GB2502362A - Exterior curtain walling system comprising adjustable bracket. - Google Patents

Abstract

The system comprises an exterior wall panel 100 and a building frame: the wall panel comprises a top structure for mounting additional wall panels on and an adapter 200 for securing the panel to a horizontal floor structure 60 on the building frame. The adapter may secure the panel to the building from within the building. The adapter is preferably variable and allows adjustment of an upper panel in two horizontal directions and a vertical direction relative to the building while attached to a lower panel. The panel may include a temporary base protection track for reducing the likelihood of damage during the transit of the panel. The panel may include lifting cleats or anchors for assisting in the hoisting of the panel. Also claimed is a method of erecting an outer wall where a base panel is fixed at ground level and extends above a floor section of the building and has a further panel mounted on top.

Description

Walling System The present invention relates to a method and apparatus for constructing a wall panelling system of a building structure.

Background

External walling systems for buildings may be provided in the form of panel systems.

These are typically used for a variety of building projects such as hotels, student accommodation, commercial public, and residential buildings. In such building projects, a so-called primary frame is constructed as an initial building structure comprising load-bearing structures and floor slabs. The primary frame serves as support for subsequently fitted walls or walling systems Although wall panels or wall panel components can be pre-fabricated to a certain extent, there is a trade-off between reduced ease of handling and avoiding the need for on-site assembly of wall panels. Whereas some walling systems are assembled entirely on site, other components may be provided in the form of panels covering a full storey height. In either case, the presence of a number of operatives and machinery is required to assemble and/or install the walling system components to within required tolerances. In either case, the alignment of the walling panels to accommodate building tolerances of the primary frame is challenging. There is a desire in the industry to reduce the number of operatives required for assembling, handling, and aligning walling system components whilst reducing the on-site programme and minimising wastage.

The present, invention aims to provide improvements to walling systems and improvements to pre-panelised walling systems.

* Summary

j:". In a first aspect, a wall panel is provided for mounting to a building frame, wherein the building frame comprises at least one horizontal floor structure dividing two storeys of the building. The wall panel is adapted to be mounted to the outside of said building frame so as to eend from below to above said horizontal floor structure. The panel comprises a top structure for supporting another wall panel; and an adapter for securing the wall panel to said building frame.

It is an advantage that, by extending above the horizontal floor structure, the wall panel can serve as an edge protection system. This reduces the need for external scaffolding and edge protection. Because the wall panel extends below the horizontal floor structure it can be mounted to the underlying operatives at a convenient operating height. The adapter allows the wall panel to be secured to the building frame while the load of the panel is supported by underlying panels or support ledgers.

Thereby, construction and alignment is facilitated. Because the panel is pre-fabricated there is less need for on-site assembly.

The wall panel adapter may be provided for securing the wall panel to the horizontal floor structure of the building frame. The adapter may be provided for securing the wall panel to the building frame from within the building frame.

It is an advantage that this arrangement allows each wall panel to be lifted onto the wall panel below, for instance using a crane. Once a panel is aligned in place, the adapter allows securing the wall panel to the frame such that the next panel can be added. By minimising the number of fixture points, a continuous walling system can be erected in short time. Thereby, the number of operatives on required site can be reduced.

Further because the fixtures can be located on the floor slab, they are easily accessibla This is believed to facilitate compliance with safety requirements and to reduce the need for operatives on site. It is expected that no external scaffolding is required for erecting the continuous walling system.

The adapter may allow adjustment of the panel position relative to the building frame.

The adjustment may occur from within the building frame when the wall panel rests on a lower panel mounted to the building frame below. The adapter may allow adjustment *\ in a horizontal direction parallel to the face of the building frame. The adapter may allow adjustment in a horizontal direction perpendicular to the face of the building * frame. The adapter may allow adjustment in a vertical direction. The adapter may :.: . 30 allow adjustment in a vertical direction when the adapter is horizontally fixed to the building frame.

It is an advantage that the adjustability of an adapter allows the panel to be aligned * with the supporting underlying panel or support ledger, while the adapter can be adjusted to accommodate any allowed building tolerances. After adjustment, the adapter is horizontally mounted and thereby anchors the panel towards the building frame. The vertical leeway provided by the adapter allows a horizontal connection to be maintained while accommodating any vertical deflection of the floor slab. Such deflections can be considerable during the lifetime of a building structure, and have hitherto been an impediment to implementing continuous walling systems.

