BUILDING SYSTEM

A building which has as a wall of its envelope, a wall of a size of at least 2.4 m high, and at least 4 m wide; wherein the wall has a frame or a substructure having studs at least some of which are spaced by a modular distance, battens supported from and fixed to said frame or substructure, such battens fixed both on and between studs, a first mesh (“inner mesh”) attached to such battens, a second (“outer”) mesh supported at least in part by a plaster matrix, and the plaster matrix applied as more than one layer, the plaster matrix penetrating the first mesh, interposing both meshes, attaching to the second mesh and covering the second mesh; wherein the wall has at least one opening selected from a group consisting of door and window openings; and wherein at least part of the periphery of each opening, within the matrix, has been further reinforced by one or more of (a) one or more of at least one mesh and/or lattice-work at each corner, (b) one or more of at least one mesh and/or lattice-work at each vertical side, and/or one or more mesh between adjacent openings.

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Description
FIELD OF THE INVENTION

The present invention relates to a building system. More particularly the invention relates to stucco type cavity wall construction techniques and resultant consumables, subassemblies, assemblies, etc.

Exterior panels defined in situ in a plaster material in New Zealand have been restricted to a height no higher than about 2.4 meters high and 4 meters wide by building regulation. Larger cladding areas require movement control joints.

The present invention in one aspect is directed to a building system (eg. structures, methods, procedures, apparatus, etc) which would allow panels of greater than 2.4 meters in height to be created and/or greater than 4 meters width to be created without movement joints.

The present invention also or instead is directed to building envelopes being closed by a cavity wall plaster system which, with our without movement control joints (eg. vertical and/or horizontal control joints), can provide walls of considerable size and/or non-square or non-rectangular perimeter.

BACKGROUND OF THE INVENTION

For a typical (nominal) 21 mm panel thickness in compliance with NZS3604, we envisage at least square or rectangular panels being created in situ that can achieve, without a movement control joint, a height of at least 4.85 meters and can be as wide as much as, for example, up to 12 meters, all without mandatory movement control joints. Smaller panel widths of 6 meters, 8 meters or other are also within the compass of the present invention. Likewise heights.

By way of example, and without in any way being limiting, we expect for an in situ panel, of say 21 mm thickness so as to be NZ compliant, a single level panel size of, say, 2.4×6 metres and a double level panel size of say, 5.2×8 metres without any mandatory movement control joint.

In other countries (eg. USA) a thicker panel of say, about 40 mm may find favour. We expect our system to cater similarly for such panels.

Irrespective of the dimensions of any resultant panel, its peripheral shape, etc any method of in situ formation of a reinforced plaster panel that allows that greater dimensional reach of a panel is also within the scope of the present invention. However a preferred system of plaster matrix will be described with respect to NZ requirements but in no way restricted to NZ regulatory constraints.

It is an aim or object of the present invention to provide a building and/or a building system, related assemblies, sub assemblies, procedures, methods, panels, flashings, reinforcements, cavity walls of part stucco construction, etc which will at least provide the public with a useful choice.

It is a further or alternative aim or object of the present invention to provide compliance with the plaster code NZS4251 in the provision of a building and/or a building system, related assemblies, subassemblies, procedures, methods, panels, flashings, reinforcements, cavity walls of part stucco construction etc, all which will at least provide the public with the useful choice.

It is a further or alternative aim or object of the present invention to provide compliance with the building code NZS3604 in the provision of a building and/or a building system, related assemblies, subassemblies, procedures, methods, panels, flashings, reinforcements, cavity walls of part stucco construction etc, all which will at least provide the public with the useful choice.

It is a further or alternative aim or object of the present invention to provide compliance with the building code NZS3604 and plaster code NZS4251 in the provision of a building and/or a building system, related assemblies, subassemblies, procedures, methods, panels, flashings, reinforcements, cavity walls of part stucco construction etc, all which will at least provide the public with the useful choice.

It is a further or alternative aim to provide stucco walled structures having panel rigidity and integrity.

It is a further or alternative aim or object of the present invention, or at least some embodiments, of the present invention to provide methods to meet what is expected to be allowable under NZ regulation.

BRIEF DESCRIPTION OF THE INVENTION

In an aspect the invention is a building which has as a wall of its envelope, a wall of a size of at least 2.4 m high, at least 4 m wide and about 21 mm thick;

wherein the wall has

a frame or a substructure having studs at least some of which are spaced by a modular distance,

battens supported from and fixed to said frame or substructure, such battens fixed both on and between studs,

    • a first mesh (“inner mesh”) attached to such battens,
    • a second (“outer”) mesh supported at least in part by a plaster matrix, and the plaster matrix applied as more than one layer, the plaster matrix penetrating the first mesh, interposing both meshes, attaching to the second mesh and covering the second mesh;

wherein the wall has at least one opening selected from a group consisting of door and window openings;

and wherein at least part of the periphery of each opening, within the matrix, has been further reinforced by one or more of

    • (a) one or more of at least one mesh and/or lattice-work at each corner,
    • (b) one or more of at least one mesh and/or lattice-work at each vertical side, and/or
    • (c) one or more mesh between adjacent openings.

Preferably the studs are of minimum cross-section of 45 mm×90 mm.

Preferably there are dwangs at nominal 900 mm spacings between the studs.

Preferably the batten attached mesh is of a metal.

Preferably the batten attached mesh overlies a backing sheet.

Preferably the battens are of nominal 35 mm×40 mm cross-section.

Preferably the second mesh is non-metallic

Preferably regional reinforcement is by or includes metallic mesh.

Preferably the metallic mesh regional reinforcement has been attached prior to being embedded.

Preferably regional reinforcement is by or includes a non-metallic sheet material or mesh able to be embedded and penetrated by the matrix material.

Preferably panel boundaries include at least partially embedded lattice-like periphery defining members.

In another aspect the invention is a building which has a wall that has

a frame or a substructure that includes studs substantially to a modularly spacing of about 600 mm where suitable,

battens supported from and fixed to said frame or substructure, said battens being fixed both to at least the modularly spaced studs and inbetween,

a first mesh attached to such battens,

a second mesh supported at least in part by a plaster matrix, and

one or more additional mesh as regional mesh reinforcement,

the plaster matrix applied as more than one layer, the plaster matrix penetrating the first mesh, embedding the second mesh, embedding the regional mesh or meshes.

Preferably the studs are of minimum cross-section of 45 mm×90 mm.

Preferably there are dwangs (preferably at nominal 900 mm spacings) between the studs.

Preferably the batten attached mesh is of a metal.

Preferably the batten attached mesh overlies a backing sheet.

Preferably the battens are of nominal 35 mm×40 mm cross-section.

Preferably the second mesh is non-metallic

Preferably regional reinforcement is by or includes metallic mesh.

Preferably the metallic mesh regional reinforcement has been attached prior to being embedded.

Preferably regional reinforcement is by or includes a non-metallic sheet material or mesh able to be embedded and penetrated by the matrix material.

Preferably panel boundaries include at least partially embedded lattice-like periphery defining members.

In still another aspect the invention is a stucco wall comprising or including

a stud including wall frame,

battens carried by the wall frame and in excess of the number of studs in the wall frame,

a mesh or the like perforate reinforcement sheet(s) carried by the battens,

a mesh or the like perforate reinforcement sheet(s) outwardly of and spaced from the batten carried sheet(s),

additional regional reinforcement mesh,

lattice and/or perforate reinforcement, and

a plaster or cementitious matrix, applied as at least a two layer application, that penetrates the batten carried sheet(s) and embeds or also embeds the other said reinforcement(s).

Preferably the studs are of minimum cross-section of 45 mm×90 mm.

Preferably there are dwangs (preferably at nominal 900 mm spacings) between the studs.

Preferably the batten attached mesh is of a metal.

Preferably the batten attached mesh overlies a backing sheet.

Preferably the battens are of nominal 35 mm×40 mm cross-section.

Preferably the second mesh is non-metallic

Preferably regional reinforcement is by or includes metallic mesh.

Preferably the metallic mesh regional reinforcement has been attached prior to being embedded.

Preferably regional reinforcement is by or includes a non-metallic sheet material or mesh able to be embedded and penetrated by the matrix material.

Preferably panel boundaries include at least partially embedded lattice-like periphery defining members.

In another aspect the invention is a building which has as a wall of its envelope, a wall of a size of at least 2.4 m high, at least 4 m wide and about 21 mm thick;

wherein the wall has

a frame or a substructure,

battens supported from and fixed to said frame or substructure,

a first mesh (“inner mesh”) attached to such battens,

a second (“outer”) mesh supported at least in part by a plaster matrix, and

the plaster matrix applied as more than one layer, the plaster matrix penetrating the first mesh, interposing both meshes, attaching to the second mesh and covering the second mesh;

wherein the wall has at least one opening selected from a group consisting of door and window openings;

and wherein the, or each, opening is positioned only as allowed and the, or each, opening is further reinforced in the plaster matrix at least substantially in accordance with the Rules as herein provided (preferably thereby to be NZS3604, or both NZS3604 and NZS4251, compliant, all as current June 2010).

