Tables 2, 3 and 4 below provide recommended numbers of cladding fasteners per fixing point for different fastener types (cladding element 160 to ventilated structural cavity batten 120).
• Table 2 provides recommendations for 50 ⁇ 2.50mm ring shank coil nails for use as cladding fastener 150
• Table 3 provides recommendations for ND 50mm stainless steel brad nails for use as cladding fasteners 150
• Table 4 provides recommendations for Paslode 50 ⁇ 2.87mm DekFast nails for use as cladding fasteners 150.
• concealed fastening may be used, where cladding fasteners 150 are disposed on the underlapping side edge of complementary interlocking edge profile 168. Once the overlapping side edge of complementary interlocking edge profile 168' is placed in position, the location of cladding fastener 150 is hidden, and a concealed fix finish is achieved.
• Table 5 below provides the stud and batten spacings for a concealed fix installation practice, and Table 6 provides the number of fasteners for a 40 ⁇ 2.8mm fibre cement nail, and a 50 ⁇ 2.50mm ring-shank coil nail or Paslode 45 ⁇ 2.50mm ring-shank nail.
• Wind Classification Framing Member spacing (mm) Ventilated Structural Cavity Batten Spacing (mm) General Edges General Edges N1, N2 600 600 600 600 N3/C1 600 600 600 600 600 Table 6 Wind Classification 40 x 2.80 fibre cement nail 50 x 2.50mm ring-shank coil nail or Paslode 45 x 2.50mm rinq-shank nail 350mm wide Stria / 30mm wide Oblique cladding 1200mm wide Oblique Cladding 350mm wide Stria / 30mm wide Oblique cladding 200mm wide (Oblique Cladding N1, N2 1 1 1 1 N3/C1 1 1 --- ---
• water resistant building wrap 118 is disposed on surface of building structure to provide a moisture resistant barrier layer intended to prevent or minimise migration of water from the cavity into the interior of a building such as a residential construction. It is generally chemically and/or mechanically fixed into position according to instructions provided by their respective manufacturers.
• ventilated structural cavity batten 120 comprises ventilation plane 122 on the rear face 123 comprising castellations in the form of a series of spaced apart substantially rectangular recesses ('embrasures') 124 and adjacent merlons. Castellations evenly spaced apart along the length of ventilated structural cavity batten 120. Each castellation comprises a recess of approximately 20-25 mm wide, preferably approximately 22 mm wide, and preferably about 3 - 9 mm deep, preferably 5 mm deep. Adjacent recesses between merlons of the castellations are spaced apart by 50 mm - 100 mm, preferably approximately 75mm.
• ventilated structural cavity batten 120 is shown with an intermediate break line for convenience in order to best show detail without showing a full length of the batten at scale.
• the castellation features are formed into timber battens by machining techniques like cutting, sawing, routing, and the like. In any mechanical process, there is some natural variability that occurs. All dimensions stated in this disclosure relative to the frame elements, studs, batten and / or batten elements should be read to include a normal machining tolerance of ⁇ 1 % of the maximum stated dimension is normal. For example, for dimensions under 50 mm, a ⁇ 0.5 mm normal machining process variation (tolerance) may occur. For dimensions between 50 mm and 500 mm that may be up to ⁇ 5 mm, and for dimensions of more than 1 metre a tolerance of ⁇ 10 mm per metre may be expected.
• substantially rectangular recesses ('embrasures') 124 are formed at 90 degrees to the long axis of ventilated structural cavity batten 120 to maximise air flow opportunity in a cavity wall construction when battens are installed with their long axis oriented horizontally. Installation in this orientation results in the castellations being oriented vertically and providing the maximum unrestricted air flow path possible for ventilating the cavity.
• Drainage plane 126 comprises a series of spaced apart grooves 128 formed in front face (or 'cladding directed face') 127.
• grooves are all the same dimensions and are evenly spaced apart along the length of ventilated structural cavity batten 120.
• the grooves are orthogonal to the long axis of ventilated structural cavity batten 120 so that, when installed with the long axis oriented horizontally, the grooves provide vertical channels for water drainage.
• each groove is 6 mm wide and 5 mm deep.
• adjacent grooves are spaced about 100 mm - about 200 mm apart, preferably approximately 150 mm apart.
• each ventilated structural cavity batten 120 and the first groove 128 Spacing between each end 136 of each ventilated structural cavity batten 120 and the first groove 128 is approximately of that between adjacent grooves along the length of the batten so that, when two battens are installed with the ends adjacent, the spacing between adjacent grooves will be similar to that along the body of the batten. Normal tolerances, as described above, also apply to these dimensions.
• angled top face 132 of ventilated structural cavity batten 120 is angled at 70 to 86 degrees, and preferably at approximately 80 degrees, with respect to front face (or 'cladding directed face') 122.