In some embodiments each wall panel comprises a plurality of adapters. The plurality of adapters would be in horizontal alignment. The, or each, adapter may be located at less than the full height of the wall panel. The or each adapter may be located more than 70cm, more than 80cm, more than 90cm, more than 1 m, more than 1.1 rn more than 1.2 m, more than 1.3 m, more than 1.4 m, more than 1.5 m, more than 1.7 m, more than 1.8 m, or more than 2 m below the top edge of the wall panel.

It is an advantage that the horizontal alignment corresponds to the horizontal orientation of the floor slab to which the adapters are to be mounted. Locating adapters at less than the full panel height allows a panel portion above the adapters to be defined as an upper wall panel portion. This upper wall panel portion would correspond approximately to the panel portion that extends above a horizontal floor structure, and thus to the temporary edge protection. The height should be tall enough to comply with safety regulations or edge protection requirements, but not so high as to hinder easily connecting the panel with the subsequently supplied wall panel.

The wall panel may have a height of more than 1.8 m, more than 1.9 m, more than 2 m, more than 2.1 m, more than 2.2 m, more than 2.3 m, more than 2.4 rn more than 2.5 m, more than 2.6 m, more than 2.7 rn, more than 2.8 m, more than 2.9 m, more than 3 m, more than 3.2 m, more than 3.4 m, more than 3.6 m, more than 3.8 m, more than 4 m, or more than 4.5 rr.

it is an advantage that these heights correspond to typical building storey heights.

Thus, the erection of the continuous walling system can take place at a rate of one storey per panel.

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The wall panel may comprise a temporary base protection track, or one or more temporary base protection track sections.

It is an advantage that the temporary base protection track can serve as protective cover during transport, and can aid alignment with an underlying wall panel.

Temporary tracks may maintain an edge protection function at panel sections that are subsequently replaced, such as windows or balconies. Temporary tracks may provide structural support while the wall panel is not fixed to the building frame but can be removed once the support is not required for the panel.

The wall panel may comprise a compressive sealing at the panel edge faces.

It is an advantage that the compressive sealing improves the early tightness or sealing between panels, before any exterior cladding is applied. The tightness may be sufficient to provide early air-tightness or weather-tightness, Such early tightness is a milestone during a construction project. For instance, once weather-tightness has been achieved, interior fittings can commence, An external walling system allowing for early weather-tightness removes the external scaffolding hitherto required for sealing any gaps from the critical path for interior fittings.

The wall panel may comprise one or more lifting cleats. It is an advantage that the lifting cleats facilitate lifting by a crane. The lifting cleats may be temporary such that they can easily be removed once the panel is mounted to the building frame, before the next panel is received on the panel. Providing pre-fitted lifting cleats further reduces on-site assembly.

The wall panel may comprise a surface finish on the exterior, or second, surface. The surface finish may be a type of cladding. A pre-fitted finish has advantages in respect of the external work. The amount of construction, assembly, alignment, and sealing time, as well as associated risk faced by operatives, can be reduced. It allows construction in a controlled factory environment. It is believed that these advantages * are made possible by providing pre-fabricated wall panels.

In a second aspect, there is provided an exterior wail panel system designed for mounting to a building frame and comprising one or more panels as defined in the first aspect and a top panel, wherein the top panel is adapted to rest on top of a lower panel mounted to the building frame below, and to extend from the top of said lower panel to a top level of said building structure.

It is an advantage that the provision of wall panels improves the building quality because panels can be fabricated in a factory-controlled environment. Further the time and resources required on-site for erecting the walling structure are reduced.

In a third aspect, there is provided a method of erecting an outer wall of a building. The method comprises a step of providing a building frame that comprises at least one horizontal floor structure dividing two storeys of the building. The method comprises another step of securing a base panel to the building frame wherein the base panel is supported on a ground base and extends upwards a floor structure of said frame to a height above said horizontal floor structure. The method comprises another step of securing an upper panel to the building frame from within the building frame, the upper panel resting on a top structure of said base panel.

The method according to the third aspect may comprise, during securing the upper panel to the building frame, a step of securing said upper panel to said building frame using an adjustable adapter.

It is an advantage of the invention that both adjusting and fixing in position of the adapter can be undertaken from inside the building.

Brief Description of the Drawings

Fig. 1 shows a perspective view of a prior art walling system.

Fig. 2 shows a front view elevation of a pre-fabricated wall panel.

Fig. 3 shows a schematic view of wall panels forming a continuous walling system.