Preferably the frame or substructure has studs that are of minimum cross-section of 45 mm×90 mm.

Preferably there are dwangs at nominal 900 mm spacings between the studs.

Preferably the batten attached mesh is of a metal.

Preferably the batten attached mesh overlies a backing sheet.

Preferably the battens are of nominal 35 mm×40 mm cross-section.

Preferably the second mesh is non-metallic

Preferably regional reinforcement is by or includes metallic mesh.

Preferably the metallic mesh regional reinforcement has been attached prior to being embedded.

Preferably regional reinforcement is by or includes a non-metallic sheet material or mesh able to be embedded and penetrated by the matrix material.

Preferably panel boundaries include at least partially embedded lattice-like periphery defining members.

In yet another aspect the invention is a building having at least one stucco wall, the stucco matrix having been layed up as plural settable layers, the wall being of at least 2.4 m high, at least 4 m wide and about 21 mm thick, the wall comprising or including

a frame or a substructure that includes studs of at least 45×90 mm cross-section, where appropriate, at about 600 mm centres,

battens of about 40 by 35 mm cross-section supported from the frame or substructure both on and in

between the studs,

reinforcement metal mesh attached to the battens and penetrated by a said layer of the stucco matrix,

reinforcement set out from the batten carried metal mesh and embedded in the stucco matrix,

regional extra embedded reinforcement, and

the stucco matrix

Preferably there are dwangs at nominal 900 mm spacings between the studs.

Preferably the batten attached mesh is of a metal.

Preferably the batten attached mesh overlies a backing sheet.

Preferably the second mesh is non-metallic

Preferably regional reinforcement is by or includes metallic mesh.

Preferably the metallic mesh regional reinforcement has been attached prior to being embedded.

Preferably regional reinforcement is by or includes a non-metallic sheet material or mesh able to be embedded and penetrated by the matrix material.

Preferably panel boundaries include at least partially embedded lattice-like periphery defining members.

In another aspect the invention consists in a building [or any kit, method or procedures which results in such a building] which has, or is to have, as part of its envelope and/or any wall,

    • a frame or a substructure,
    • battens supported from and fixed to said frame or substructure,
    • a first mesh (“inner mesh”) attached to such battens,
    • a second mesh (“outer mesh”) supported at least in part by a plaster matrix, and
    • the plaster matrix applied as more than one layer;
    • wherein the plaster matrix penetrates the first mesh, interposes both meshes, attaches to the second mesh, and covers the second mesh;

wherein the panels (at least of said primary plaster matrix and the meshes has one or more of the following characteristics,

    • is about 21 mm thick
    • is of a size of at least 2.4×4 m
    • has no movement control joints
    • has movement control joints mandated by the Rules hereafter
    • has extra mesh reinforcement outwardly of the corners of openings
    • has extra mesh reinforcement between openings
    • has said extra mesh positioned within a base layer of the plaster matrix, the plaster matrix being of several applied layers
    • has embedded unfixed extra mesh reinforcement mandated by the Rules hereafter
    • has such extra reinforcement mandated by the Rules positioned within a layer of the plaster matrix, the plaster matrix being of several applied layers.

Preferably the first mesh is a metal mesh.

Preferably said first mesh “wraps” (as herein defined) the framing or substructure over the battens and to and/or substantially to any openings of the envelope.

Preferably prepared mesh sheet (preferably zinc coated) has been used as the inner mesh, paper side inwards.

Preferably the pre-papering provides, as if formwork, for first layer plaster application capture behind and to the inner mesh.

Preferably, or optionally, the inner mesh is of vertical and horizontal wire.

Optionally and preferably corners of openings have as additional reinforcement for and/or support for the plaster matrix (almost as if a patch), a zone a mesh with its wires running substantially at an angle with respect to the vertical and horizontal wires of the inner mesh “wrap”. These are outwards of each corner of any opening (e.g. doors or windows).

Preferably each corner is also further reinforced as additional reinforcement for, and/or support for, the plaster matrix, (almost as if a patch) a zone of a Rules mandated mesh between openings of close proximity (whether of same height or not). Preferably this is embedded in the base coat of the plaster system.

Preferably the first or inner mesh is a metal or wire mesh. It can be woven, forge knotted, welded or the like mesh or can be expanded perforate sheet material to define a “mesh”.

Preferably the outer or Rules mandated mesh is a non-metal mesh e.g. preferably fibreglass. Preferably that is a woven mesh.

Preferably external corners have a skeletal or lattice member embedded at least in part by the plaster matrix and embedded on both sides of the corner by the plaster matrix (eg. as if flanges).

Preferably the skeletal or lattice member is batten supported.

Preferably the external corner skeletal or lattice member is over the inner mesh.

Preferably the corner has acted as formwork.

Preferably said skeletal or lattice member is a corner moulding.

Preferably the external corner skeletal or lattice member is of a plastics material (eg. PVC).

Preferably window and/or door openings each have a head flashing to provide a canopy and that head flashing receives the inner mesh (ie. preferably holds the free ends of vertical wires of the mesh).

Preferably such flashings have end stopping (eg. flashing tape provided).

Preferably the flashings are of a plastics material (eg. PVC).

Preferably the head flashing is in part below the bottom ends of vertical battens and in part over a trim batten.

Preferably window and/or door openings have side jamb flashings.

Preferably each side jamb flashing locates a skeletal or lattice member (“side jamb skeletal or lattice member”) embedded at least in part by the plaster matrix.

Preferably each side jamb flashing is batten supported (at least in part).

Preferably each side jamb flashing is fixed to a trim batten or other batten.

Preferably window and/or door openings have a sill flange spanning between battens it is attached to.

Preferably a sill flashing (eg. of aluminium) overlays at least part of said sill flange.

Preferably the sill flashing is of “Z” section.

Preferably the sill flashing is of aluminium.

Preferably the sill flange has acted as a formwork periphery of the plaster matrix.

Preferably the top region of the sill flashing underlies the window frame (if opening is a window).

Preferably an inner mesh overlaps a flange of a wall bottom member (with preferably a drip edge).

Preferably the wall bottom member has two flanges, one to be positioned behind the bottom of vertical battens (and preferably to above any floor level) and one to be positioned over the same vertical battens and overlayed by the inner mesh.

Preferably the wall bottom member has acted as formwork for the plaster matrix.

Preferably the “Rules” hereafter described are or have been followed.

In another aspect the invention consists in a cavity wall type structure comprising:

    • a framing or a substructure,
    • a paper or like wrap of such structure,
    • battens supported from said framing or substructure but over said paper or like wrap,
    • an inner metal mesh (preferably with its own paper) stapled or otherwise fixed to such battens,
    • extra metal mesh attached to said battens and/or to the inner mesh outwardly of corners of openings,
    • a second mesh (preferably a non-metallic mesh) as the (hereafter referred to as “outer mesh”) supported at least in part by a plaster matrix,
    • mesh reinforcement (preferably a non-metallic mesh) of some regions with additional mesh as required by the Rules hereafter, and
    • a plaster matrix that has been applied as more than one layer, at least one and preferably two layers having being applied prior to the association thereto of said outer mesh, the plaster matrix not showing any substantial amount of said outer mesh at the face surface to the outside of the building.

Preferably the plaster matrix is of at least a three layer application.

    • Preferably the inner metal mesh, extra metal mesh and the additional mesh reinforcement is in or to a base layer of the plaster matrix and the second mesh reinforcement is to a second layer of the plaster matrix.

In an aspect the invention is an in situ formed type stucco (ie. plaster matrix) panel of a building structure supported from cavity providing battens;

wherein the panel is supported (at least in part) from the battens by an embedded metal mesh (optionally and preferably of two layers in some areas) and the plaster matrix embeds, more outwardly than the metal mesh, another mesh (eg. of fibreglass) [optionally and preferably of two layers] in some areas;

wherein [optionally but preferably] the panel is about 21 mm thick;

and wherein the panel has no movement control joints;

and wherein the panel is of perimeter larger than 2.4 mm×4 m.

Preferably outwardly of corners of opening there is two layers of the metal mesh.

Preferably “Rules” as hereinafter described mandate use of an extra layer of the mesh more outwardly of the metal mesh and embedded into the base coat.

In still a further aspect, the invention consists in a building envelope having battens that support part or all of an in situ formed panel (preferably of about 21 mm thick);

wherein there is

    • an inner mesh attached to the battens,
    • zonal reinforcement mesh outwardly of at least some corners of any openings in the panel,
    • an outer mesh,
    • different and/or same zonal reinforcement by a mesh, and
    • a plaster matrix embedding all of the meshes;
    • and wherein the outer mesh is of smaller opening size than both the mesh of the inner mesh and the zonal reinforcement mesh of each (or some) opening(s).