• off-stud joining the ends of adjacent battens that are to be joined are not directly supported by studs or nogging of a building frame, and are in between stud locations. Preferably, the ends will are positioned to meet within the centre 1/3 of the spacing between adjacent studs.
• Adjacent ventilated structural cavity battens are joined off-stud, as shown in FIGS. 4A to 4C joining using mechanical connectors such as nail plates, strapping, or additional support nogging fixed to each adjacent batten end using mechanical fasteners.
• adjacent ventilated structural cavity battens 120, 120' are joined off-stud, they should be positioned so that end faces 136, 136' of the adjacent battens are in contact.
• the structural strength of the off-stud join should at least matches that of the material from which ventilated structural cavity batten 120 is made.
• a nail plate is used as the joining means.
• Nail plates are metal plates that have been punched to form an array of apertures with small prongs attached at one end of each aperture. When the nail plate is positioned onto a substrate, these prongs can be hammered down so that they extend through their respective apertures and fix into the substrate. They provide a convenient method of mechanically fastening adjacent elements together.
• first nail plate 142 is applied to angled top face 132, 132' of adjacent ventilated structural cavity battens 120, 120' so that it spans across the adjacent ends of both and is fixed in place by hammering down the integrally formed prongs that provide joining strip fastener 148, 148'.
• a second nail plate 142 is applied to bottom face 134, 134' of adjacent ventilated structural cavity batten 120, 120' and fixed in place.
• each ventilated structural cavity batten 120 should span, and be fixed to, at least two framing members 112 of building substrate 110.
• metal strapping is used to join adjacent ventilated structural cavity battens 120, 120'.
• a first metal strapping piece 144 of suitable length and width is applied to angled top face 132, 132' of adjacent ventilated structural cavity battens 120, 120' so that it spans across the adjacent ends of both and is fixed in place by joining strip fasteners 148, such as suitable mechanical fasteners like nails or screws.
• An equivalent second metal strapping piece is similarly applied to bottom face 134, 134' of adjacent ventilated structural cavity battens 120, 120' and fixed in place using joining strip fasteners 148.
• metal strapping piece 144 may be formed from hoop iron, which is commonly used for bracing timber construction and bonding masonry. It is available in 30m long rolls, and may be 25mm wide ⁇ 0.8mm thick. It is commonly made of steel and may be galvanised.
• support nogging 146 formed from a material with sufficient structural strength to match that of ventilated timber batten 120, such as an appropriate grade and thickness of structural timber or steel, is positioned in contact with rear face 122 of ventilated structural cavity battens 120, 120', evenly spanning the join.
• Each ventilated structural cavity batten is fastened to support nogging 146 by nogging fasteners 149.
• any joins between adjacent ventilated structural cavity battens ideally maintain the structural strength of the batten material itself.
• a mechanical connector such as nail plate 142
• Mechanical fasteners such as nails or screws are used to fix each mechanical connector in position.
• the resulting connection which is not done on the drainage plane face, but rather on angled top face 132 and bottom face 134, can maintain the necessary structural and mechanical strength without compromising the planar mounting surface provided by the at least two ventilated structural cavity battens.
• structure of building substrate _ may be a timber frame comprising timber studs 112, nogging and bracing. This is similar to the ventilated structural cavity wall section 100 shown in FIG. 1 , except for the framing materials, and any necessary adaptations of spacings and fixings to accommodate the desired cladding.
• cladding element 160 is a rectangular panel. In an alternate embodiment, cladding element 160 is a rectangular plank.
• each cladding element 160 has a pair of opposing side edges 166, 166' each comprising a complementary interlocking edge profile 168, 168' respectively.
• a barrier to moisture ingress through the join is provided in the cladding envelope without the need for joint sealant.
• each cladding element 160 is formed from fibre cement. In alternate embodiments, each cladding element 160 may be formed from another suitable exterior durable, building material. In one embodiment, at least one cladding element 160 may be formed from a different material to an adjacent cladding element 160.
• each cladding element 160 is between 7.5mm and 20mm thick and each cladding element has a density below 1.34 g/cm 3 .
• front face 164 of at least one cladding element 160 comprises at least one decorative element 169 (not shown).
• decorative element 169 comprises at least one of the group comprising texture, coating, applied surface layer.
• the first step 210 of method 200 is preparing building substrate. This step includes ensuring that structure is straight and vertical, and framing members are square within normal tolerancing limits. As well as ensuring structure is straight and vertical, framing members ('studs') 112 of structure 111 must also be co-planar to provide the best surface for installing subsequent components of the ventilated structural cavity wall section.
• preparing building substrate 110 also includes installing any necessary flashings around openings such as doors and windows. Where metal flashings are installed, they should be sufficiently corrosion resistant to meet any locally applicable building code requirements.