Fig. 4 shows a perspective close-up view of part of a pre-fabricated wall panel.

Fig. 5 shows a perspective view of a partial building structure fitted with a continuous walling system.

Fig. 6 shows a perspective view of a partial building structure fitted with pre-fabricated wall panels having a carrying a sheathing.

Fig. 7 shows a front elevation of a partial building structure fitted with a continuous walling system.

Fig. B shows a perspective view of an exemplary base support for a walling panel * * structure.

Fig. 9 shows a cross-sectional view of an intermediate support angle.

Fig. 10 shows a perspective view of an adjustable panel adapter.

Fig. 11 shows a perspective view of an adjustable panel adapter.

Fig. 12 shows a cross-sectional side view of an adjustable panel adapter.

Fig. 13 shows a perspective view of an adjustable panel adapter.

Fig. 14 shows a perspective view of an adjustable panel adapter.

Fig. 15 shows a cross-sectional side view of an adjustable panel adapter.

Fig. 16 shows a front view of an adjustable panel adapter.

Fig. 17 shows a cross-sectional top view of an adjustable panel adapter.

Fig. 18 shows a cross-section of a panel-to-panel joint.

Fig. 19 shows a cross-section of an external corner arrangement.

Fig. 20 shows a cross-section of an internal corner arrangement.

Fig. 21 is a schematic of steps during wall panel installation.

Detailed description

Fig. 1 shows a pre-fabricated walling panel 10 as known in the prior art. Walling panel is provided as an in-fill walling panel into a primary frame 50. In the context of a primary frame 50 of a building structure, room height R is the distance from the base surface of a floor to the ceiling the same floor. Storey height S is the distance from one floor level to the next, e.g. above, floor level. Thus, the difference between storey height and room height results from the thickness of the floor slab and its support beams. Floor slabs, which may be constructed from concrete, and support beams, which may be provided in form of hot rolled steel beams, can have considerable thickness in the region of half a metre. Typical room heights of modern buildings are between 2.4 metres and three metres, with room heights of over four meters being rare in conventional accommodation. In other words, the height of the floor slab may account for a considerable proportion of the storey height. Prior art panel 10 is ". : dimensioned to fit to a room height R. * *.t..

* Fig. 2 shows an embodiment of a pre-fabricated walling panel 100. Panel 100 is a generally planar structure having a first side and a second side Opposite the first side.

The first side is provided as the interior or inner side, which 5 designed to face towards the building structure when the panel 100 is installed on the building structure. The second side is provided as the exterior or outer side which faces away from the building structure to which the panel 100 is fixed. Panel 100 comprises a rigid frame skeleton of sturdy construction materials such as steel. Panel 100 comprises a plurality of horizontally and vertically arranged beams or tracks, which form a lattice structure, The beams and tracks are arranged as follows. A base track 110 is provided at the panel base, As shown in Fig. 2, the base track comprises a series of base beam sections 11 Oa, 11 Ob, 11 Oc, 11 Cd, 11 Oe which are placed end to end to extend over the full length 100w of the walling panel 100. For instance, width 100W may measure from to 8 metres, The base track 110 has thus a first end 112 and a second end 114.

Similar to the base track 110, a top track 120 is provided in generally parallel alignment with base track 110. lop track 120 extends from a first end 122 to a second end 124 and has the substantially same length 100w as base track 110. lop track 120 may comprise a plurality of sections but is generally a single component for stability purposes. In Fig. 2, an embodiment having a single top track beam 120 is shown. The distance lOOh between base track 110 and top track 120 is designed to correspond to the storey height S of a building structure, i.e. a panel 100 would therefore be taller than the room height R of a building structure.

in embodiments, base track 110 may be a temporary component of the lattice structure of panel 100. A temporary component is in place before or during erection of a panel 100, but will be removed subsequently. A permanent component is designed to remain in place for a significant duration of the building lifetime. Base tracks 110 can be provided as support and protection dunng transport and erection of a wall panel. In Fig. 2, a plurality of base tracks llOa to liCe is provided. Once a panel 100 is installed to the budding structure, base tracks can be removed or replaced by a permanent finishing. A base track will be permanent where it is connected to an underlying structure, e.g. for the bottom panel where this is constructed from the floor.

If panels are intended to be broken at the window sill level, as explained further below, a temporary track may be used at the base to aid construction.

: 30 Each of the individual base tracks 1 lOa-e is of a length and weight that allows it to be removed easily by as few operatives as possible, most preferably a single operative.