Preferably the Rules mandated mesh is of smaller opening size than the inner mesh.

In a further aspect the invention consists in a building envelope having battens that support part or all of an in situ formed panel (preferably of about 21 mm thick);

wherein there is

    • an inner mesh attached to the battens,
    • zonal reinforcement mesh outwardly of at least some corners of any openings in the panel,
    • an outer mesh
    • different and/or same zonal reinforcement by a mesh, and
    • a plaster matrix embedding all of the meshes;
    • and wherein the outer mesh is of smaller opening size yet at least as flexible as the inner mesh and the zonal reinforcement mesh outwardly of each (or some) opening(s).

In a yet further aspect the invention consists in a building envelope having battens that support part or all of an in situ formed panel (preferably of about 21 mm thick);

wherein there is

    • an inner mesh attached to the battens
    • zonal reinforcement mesh outwardly of at least some corners of any openings in the panel
    • an outer mesh,
    • different and/or same zonal reinforcement by a mesh, and
    • a plaster matrix embedding all of the meshes;
    • and wherein the Rules impose a mesh of smaller opening size than the inner mesh (or the inner mesh and the zonal reinforcement mesh outwardly of each (or some) corner(s)) for some spaces between openings (or elsewhere as the Rules mandate).

In yet another further aspect, the invention consists in a building envelope having battens that support part or all of an in situ formed panel (preferably of about 21 mm thick);

wherein there is

an inner mesh attached to the battens

    • zonal reinforcement mesh outwardly of at least some corners of any openings in the panel
    • an outer mesh,
    • different and/or same zonal reinforcement by a mesh, and
    • a plaster matrix embedding all of the meshes;
    • and wherein the perimeter of the in situ formed movement control jointed containing panel is other than square or rectangular;
    • and wherein there is a Rule dictated movement control joint provided as a consequence of any significant departure of the square or rectangular perimeter.

In another aspect the invention consists in any of the assemblies, procedures, structures, NZ regulatory authority satisfying cavity wall stucco panels or the like substantially as herein described with or without reference to the “Rules” and/or with or without reference to any one or more of the accompanying drawings.

In a further aspect the invention consists in a building envelope having battens that support, part or all of an in situ formed panel of about 21 mm thick;

wherein there is

    • an inner mesh attached to the battens,
    • a plaster matrix carried at least in part by the inner mesh and
    • an outer mesh in turn supported, by embedment by the plaster matrix;
    • and wherein any one or more of the preferments apply.

Preferably an envelope is further characterised in that the battens are supported from framing or a substructure.

Preferably that framing or substructure includes studs of timber, metal or other material.

Preferably the battens are fixed by penetrative fixers with preferably no fixing of the wire mesh is fully through a batten.

Preferably the panel reinforced by overlays of one or both the inner and outer mesh with further mesh reinforcing.

In another aspect the invention consists in a method of in situ formation of a reinforced plaster panel as cladding of a support structure, (eg. thereby to define a stucco type cavity wall structure) said method comprising or including the steps of

    • said fixing battens to the support structure,
    • preparing for the panel creation
      • (A) by affixing a mesh (as an “inner mesh”) to the battens, and
      • (B) providing prior to such affixing of the inner mesh, during the affixing of the inner mesh and/or after the affixing of the inner mesh, a periphery to co-act with the inner mesh as at least part of the formwork,
    • applying plaster into and onto the inner mesh and/or to or adjacent to the periphery to provide a base coat of plaster,
    • after at least a partial set of the base coat, applying plaster onto the base coat as a second and levelling coat to the periphery,
    • overlaying the second and levelling coat with a mesh (the “outer mesh”),
    • by any suitable means (eg. trowelling and or otherwise) embedding or part embedding the outer mesh into the second and levelling coat, and
    • applying a third plaster coat onto the second and levelling coat or the second and levelling coat and the at least partially embedded outer mesh;
    • and wherein steps leading to any of the preferments are employed.

Preferably a building, cavity wall type structure, or stucco panel, of any of the previously defined or preformed forms is a result of such method.

The invention is also any product of such a method.

The invention is also, in combination, components suitable for or of any such product produced by such a method.

In another aspect the invention is a building structure comprising or including

    • framing of a pair of intersecting walls;
    • battens outwardly (as herein defined with respect to internal or external intersections);
    • a lower set of stucco panels cladding over some of the battens;
    • a higher set of stucco panels cladding over some of the battens, there being a space defined between the lower and higher sets; and
    • plural flashing members in and/or behind said space, including one flashing member that extends about the framing at the transition of framing for one of the intersecting walls to the other, in a mutual lapping condition flashing member to flashing member, affixed to the framing behind the lower regions of the higher set of panels and behind some of the battens, and extending over and down higher regions to the outside of the lower set of panels.

Preferably any one or more of the preferments herein referred to apply.

In still another aspect the invention is a building structure comprising or including:

    • framing of a pair of intersecting walls;
    • battens outwardly (as herein defined with respect to internal or external intersections);
    • a lower set of panels being of mesh reinforced plastered material(s), cladding over some of the battens and attached by the mesh at least to the battens and/or framing;
    • a higher set of panels, being of mesh reinforced plastered material(s), cladding over some of the battens and attached by the mesh at least to the battens and/or framing, there being a space defined between the lower and higher sets; and
    • plural flashing members in and/or behind said space, including one flashing member that extends about the framing at the transition of framing for one of the intersecting walls to the other, in a mutual lapping condition flashing member to flashing member, affixed to the framing behind the lower regions of the higher set of panels and behind some of the battens, and extending over and down higher regions to the outside of the lower set of panels.

Preferably any one or more of the preferments herein referred to apply.

In still another aspect the invention is a building structure of a stucco type comprising or including:

    • framing of a wall;
    • battens on said framing;
    • a horizontally spaced pair of in situ formed panels cladding over said battens on said framing, the pair of panels defining a vertical movement control joint
    • wherein the vertical movement control joint is being a vertically extending space bounded by opposing edges of each panel, and a vertically extending flashing having
      • (i) a zone (“zone 1”) underlying, as a flange, each proximate edge region of a panel but over a said batten;
      • (ii) a zone (“zone 2”) from each flange-like zone facing and/or keying to the edge of the panel; and
      • (iii) a zone (“zone 3”) of allowing flexure horizontally between zones (i), zones (ii) or zones 1 and 2.

Preferably any one or more of the preferments herein referred to apply.

In yet another aspect the invention is a side jamb assembly of or for a peripherally framed glazed or glazable assembly of a stucco type structure, the side jamb assembly having:

    • at least one framing member vertically extending about the opening to be glazed and dressed;
    • at least one batten vertically extending from said framing members;
    • a first extruded flashing affixed to at least one batten to underlie in part behind an inserted, or to be inserted, peripherally framed glazed or glazable assembly, and
    • a second extruded flashing outwardly of but extending laterally to the first extruded flashing, and affixed to at least one batten.

Preferably any one or more of the preferments herein referred to apply.

    • In still another aspect the invention is a sill flashed window or door assembly of a stucco type building structure:

wherein a “Z” type flashing has

    • an upper flange behind part of each side jamb flashing extending down towards the median part of the “Z” form;
    • an upturn of each partly freed end region of the median part, rising as it extends rearwardly from the lower flange, to or towards the upper flange, and
    • each such upturn is sealed to the upper flange.

Preferably any one or more of the preferments herein referred to apply.

In still a further aspect the invention is a head flashed window or door assembly of a building structure of a stucco type:

    • wherein there is a ‘Z’ type head flashing with its median part and lower flange at each end overlying a top part of a side jamb flashing;
    • and wherein a flashing tape from (preferably under) the median part at each end of the ‘Z’ type head flashing is captured above the median part of the ‘Z’ type head flashing as at least part of a stop-end of an extruded still like drip edge extrusion as a flashing above both the median part and lower flange of the ‘Z’ type head flashing.

Preferably any one or more of the preferments herein referred to apply.

As used herein the term “and/or” means “and” or “or”. In some circumstances it can mean both.

As used herein the term “(s)” following a noun means one or both of the singular or plural forms.

As used herein “stucco” or “stucco panel(s)” includes (but is not limited to) any batten fixed mesh carrying a plaster matrix which itself embeds a mesh more outwardly of the batten fixed mesh, the panel(s) having been in situ formed to structure or frame carried battens.

Preferably regional reinforcement by one or both meshes being overlayed is provided.

As used herein the term “wrap” and related words) in respect of the first or inner mesh envisages, but is not limited to, discrete mesh expanses being placed (preferably with lapping) to provide an inner mesh support wheresoever there is to be the laying up of the plaster system.

As used herein “mesh” includes any lath or indeed alternatives such as any suitable perforate sheet. Preferably in respect of the batten fixed “inner” reinforcement it is of metal substantially as herein described. However in other variants it can be of, for example, stainless steel. The term “mesh” (or indeed the alternatives referred to) where not the batten fixed “inner” reinforcement or fixed regional reinforcement preferably is of a suitable glass or plastics fibre or at least derived from such materials (i.e. glass or plastics). In still other less preferred embodiments it can be of metal.