• building substructure includes a concrete slab foundation
• a slab edge cover or other equivalent trim can be installed if required.
• building wrap 118 also known as a building paper, is installed to cover all framing members ('studs') 112 of structure to form a moisture resistant barrier layer. Installation instructions from the respective manufacturers of building wrap should be followed to ensure adequate performance in preventing accumulated water in ventilated cavity 170 from being able to migrate through building wrap 118 into the interior of the building.
• a starter strip or ore particularly a vented cavity strip, can be installed at the lower edge of building substrate 110 to provide a guide and support for cladding elements 160, 160'. If a starter strip is not used, a string line may be set up to provide a datum for installing cladding elements 160, 160' with ends aligned.
• Step 220 of the method applies if installation is installation of at least two ventilated structural cavity battens 120, 120'.
• Ventilated structural cavity battens 120, 120' are positioned with their respective long axes oriented horizontally and with their respective rear face 123 comprising ventilation plane 122 oriented towards building substrate 110.
• Batten fasteners 140 in the form of collated gun nails or screws of the appropriate grade are used to fasten the at least two ventilated structural cavity battens 120, 120' to respective framing members 120.
• Vertical spacing between ventilated structural cavity battens 120, 120' is dependent on factors such as cladding, type, cladding weight, local climate conditions, such as wind loads and the like, and the cladding manufacturer's recommendations should be followed.
• each ventilated structural cavity batten 120 should span at least two framing members 112, and there should be no joins located within the stud bay immediately adjacent a corner of edge of a wall section.
• the respective ends 136 of each stud can be brought together at an off-stud location, preferably within the central 1/3 of the spacing between adjacent framing members that form the respective stud bay and the adjacent ends 136, 136' of respective ventilated structural cavity battens 120, 120' are mechanically fixed together using nail plates, metal strapping, or support noggings and appropriate fasteners.
• any optional trims, joints and corner flashings, as recommended by the cladding manufacturer can be installed as per the manufacturer or supplier's instructions.
• a first cladding element 160 is positioned in a vertical orientation, with its rear face in contacting engagement with front face 127, 127' of at least two ventilated structural cavity battens. Cladding element 160 should be aligned according to the manufacturer's installation instructions and urged into the desired position. Cladding member 160 should be fixed to each ventilated structural cavity batten 120 using recommended fasteners.
• Second cladding element 160' is then positioned adjacent the first cladding element 160, and the complementary interlocking edge profiles 168, 168' of respective side edges 166, 166' are brought into contacting engagement and second cladding element 160' is fixed into position with cladding fasteners 150. This process is repeated with further cladding elements 160, until the desired wall section width is clad with cladding elements 160.
• Step 250 of method 200 provides for any optional protective or decorative finish to be applied to front face 164 of each cladding element to improve aesthetics and/or durability of the constructed ventilated structural cavity wall section.
• Example 1 Ventilated Cavity Wall System using Ventilated Structural Graded Timber Batten
• a successfully tested ventilated structural cavity batten 120 is formed from structurally graded timber.
• a batten with sufficient structural strength there are local, regional and/or national building standards and codes that may need to be adhered to.
• the timber should have a fifth percentile (lowest 5%) characteristic flexural strength of 12MPa, a fifth percentile characteristic shear strength of 1.3MPa, and a fifth percentile characteristic Young's Modulus of 6.1GPa.
• the shape and size of the structural batten will determine factors like batten spacing.
• the successfully tested, exemplary ventilated battens are from about 20 mm to about 40 mm thick. Preferably around 35mm thick and formed from structural grade timber, which is seasoned Radiate pine, graded to F4 level.
• Each ventilated batten 120 has a height dimension on the rear face ( ⁇ stud directed face') of the batten ranging from about 65mm to about 75mm and a front face height dimension of about 55 mm to 65 mm, preferably about 64 mm. Good results have been achieved with a front face height of approximately 70mm and a batten depth or thickness of 35 mm or 40 mm, and a rear face height of about 64 mm.
• the terms 'approximately', 'about', 'generally' and 'substantially' as used herein represent a value, amount, or characteristic close to the stated value, amount or characteristic that still performs a desired function or achieves a desired result.
• the terms 'approximately', 'about', 'generally' and 'substantially' may refer to an amount that is within less than or equal to 10% of, within less than or equal to 5% of, within less than or equal to 1% of, within less than or equal to 0.1% of, and within less than or equal to 0.01% of the stated amount.

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• 2024
  • 2024-05-20 EP EP24176900.9A patent/EP4653633A1/de active Pending
• 2025
  • 2025-02-14 AU AU2025201019A patent/AU2025201019A1/en active Pending

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