As used herein, the term “regional” means less than coextensive with the whole panel (minus openings). The preferred inner and outer reinforcements that are preferably so coextensive are “nonregional” in that sense.

As used herein “plaster” or “plaster matrix” can include (but is not restricted to) in the same panel, the same or different “plaster” for different layers of application.

For example MCL® Stucco Rite® System plaster mixes. Such as, in sequence, NZ660 Multicoat cement plaster (pumped, and trowelled only after outer mesh placement) and top coat layer NZ660 Multicoat cement plaster (hand skimmed) and sponge finish.

Alternatively, a water repellent plaster sealer may be applied as a seal to the second layer and a top coat of a finishing plaster applied [e.g. MCL® Stucco Rite® AL40 SP Polymer Modified Finishing Plaster.

A water repellent plaster sealer may be applied prior to full set. A final waterproof coating can be applied post set.

To those skilled in the art to which the invention relates, many changes in construction and widely differing embodiments and applications of the invention will suggest themselves without departing from the scope of the invention as defined in the appended claims. The disclosures and the descriptions herein are purely illustrative and are not intended to be in any sense limiting.

BRIEF DESCRIPTION OF THE DRAWINGS

One preferred form of the present invention will now be described with reference to the accompanying drawings in which

FIG. 1 shows in isometric a preferred moulding (or if an extrusion preferably with added machining) to provide for leakage bottom preferably with a drip edge (eg. as in our NZ Registered Design 408975),

FIG. 2 shows in isometric a moulding (or extrusion preferably optionally with machining) suitable for use for the window and door head, and which also provides a drip edge (eg. as in our NZ Registered Design 408975),

FIG. 3 shows a soffit or sill flange (eg. as in our NZ Registered Design 408977) able to be extruded,

FIG. 4 shows a jamb flashing able to be extruded (eg. as in our NZ Registered Design 408976),

FIG. 5 shows a vertical movement control joint extrusion (eg. as in our NZ Registered Design 408978),

FIG. 6 shows a preferred form of mesh to be used as the first or inner mesh, the mesh having a full or partial paper backing,

FIG. 7 shows a variety of horizontal movement control joints each in the form of a Z flashing and with complementary components able to accommodate for both external and internal corners of the outer cladding of the building envelope, FIGS. 60-72 show these components in more detail,

FIG. 8 shows a typical batten for use in the framing or substructure in accordance with the present invention, such battens for example being treated to H3.1 or H3.2,

FIG. 9 shows a typical framing radiata pine dwang treated to H3.1 or H3.2,

FIG. 10 shows a typical stainless steel ring grip nail (for example of 75 mm×2.8 mm diameter) for insertion into battens and/or framing components,

FIG. 11 shows a typical hot dipped galvanised round head nail (for example 20 mm×2.8 mm) used in some of the subassemblies or assemblies hereinafter depicted,

FIG. 12 shows a typical stainless steel staple (for example of at least 1.6 mm diameter) able to be used to locate the inner mesh to the dwangs,

FIG. 13 shows a typical flashing tape to be used,

FIG. 14 shows a typical silicone sealant dispenser,

FIG. 15 shows a typical wall wrap which can be used between the framing members and dwangs such as in FIG. 9 and the battens (such as shown in FIG. 8),

FIG. 16 shows the Z form flashings preferably of powder coated aluminium that can be used as head or sill Z flashings,

FIG. 17 shows a typical timber framing layout typically of double stud adjacent openings and with dwang spacings of 900 mm or less, typical dwang sizes being 45 mm×90 mm or larger with the stud sizes being complementary,

FIG. 17A shows nominal stud spacings of 600 mm, nominal dwang spacings of 90 mm centres and batten placement on each stud and midway (i.e. at about 300 mm) between studs.

FIG. 18 shows framing such as shown in FIG. 17 wrapped with the moisture barrier wall wrap of FIG. 15, also showing the use of flashing tape about the openings,

FIG. 19 shows a concrete floor slab and its juxtaposition to the bottom member depicted in FIG. 1,

FIG. 20 shows a batten layout for a double level wall showing with the detailing head, from the top left in a clockwise sense, the sill detail, the head batten detail and the butt joint on a double dwang,

FIG. 21 is an elevational view detailing the positioning of the sill flange and its relationship to the sill Z flashing,

FIG. 22 details the side jamb flashing,

FIG. 23 shows the elevation of the head Z flashing in its subassembly,

FIG. 24 shows the soffit flange in elevation in its subassembly,

FIG. 25 shows in elevation where it is a movement control joints meets a horizontal movement control joint, the Z flashing extending horizontally,

FIG. 26 is a plan view of the vertical movement control joint and its relationship to the inner metal mesh, the outer fibreglass mesh, the plaster matrix and the battens,

FIG. 27 shows, to the bottom right of an opening, how sheets of inner mesh substantially as depicted are lapped and are fixed by staples to the underlying battens through the carried paper,

FIG. 28 shows some metal mesh, without the paper being used, as a zonal reinforcement overlay or reinforcement “patch” outwardly of the opening at each corner, such square mesh being laid diagonally in order to provide strength in directions other than primarily the vertical and horizontal, outer fibreglass mesh is then laid outwardly of the metal mesh.

FIG. 29 is a typical detail of the bottom of a door,

FIG. 30 shows an inner mesh and inner mesh corner reinforcement at the head of an opening,

FIG. 31 shows a similar arrangement for the bottom of an opening (in this case a window),

FIG. 32 shows a typical mesh to be used as the outer mesh (typically of fibreglass),

FIG. 33 shows a gun applying a second layer of plaster onto the first layer or base layer of plaster which has passed through the inner mesh and has attached at least in part to the inner mesh,

FIGS. 34A and 34B show the skeletal or lattice external corner members (eg. as in our NZ Registered Design Application 408974) positioned respectively to the top of the wall and to the bottom of the wall over the inner mesh,

FIGS. 34C and 34 D show the skeletal or lattice flange members positioned to the side of a window opening,

FIG. 35A shows the skeletal or lattice-like flange member (eg. of NZ408974) for use with each window and door opening,

FIG. 35B shows a jamb flashing (as in our NZ Registered Design Application 408976) able to locate and anchor one part of the skeletal or lattice flange of FIG. 35A,

FIG. 36 shows the combination of the two components of FIGS. 35A and 35B with the flange toeing into and being kept located by a shoulder of the side jamb flashing, the lattice region of the flange being able to be fixed by nail into a batten,

FIG. 37 shows an exploded diagram able to explain spacially how various components cooperate when an opening is to be glazed,

FIG. 38 shows in part the application of a mesh, as shown in FIG. 2, over part of the lattice region of the flange of FIG. 35A,

FIG. 39 shows the location of the lattice flange of FIG. 35 relative to a sill of a window opening,

FIG. 40 shows a base coat plaster being applied and using in part the lattice region to the nose of the member of FIGS. 34A, 34B and 35 substantially as both reinforcement and formwork,

FIG. 41 shows the trowelling in of the outer mesh (as shown in FIG. 32) subsequent to the application of the second coat shown being applied in FIG. 33,

FIG. 42 shows a plan view of the relationship of the components of the cavity wall system of the present invention,

FIG. 43 shows a vertical section of the detail shown in FIG. 42,

FIG. 44 shows in elevation the detailing with respect to a soffit,

FIG. 45 shows in more detail the arrangement previously shown in FIG. 19 ie. the concrete foundation and base detail,

FIG. 46 shows in plan the detail of an external corner, there being seen the lattice and nose providing corner member as shown in FIGS. 34A, 34B and 35,

FIG. 47 shows an internal corner (ie. internal only in the sense that it is still part of the exterior of the wall structures), no similar (but complementary) lattice member to that as depicted in FIG. 34A, 34B or 35 being necessary,

FIG. 48 shows head detail in elevation,

FIG. 49 shows sill detail in vertical section,

FIG. 50 shows jamb detail in plan,

FIG. 51 shows in vertical section the bottom of a door to deck with some sill detail,

FIG. 52 shows the bottom of a door to deck with flush detail,

FIG. 53 shows, in vertical section, a horizontal movement control joint between different wall levels (ie. its position optionally at an intermediate floor location),

FIG. 54 is a three dimensional view of a break away drawing of some features of the present invention,

FIG. 55 shows a vertical movement control joint meeting a horizontal movement control joint, all in vertical section,

FIG. 56 shows bottom drip edge detail to a flat roof wall, all in elevation.

FIG. 57 shows the plan section through a jamb to a typical door,

FIGS. 58A through 58MMM show diagrams and detail (herein incorporated as text hereof by reference) appropriate for application of certain rules (“Rules”) as to movement control joint (“MCJ”) location and extra fibreglass mesh reinforcement placement, such extra fibreglass being insertable by, for example, trowelling of it into an unset plaster layer, preferably the base coat layer.

FIG. 59A shows MCL® Stucco Rite® NZ660 multicoat cement plaster in 25 kg bags,

FIG. 59B shows MCL® Stucco Rite® A140 SP polymer modified finishing plaster in 25 kg bags & pre-mixed in plastic buckets,

FIG. 59C shows MCL® water repellent plaster sealer in plastic containers,

FIG. 59D shows MCL® fibreglass mesh 1×50 m rolls 160 grams per square metre,

FIG. 59E shows a MCL® uPVC Kwik™ corner,

FIG. 59F shows a MCL® uPVC Kwik™ flange for windows and doors,

FIG. 59G shows a MCL® Stucco Rite® mortar pump (G5C),

FIG. 59H shows a MCL® Stucco Rite® pump (Blitz),

FIG. 59I shows a MCL® Stucco Rite® Mortar Pump (Ritmo),

FIG. 60 shows a straight joiner moulding,

FIG. 61 shows a ‘Z’ flashing aluminium extrusion,

FIG. 62 shows a straight joiner moulding joining two ends of ‘Z’ flashing aluminium extrusions,

FIG. 63 shows a front view of the assembly of FIG. 62, and shows the location of the cross section A-A,

FIG. 64 shows an end view of the assembly of FIG. 62,

FIG. 65 shows the cross section view A-A of FIG. 63, and shows the location of the detail ‘B’,

FIG. 66 shows the detail ‘B’ of FIG. 65,

FIG. 67 shows a corner joiner moulding (as moulded), which is reversible to suit both external and internal corner configurations via the use of packers,

FIGS. 68A and 68B shows corner joiner packer mouldings which can be clipped into the corner joiner moulding of FIG. 67 for the external corner configuration,

FIG. 69 shows an external corner joiner assembly with packers clipped into place,

FIG. 70 shows an end view of the external corner joiner assembly of FIG. 69,

FIG. 71 shows an internal corner joiner assembly, no packers are required,

FIG. 72 shows an end view of the internal corner joiner assembly of FIG. 71.

 DETAILED DESCRIPTION OF THE INVENTION

The existing MCL StuccoRite® Cavity Wall Cavity System is a masonry cladding system incorporating a 35 mm vented cavity, comprising of special pre-papered steel mesh fixed to H3.1 treated timber battens, incorporating flashings for openings and penetrations, control joints, H3.1 treated fixing blocks, plus a proprietary cementitious render. The cladding system is installed on timber framing that complies with NZS3604 protected by a building wrap and protected by a building wrap and pre-qualified window sealing tape that complies with Table 23 of E2/AS1 and BQI interim Performance Standard BQI C4021*. The render is protected from the weather with a coating system complying with BQI interim Performance Standard C5031*.

In the opinion of BEAL, the MCL StuccoRite® Cavity Wall Cavity System (known as MCL StuccoRite®) and when installed according to the MCL StuccoRite Technical Manual dated January 2006, will meet the following performance requirements of the Building Code:

    • Clause B1—Structural Integrity (including to NZS3604: 50 m+wind speed)
    • Clause B2—Durability
    • Claims C—Spread of Fire (resistance)
    • Clause E2—External Moisture

The present invention is an evolution of that system.

The current system of the invention comprises proprietary plaster, reinforced with pre-papered hot dipped galvanised zinc steel wire MCL® StuccoRite® Mesh Sheet and other reinforcement, to achieve a nominal thickness of 21 mm with a standard sponge or plastic float finish. The plaster is applied by MCL® StuccoRite® Mortar Pumps over the mesh which is stapled to 35 mm×40 mm nominal sized H3.1 or H3.2 treated vertical timber battens providing a ventilated and drained cavity.

The proprietary plaster is applied in three coats; a base coat, a levelling coat, and the top coat. The base coat encapsulates the pre-papered MCL® StuccoRite® Mesh Sheet reinforcement as well as additional reinforcement at corners and around joinery. The levelling and mesh coat contains further reinforcement in the form of fibreglass mesh (MCL® Fibreglass Mesh).

The final skim coat is sponge or plastic float finish.

The MCL® StuccoRite® Mesh Sheet is fabricated from copper bearing cold drawn hot dipped galvanised zinc vertical face wires and horizontal back wires, electrically welded at all points of intersection. The zinc coating is not less than 27.9 g/m2.

The face and back wires are 1.5 mm diameter with openings not exceeding 51 mm. A layer of absorptive, slot perforated paper is placed between the face and back wires. The mesh is self furring by being fabricated horizontally into the lath at 152 mm centres with a 6.5 mm crimp in each face wire at its intersection with double back wires. A layer of Type 1, Grade D, Style 2 black building paper in compliance with UBC Standard No. 17-1 is strip glued to the back of the high absorbent slot perforated paper and is extended 100 mm beyond the lath at the left end of the sheet and 100 mm beyond the upper long edge of the sheet.

Reinforcement at all external corners is provided by MCL® uPVC Kwik corners being a 55 mm×55 mm angle with nosing and MCL®uPVC Kwik flanges, being 65 mm×15 mm angles with nosing, provide reinforcement at window and door openings.

MCL®Fibreglass Mesh is contained locally at certain openings in the base coat and continuously in the levelling and mesh coat. The MCL®Fibreglass Mesh is alkali resistant and woven with a 4 mm×4 mm aperture weighing not less than 165 grams per square mere.

The edges of the plaster are formed and supported by a number of uPVC mouldings. The MCL® Bottom J-Mould with Drip Edge and the MCL® Window/Door head with Drip Edge also provide vermin proofing and allow for drainage and ventilation to the cavity.

Movement is accommodated by providing physical breaks in the plaster. This is achieved with a uPVC moulding for the vertical movement control joint (VMCJ) and with a uPVC window head moulding and Z flashing for the horizontal movement control joint (HMCL).

Joinery shall comply with the requirements of E2/AS1 and be flashed with head and sill Z flashings as described in this Appraisal.

To provide a moisture resistant surface the completed plaster is sealed with the MCL® Water Repellent Plaster Sealer. The MCL® StuccoRite® System is completed by being waterproofed with the application of not less than a 2 coat paint system in accordance with Paragraph 9.3.7 of E2/AS1.

Components and consumables of the new system are preferably:

Battens—No. 1 framing, rough sawn or gauged 35 mm×40 mm Radiata Pine treated to H3.1 or H3.2.
Tolerance shall be + or −3 mm on both dimensions.
No. 1 framing Radiata Pine dwangs treated to H3.1 or H3.2. Minimum gauged 45 mm×90 mm.
Wall wrap complying with Table 23 of E2/AS1.
Flashing tape complying with Paragraph 4.3.11 of E2/AS!.
Powder Coated Aluminium Z flashings at head and sill of joinery.
Plain Aluminium Z flashing at garage door heads.
Mesh staples to the battens shall not be less than 1.6 mm diameter, 38 mm×9.5 mm or wider type 304 stainless steel gundriven divergent point staples.
Batten nails shall be not less than 75 mm long×2.8 mm diameter ring grip 304 stainless steel gun driven nail.
20 mm×2.8 mm diameter hot dipped galvanised round head nails.
Sealant to soffit, window/door jambs, HMCJ jointers and corners, meter box and all penetrations as per Paragraph 4.5.2 (g) of E2/AS1 which is a neutral cure silicone sealant.
At meter boxes 20 mm×20 mm×0.75 mm aluminium angle.
At decks:
M12 bolt with nut and washers; all Type 304 stainless steel length to suit.
50 mm×50 mmsq.×3 mm washer with 14 mm diameter hole, Type 304 stainless steel. 50 mm×50 mm sq.×3 mm EPDM washer.
10DN PVC Sleeve 22 mm long.
Saddle flashings as described in NZS 3604 and E2/AS1 can be used but to the dimensions described herein. Flashing material shall comply with Clause 4.10.2 of NZS 3604 or the ‘50 year’ requirement of Table 20 in E2/AS1.
Proprietary Type 304 Stainless Steel Joist Hanger minimum shear strength half span x spacing×3.35 kn (for 2.0 kpa Deck) or 4.85 kpa (for 3.0 kpa Deck)
140 mm×140 mm sq.×13 mm fibre cement board with 14 mm diameter hole.
Aluminium Z Flashings and uPVC Mouldings
MCL® Plain Aluminium deck and HMCJ Z flashings including uPVC Jointers and Corners to the HMCJ Z flashings all as described in the Technical Manual.
MCL® uPVC Bottom J-Mould with Drip Edge
MCL® uPVC Window/Door head with Drip Edge
MCL® uPVC Soffit/Sill Flange
MCL® uPVC Side Jamb Flashing
MCL® uPVC Vertical Movement Control Joint

Plaster and Sealer:

MCL® StuccoRite® NZ 660 Multicoat Cement Plaster (25 kg bags)
MCL® StuccoRite® AL 40 SP Polymer Modified Finishing Plaster (25 kg bags and pre-mixed in plastic buckets).
MCL® Water Repellent Plaster Sealer in plastic container.

Reinforcement

MCL® StuccoRite® Mesh Sheets by K-Lath Division of Tree Island Steel Inc, Monrovia California Fed. Spec. QQ-L-10c. (2.180 m×0.7 m)
MCL® uPVC Kwik Corner Reinforcing
MCL® uPVC Kwik Flange Reinforcing
MCL® Fibreglass Mesh with 4 mm×4 mm apertures and weighing 160 g/sqm (1 m×50 m rolls).
The MCL® plaster shall be mixed with potable water and applied to walls by a MCL® StuccoRite® Mortar Pump. These electric powered rotor/stator pumps are as shown in the Technical Manual and are supplied for purchase or hire by MCL®.

Materials for use as the plaster system are available from Mineral Coatings (NZ) Limited.

The MCL® StuccoRite® System requires a continuous concrete foundation or slab edge thickening under all walls.

The MCL® StuccoRite® System is intended to be fixed to timber walls with studs at 600 mm centres, heights up to 4.8 m and dwangs spaced at up to 900 mm centres. An additional dwang is required at soffit level as described in the Technical Manual.

The system is able to resist wind face loading up to and including those associated with VH wind speed zones.

The weight of the total system is 41 kg/m2 and does not contribute to the building lateral bracing.

The system may be fixed to wet timber framing provided the interior lining and insulation is not installed until the framing moisture content is less than 18%.

The location of Movement Control Joints (VMCJs) shall be shown on the consented building elevations in compliance with the Rules.

Vertical Movement Control Joints (VCNJ's) shall be provided at changes in elevation, at openings and to break the length of a wall into sections no wider than 8 meters or 2.75 times the panel's height all as required by the Rules hereafter. Where VMCJ's are required they shall not be located any closer than 175 mm to any penetrations including those for windows or doors.

Horizontal Movement Control Joints (MMCJ's) shall be provided at intermediate floor level where the moisture content of flooring timbers or wall plates abutting the intermediate floor is greater than 18%. Checks on moisture content shall be conducted prior to plastering commencing to ensure this requirement is met.

Where battens extend continuously past an intermediate floor (i.e. with no provision for a HMCJ) and checks before plastering reveal a moisture content higher than 18% then either the wall shall be re-battened allowing for the provision of a HMCJ at intermediate floor level or plastering operations shall be delayed until such time as the moisture content has dropped to 18% or less.

In addition to any HNCJ that may be required at the intermediate floor level, HMCJ's shall be provided at horizontal steps and to break the height of the wall into panels with a maximum average height of 5 meters except at gable ends and other certain narrow panels all as required by the Rules hereafter. Where HMCJ's are required to limit height they shall be located at an intermediate floor as shown herein.

The MCL® Stucco Rite® System allows for the construction of decks, simply supported or cantilevered. The requirements of NZS 3604 must be followed except to extent required to account for the junction.

Whilst specific materials have been specified for various employments herein, various consumables in so far as the reinforcement attachment and building up the matrix, a person skilled in the art will appreciate other alternatives that might exist Likewise in respect of any weather proofing of the plaster matrix other options to those described or described in the aforementioned website can be used.

FIG. 1 shows a preferred bottom member 1 preferably of a small uPVC and having two main flanges and a drip edge as well as openings 1A for moisture drainage purposes.

FIG. 2 shows, similarly of a uPVC material, a member able to act as a window and door head. This member 2 also has a drip edge feature 2A and moisture drainage openings 2B for use in the assembled condition shown in FIG. 55 as an example.

FIG. 3 shows a soffit and sill flange 3, preferably also of uPVC.

FIG. 4 shows a member 4 which can act as a jam flashing. This also is preferably of uPVC.

FIG. 5 shows a preferred member, preferably also of uPVC, able to be used to provide a vertical movement control joint. This member with its bellows like central region and its two flanges (each with openings to facilitate water migration and/or fixing) is used in the manner as shown in FIG. 26.

FIG. 6 shows MCL® Stucco Rite® zinc coated mesh sheet typically of 2.180 m×0.7 m double wire. This wire mesh is used as the inner mesh 6 and is laid with overlapping over battens 8 to be stapled by staples 12.

The same mesh, without the paper backing shown in FIG. 6, can be used for the reinforcement requirements at the corners herein described. These reinforcement members 23 likewise can be stapled to battens or can be tied to the existing mesh 6, or both.

FIG. 7 shows aluminium control joint members showing assemblies of corner elements with straight flashing portions. The Z form flashing members 7 are used as part of the horizontal movement control hereinafter described. Shown as 7A and 7B respectively are assemblies of such components for use on an inside exterior corner and an outside exterior corner respectively.

FIG. 8 shows a typical rough sawn treated batten as foresaid typically 35 mm by 40 mm.

FIG. 9 shows a typical dwang component 9 preferably of minimum size 45 mm by 90 mm for use with the framing (typically shown in FIG. 17).

FIG. 10 shows a typical nail 10 that can be used in the system to secure battens to the under lying building structure or wooden frame such as shown in FIG. 17.

FIG. 11 shows nails 11 able to be used to secure some of the flashing components and other components as hereinafter described.

FIG. 12 shows a staple 12 able to be used to secure the mesh 6 to the underlying battens 8 as hereinafter described.

FIG. 13 shows flashing tape 13 used, for example, in a manner shown in FIG. 18 in connection with the wall wrap 14.

FIG. 16 shows powder coated aluminium head and sill Z flashings 15 used as hereinafter described.

FIG. 17 shows, by way of example, a simplified frame of studs, paired about openings and provided with appropriate dwangs.

Preferably the studs are at 600 mm centres or less.

Preferably the gaps between bottom plates and dwangs and between dwangs is a maximum of 900 mm.

The underlying frame as shown in FIG. 17 is then wrapped with the wrapping material 14 as already used in the Stucco Rite® system. The flashing tape 13 is applied as shown about a window opening 16 and door opening 17.

Battens 8 are then applied over the surface. These battens are shown over the wrap as shown in FIG. 8. Battens are paired alongside openings and are elsewhere spaced vertically such that there is a batten to all studs and in between. The maximum batten spacing is 300 mm.

The batten fixing with nails 10 is shown in FIG. 20 for a two level structure, the transition between the two levels being shown.

The construction method is preferably as previously stated. This results in a bottom panel near a foundation or concrete slab 18 having a batten 8 nailed by nails 10 into a floor plate on the slab 18 with building paper 14 interposed. A bottom member 1 as in FIG. 1 is located with its flanges as shown in FIG. 19 and nailed by nails 11 to the floor plate. In turn the inner metal mesh 16 is fixed to the battens 18 by staples 12 thereby to allow a sequence of applications of plaster to provide the build up of a plaster matrix 20 (preferably of three layers) which also embeds the fibreglass mesh 19.

FIGS. 21 and 22 shows similar arrangement for the use of a sill flange and the side jam flashing.

In FIG. 21 the steam attached to a batten by nail a sill flange 3 and in turn its been overlayed so as to provide a canopy effect by a head flashing 15 or 7.

FIG. 22 shows in plan a double batten arrangement 8 into a double stud arrangement about a window or door opening. Shown is a lattice like member 21 toed as in Figure?

In FIGS. 35A to 36 show the side jam flashing 4, the lattice providing member 21 (preferably also of a PVC material) to be used in position substantially as shown in FIGS. 38 and 39. Shown in part in FIG. 38 is the outer mesh 19 overlying the lattice type member 21.

With reference to FIGS. 35 to 36 jamb flashing 4 may be installed flush with the inner window trim edge. The window flange 21 can then be fitted, by clipping the window flange 21 into the vertical groove of the jamb flashing 4. Nails/clouts 11 can then be used to fasten the window flange 21 in place.

FIG. 37 shows in respect of an opening how a side jam member 4 is to be used to underlie the canopy of the to be fitted head flashing 7. This position alongside an opening and to battens subsequently enables lattice member 21 to be toed in for nail fixing.

Incidentally FIG. 37 shows bevelled battens 8 to allow both the top 13 (and the end-stop tape 13A) and the top region of flashing 7 under the battens 8.

Later drawings show other preparative arrangements and the resultant stucco panels.

A feature that enables the satisfying of likely regulatory requirements for such larger size panels (albeit nominally of 21 mm thickness) is all as shown. A major requirement is not to take panels beyond an approved size without moving control joints or by satisfying the reinforcement requirements (that preferably involves the use of an extra amount of mesh as dictated by the Rules hereinafter described) and the movement control joint requires (also as dictated by the Rules).

FIG. 44 shows soffit 25 positioned relative to an underlying panel of the system, the soffit 25 being overlayed by a timber member 35.

FIG. 51 shows flooring 30 over blocking 31 in relation to an in situ formed panel. FIG. 52 similarly but note the set down option.

FIG. 53 shows a HMCJ below flooring 30 and a joist 32. Shown is a top plate 33 and a stud 26. Also a bottom plate 34.

The bevelling of battens 8 can be seen in a number of locations to accommodate flashing taped flashings.

The usual method of construction can be seen by reference to our website mentioned previously.

Shown, by way of example, in FIG. 1 is an already applied basecoat A over and through the mesh 6 and any additional regions of mesh 23 as mandated outwardly of each corner.

The second layer B is being shown applied in FIG. 3 and this is the region on to which mesh 19 is positioned and trowelled in as shown in FIG. 41.

Any extra mesh material (e.g. of preferably a similar type to 19) mandated by the Rules is positioned on or applied into the base layer A (e.g. by a similar technique to that shown for mesh being positioned into layer B). This is in addition to the mesh 23 requirements.

Once the mesh impregnated layer B has been smoothed the third coat can then be applied thereby to leave the plaster matrix ready for finishing in a manner as previously described. For example any suitable preset/post set water repellent/resistance coating system.

Rules for MCJ Location and Fibreglass Mesh Reinforcing

For the purpose of these Rules the alphanumeric and numeric content of the appended drawings is here included by reference.

The location of movement control joints, both vertical (VMCJ) and horizontal (HMCJ), and additional Fibreglass Mesh into the basecoat, all is required by these Rules, shall be shown on plans and specifications.

With stucco extending vertically from the base of the wall (i.e. bottom member of FIG. 1) to the top of the wall (i.e. soffit flange shown in FIG. 44) and horizontally between external or internal corners (see FIGS. 46 and 47) it shall be divided (where size of panel dictates) into wall panels by means of horizontal (HMCJ) and vertical (VMCJ) control joints (see FIG. 25 and FIG. 26) as required by the following Rules.

The width and average height of a wall panel shall be measured between the control joints or the stucco edges (base soffit or internal/external corners) that bound the wall panel.

For the purposes of these Rules the locations and dimensions of the “openings” shall be measured to the plasters' edge.

Rule 1 A VMCJ, as required by these Rules, shall extend from the bottom member of FIG. 1 or a HMCJ of FIG. 25 up to the soffit or upper HMCJ. A HMCJ shall extend the full width of the wall panel and around internal or external corners along the adjacent wall panel to a VMCJ. A HMCJ does not have to extend beyond a VMCJ.

Rule 2 A VMCJ is required:

    • a) At each end of all openings wider than 3 m or higher than 1.95 m. the VMCJ's shall be placed no further than 300 mm from each side of the openings except a VMCJ is not required if the openings is closer than 600 mm from an internal or external corner or when Rule 10 applies.
    • b) At a change in wall heights except as allowed by c) below.
    • c) Where a change of direction occurs in either the top or bottom of the MCL®Stucco Rite® wall panel and the angle between the panel surfaces, as shown in the figures below, is less than 135°. A vertical offset (angle is 90°±20°) up to 600 mm long does not require a VMCJ.
      VMCJ required at the locations shown in broken lines in each of FIGS. 58A to 58D. FIGS. 58A and 58B is for vertical offset lower and upper edge where height greater than 600 mm. FIGS. 58C and 58D were offset lower and upper edge at angle between surfaces less than 135°.

Rule 3 Install a HMCJ at any horizontal step in a wall panel where the width of the step is wider than 600 mm. For steps less than 600 mm embed a 400 mm square of fibreglass mesh in the basecoat diagonally across the step.

Rule 4 HMCJs shall be provided at intermediate floor level where, at the time of plastering, the moisture content of flooring timbers or wall plates abutting the intermediate floor is greater than 18%. In addition, HMCJs at intermediate floor level shall be provided where necessary to ensure the requirements on panel height are met.

The maximum average height of a MCL® Stucco Rite® wall panel shall be 5.2 m except in the following situations where the maximum height of the wall panel shall be 7 m:

    • a) Panels wider than 2.5 m and less than 6 m with a monoslope top edge of angle greater than 11° from the horizontal, and
    • b) Panels wider than 4, and less than 8 m with sloping top surfaces of angle greater than 11° from the horizontal forming a gable with the apex located within the middle third of the panel width.
    • c) The Z-Flashings below a cantilevered timber deck, as required by on page and shown on drawing is also a HMCJ.

Rule 5 Not withstanding the above Rules, the maximum width (L) of a wall panel shall not be greater than 2.75 times its height or 8 m.

Rule 6 A minimum separation distance of 175 mm shall be provided between the following:

    • a) VMCJ's and openings
    • b) VMCJ's and corners (internal or external)
    • c) VMCJ's
    • d) Openings
    • e) Openings and corners (internal or external)
    • f) Corners (internal or external)

In all situations above where the separation distance is less than 300 mm provide a layer of fibreglass mesh in the basecoat over the full length of the separation distance. Where the separation distance is at an opening extend the mesh 300 mm beyond each end of the opening. See FIG. 58E onwards.

If the separation between openings is not horizontal or vertical but instead at some angle then the layer of fibreglass mesh in the basecoat shall extend out perpendicular to that angle, in both directions, over the full width of the separation for a distance of at least twice the separation distance. See FIG. 58E onwards (particularly FIGS. 58H to 58I).

Rule 7 When the sum of the opening heights (Σh) in a wall panel exceeds 40% of the wall panel's average height (H) then reduce the wall panel's width to not greater than 6 m. When determining the sum, openings separated horizontally by 900 mm or less shall be included as shown in FIG. 58E onwards.

Rule 8 When the ratio Σh/H as determined by Rule 7 exceeds 80% of the wall panel average height then in addition to meeting the Rule 7 a VMCJ shall be provided no further than 300 mm from each side of all openings. A VMCJ is not required if the opening is closer than 600 mm from an internal or external corner or when Rule 10 applies. See FIGS. 58H to 58I).

Rule 9 When the sum of the opening widths (Σb) exceeds 60% of wall panel width (L) then a layer of fibreglass mesh embedded in to the basecoat, shall be provided between all openings between openings and the panels edges extending from 300 mm above to 300 mm below he openings. When determining the sum, openings separated vertically by 900 mm or less shall be included as shown in FIG. 58E onwards (particularly FIGS. 58K to 58M). This mesh is not additional to that required by Rule 6.

Rule 10 If the distance between two openings is 1.2 m or less than two MVCJ's between the openings may be replaced by one centrally located VMCJ.

In respect of FIGS. 58E to 58M the following is the key:

L = width of MCL ® H = average Panel MCL ® Fibre Mesh in Stucco Rite ® Wall Height base coat extending Panel Σb = Sum of Opening 300 mm above and Σh = sum of Opening Widths below opening Heights b1b2 = opening widths h1h2 = opening heights

In FIGS. 58N to 58KK are shown examples for MCJ and mesh location on single level buildings. In these drawings the key is as follows:

L = Width of MCL ® R = Rise of Gable MCL ® Fibre Glass Stucco Rite ® Wall B = Opening width − Mesh in base coat Panel Single Level extending 300 mm H = Average Panel Σb = Sum of Opening above and below Height width opening H′ = Lower Panel b′ = Opening width − * = CMCJ's required Height lower level by Rules 2 or 8 and H″ = Upper Panel b″ = opening width − placed at min Height Upper Level separation distance h = opening heights − He - Eaves Height i.e. 175 mm single level VMCJ or HMCJ ------- * = CMCJ's required Σh = Sum of Floor/Wall Junction by Rules 2 or 8 and Opening Heights — placed at max h′ = Opening Height − separation distance Lower Level i.e. 300 mm h″ = Opening Height − Upper Level

In FIGS. 58LL to 58MM are shown examples for MCJ and mesh location on two level buildings. In these drawings the key is as follows:

L = Width of MCL ® R = Rise of Gable MCL ® Fibre Glass Stucco Rite ® Wall B = Opening width − Mesh in base coat Panel Single Level extending 300 mm H = Average Panel Σb = Sum of Opening above and below Height width opening H′ = Lower Panel b′ = Opening width − * = CMCJ's required Height lower level by Rules 2 or 8 and H″ = Upper Panel b″ = opening width − placed at min Height Upper Level separation distance h = opening heights − He - Eaves Height i.e. 175 mm single level VMCJ or HMCJ ------- * = CMCJ's required Σh = Sum of Floor/Wall Junction by Rules 2 or 8 and Opening Heights — placed at max h′ = Opening Height − separation distance Lower Level i.e. 300 mm h″ = Opening Height − Upper Level

The present invention has been described by reference to the drawings and requirements that might satisfy New Zealand regulatory approvals. Whilst the description is in respect of a wooden framed structure having a cavity depth of about 35 mm clad by a reinforced and weather sealed plaster matrix of about 21 mm thick, variations that might satisfy requirements in other countries are within the scope of the present invention. Reference is drawn to our website www.mineral.co.nz/stuccorite.cfm which discloses details of the existing MCL StuccoRite cavity wall cladding system described in our Technical Manual dated January 2006.

Some features of note in the new system include:

Stucco Panel

    • Pumped in mortar to mark face
    • Bagged dry-mix—consistent high quality mix design and consistency
    • Lower water/cement to achieve lower shrinkage
    • Fibreglass mesh standard in top coat
    • Square of fibreglass mesh diagonal in top coat across corners of openings
    • Additional fibreglass mesh in base coat of narrower stucco panels located between larger stucco panels
    • Max panel size 8 m×5.2 m

Mesh

    • K-Lath mesh is stapled to batten, not timber framing
    • Mesh can span up to 460 mm 16 g wire to 300 mm system or up to 640 mm with 149 g wire.
    • Built in plastering paper
    • Built in backing bituminous paper
    • Supplied and fixed as sheet with overlap of mesh and bituminous paper on two edges

Batten

    • Vertical timber batten is structural size and enhances strength and strength of wall
    • Batten placement at 300 mm spacings fixed not only to stud face but can span up to 1.2 m between dwang to plates
    • Battens can span over floor/walls junction

HMCJ

    • Spaced up to 5 m centres (instead of 2.4 m)
    • Special PVC z-flashing
    • Special PVC z-flashing splice and corner jointers
    • If z-flashing not nailed to batten then is replaceable due to taper at back of vertical batten
    • Can be located at
      • floor/wall junction
      • window head
      • any locations on timber framed wall

VMCJ

    • Spaced up to 8 m apart instead of 4 m
    • Not located at side of openings
    • Can be located as close as 175 mm to side of openings or corners
    • No VMCJ at top corner of openings
    • No VMCJ at bottom corner of openings
    • Shrinkage absorbed by rolling/deflection of the batten
      Special uPVC Profiles
    • Special pvc moulding for base of stucco wall panel incorporating batten, insert, drip edge
    • Special pvc moulding for window head and VMCJ
    • Special pvc moulding for window/door side jamb—two piece
    • Special pvc moulding for soffit, sill and edge
    • Special pvc moulding for VMCJ
    • Fully waterproof moulding
    • Accepts shrinkage or expansion
    • Does not require double studs at VMCJ
    • Does not even require any stud at VMCJ

Compliance with the Rules as set out we believe will enable compliance with both building code NZS3604 and plaster code NZS4251.

Claims

1. A building which has as a wall of its envelope, a wall of a size of at least 2.4 m high, and at least 4 m wide;

wherein the wall has
a frame or a substructure having studs at least some of which are spaced by a modular distance,
battens supported from and fixed to said frame or substructure, such battens fixed both on and between studs,
a first inner mesh attached to such battens,
a second outer mesh supported at least in part by a plaster matrix, and the plaster matrix applied as more than one layer, the plaster matrix penetrating the first mesh, interposing both meshes, attaching to the second mesh and covering the second mesh;
wherein the wall has at least one opening selected from a group consisting of door and window openings;
and wherein at least part of the periphery of each opening, within the matrix, has been further reinforced by one or more of (a) one or more of at least one mesh and/or lattice-work at each corner, (b) one or more of at least one mesh and/or lattice-work at each vertical side, and/or (c) one or more mesh between adjacent openings.

2. (canceled)

3. A building of claim 1 wherein there are dwangs at nominal 900 mm spacings between the studs.

4. A building of claim 1 wherein the batten attached mesh is of a metal.

5. A building of claim 1 wherein the batten attached mesh overlies a backing sheet.

6. (canceled)

7. A building of claim 1 wherein the second mesh is non-metallic.

8. A building of claim 1 wherein regional reinforcement is by or includes metallic mesh.

9. A building as claimed in claim 8 wherein the metallic mesh regional reinforcement has been attached prior to being embedded.

10. A building of claim 1 wherein regional reinforcement is by, or includes, a non-metallic sheet material or mesh able to be embedded and penetrated by the matrix material.

11. A building of claim 1 wherein panel boundaries include at least partially embedded lattice-like periphery defining members.

12. A building which has a wall that has

a frame or a substructure that includes studs substantially to a modularly spacing of about 600 mm where suitable,
battens supported from and fixed to said frame or substructure, said battens being fixed both to at least the modularly spaced studs and in-between,
a first mesh attached to such battens,
a second mesh supported at least in part by a plaster matrix, and
one or more additional mesh as regional mesh reinforcement,
the plaster matrix applied as more than one layer, the plaster matrix penetrating the first mesh, embedding the second mesh, embedding the regional mesh or meshes.

13. (canceled)

14. A building of claim 12 or 13 wherein there are dwangs at nominal 900 mm spacings between the studs.

15. A building of claim 12 wherein the batten attached mesh is of a metal.

16. A building of claim 12 wherein the batten attached mesh overlies a backing sheet.

17. (canceled)

18. A building of claim 12 wherein the second mesh is non-metallic.

19. A building of claim 12 wherein regional reinforcement is by, or includes, metallic mesh.

20. A building as claimed in claim 19 wherein the metallic mesh regional reinforcement has been attached prior to being embedded.

21. A building of claim 12 wherein regional reinforcement is by, or includes, a non-metallic sheet material or mesh able to be embedded and penetrated by the matrix material.

22. A building of claim 12 wherein panel boundaries include at least partially embedded lattice-like periphery defining members.

23. A stucco wall comprising or including

a stud including wall frame,
battens carried by the wall frame and in excess of the number of studs in the wall frame,
a mesh or the like perforate reinforcement sheet(s) carried by the battens,
a mesh or the like perforate reinforcement sheet(s) outwardly of and spaced from the batten carried sheet(s),
additional regional reinforcement mesh,
lattice and/or perforate reinforcement, and
a plaster or cementitious matrix, applied as at least a two layer application, that penetrates the batten carried sheet(s) and embeds or also embeds the other said reinforcement(s).

24. (canceled)

25. A wall of claim 23 wherein there are dwangs at nominal 900 mm spacings between the studs.

26. A wall of claim 23 wherein the batten carried mesh is of a metal.

27. A wall of claim 23 wherein the batten carried mesh overlies a backing sheet.

28. (canceled)

29. A wall of claim 23 wherein the more outwardly mesh is non-metallic.

30. A wall of claim 23 wherein regional reinforcement is by or includes metallic mesh.

31. A wall of claim 23 wherein the metallic mesh regional reinforcement has been attached prior to being embedded.

32. A wall of claim 23 wherein regional reinforcement is by or includes a non-metallic sheet material or mesh able to be embedded and penetrated by the matrix material.

33. A wall of claim 23 wherein panel boundaries include at least partially embedded lattice-like periphery defining members.

34. A building which has as a wall of its envelope, a wall of a size of at least 2.4 m high, and at least 4 m wide;

wherein the wall has
a frame or a substructure,
battens supported from and fixed to said frame or substructure,
a first inner mesh attached to such battens,
a second outer mesh supported at least in part by a plaster matrix, and
the plaster matrix applied as more than one layer, the plaster matrix penetrating the first mesh, interposing both meshes, attaching to the second mesh and covering the second mesh;
wherein the wall has at least one opening selected from a group consisting of door and window openings;
and wherein the, or each, opening is positioned only as allowed and the, or each, opening is further reinforced in the plaster matrix at least substantially in accordance with the Rules as herein provided.

35. (canceled)

36. A building of claim 34 or 35 wherein there are dwangs at nominal 900 mm spacings between the studs.

37. A building of claim 34 wherein the batten attached mesh is of a metal.

38. A building of claim 34 wherein the batten attached mesh overlies a backing sheet.

39. (canceled)

40. A building of claim 34 wherein the second mesh is non-metallic.

41. A building of claim 34 wherein regional reinforcement is by or includes metallic mesh.

42. A building as claimed in claim 41 wherein the metallic mesh regional reinforcement has been attached prior to being embedded.

43. A building of claim 34 wherein regional reinforcement is by or includes a non-metallic sheet material or mesh able to be embedded and penetrated by the matrix material.

44. (canceled)

45. A building of claim 1 wherein the panel formed from the plaster matrix and mesh is about 21 mm thick.

46. A building of claim 22, wherein the panel formed from the plaster matrix and mesh is about 21 mm thick.

47. A building of claim 34, wherein the panel formed from the plaster matrix and mesh is about 21 mm thick.

48. A building of claim 44, wherein the panel formed from the plaster matrix and mesh is about 21 mm thick.

Patent History
Publication number: 20130239498
Type: Application
Filed: Jun 8, 2011
Publication Date: Sep 19, 2013
Applicant: Douglas Charles Owens and Alistair William Capamagian as Co-Trustees for the Nereides Trust (Auckland)
Inventor: Douglas Charles Owens (Grey Lynn)
Application Number: 13/703,457
Classifications
Current U.S. Class: Framing To Receive Door, Doorjamb, Or Window Sash (52/204.1); Settable Material Receiving Backer Fixed To Furring, Joist, Or Stud (52/344)
International Classification: E04F 13/06 (20060101);