This arrangement allows removal of selected track sections from within the inside of * the building, while permanent base track sections can remain in place. For instance, a temporary track section would be removed prior to the placement of a window. A track section may be temporary by design, or may be provided as a supplementary section that may either remain as a permanent track section or may be removed if this is desired for aesthetic reasons, e.g. if it cannot be concealed behind subsequently fitted internal finishes.

Fig. 2 shows additional horizontal tracks 130, 140 between1 and generally parallel, to base track 110 and top track 120. The distance between horizontal tracks 130 and top track 120 is less than distance lOCH. As indicated in Fig. 2, the distance between tracks 130 140 and top track 120 may be 3/4 or 2/3 of the panel height lOOh.

However, this ratio is only provided as an example, because the distance between the horizontal tracks 130, 140 and base track 110 will be determined by a window frame height (described below), whereas the height 1001-I of panel 100 will be determined by the storey height S. Horizontal tracks 130, 140 do not run over the full length lOOw. In Fig. 2, two horizontal tracks 130, 140 are shown, of which track 130 extends from its first end 132 to its second end 134. Similarly, track 140 extends from its first end 142 to its second end 144.

A plurality of vertical beams 150 is provided in orthogonal alignment to the horizontal tracks 110, 120, 130. Vertical beams 150 connect top track 120 to base track 110.

Where horizontal tracks 130, 140 are positioned between top track 120 and base track 1101 the vertical beams 150 connect top track 120 to horizontal track 130 or 140.

Some of the vertical beams 150 may be provided as border beams. Vertical beam 152 connects first base track end 112 with first top track end 122. Likewise, vertical beam 154 connects second base track end 114 with second top track end 124. Base track 110, top track 120 and vertical beams 152, 154 make up the panel frame 115. Once mounted to the building structure, beams of panel frame 115 may adjoin to another frame 115 of a neighbouring panel 100, as indicated in the schematic arrangement of Fig. 3. For illustration, Figs. 5 to 7 show views of a continuous walling system employing a plurality of panels 100 in accordance with the description and numerals used in Fig. 2.

* .. 30 In Fig. 2, vertical beam 156 connects a centre portion of base track 110 with a centre portion of top track 120 and further to the first end 132 of horizontal track 130 (or, correspondingly, to the first end 142 of horizontal track 140). Vertical bean, 155 * connects a centre portion of base track 110 with a centre portion of top track 120 and * * 35 further to the second end 134 of horizontal track 130 (or, correspondingly, to the second end 144 of horizontal track 140). In other words sections of vertical beams 156 and 158 may later receive, or provide the function of, window jambs or door jambs, and horizontal beams 130 and 140 can be understood as lintels or transoms.

Additional vertical beams 158 may be provided to connect centre points of top track 120 to centre points of horizontal tracks 130 or 140. Vertical beams connecting to a centre portion are provided to increase the stability of lattice structure of panel 100. In use, a plurality of panels 100 may rest on top of each other and as such, a panel 100 may be dimensioned to carry the load of a plurality of other panels 100. For instance, panels may be dimensioned to carry the load of two, four, six, eight, ten, or more than ten other panels ioo. As a corollary, a panel 100 will generally be designed as a light-weight structure incorporating a plurality of hollow C-Section studs in order to reduce the load it exerts on underlying panels, while ensuring structural stability and load resistance to carry above-lying panels.

Cleats 160 are provided at the corner points between track ends 132, 134, 142, 144 and vertical beams 156, 158 to improve stability of the lattice structure and to provide strength points to the window or door jambs. Further cleats 160 are provided where vertical beams 156, 158 connect to base track 110. Fig. 2 shows two window openings and 172 that are formed by the arrangement of base track 110, horizontal tracks 130 and 140 and portions of vertical beams 156, 158.

The lattice structure composed of horizontal tracks 110, 120, 130 and of vertical beams 150, 152, 154, 156, 158 is exemplary, but is considered to combine economic manufacture and handling with strength and robustness. The generally planar structure of panel 100 is advantageous for transporting the panel 100 from the assembly facility to the construction site. For instance, a typical heavy goods vehicle employed in the industry may be suitable for transporting two stacks of ten panels each without requiring major modification. Other lathce structures, such as hexagonal or triangular arrangements, and combinations thereof, may however be employed.

* *. 30 The laftice structure of panel 100 may be complemented with external cladding.

External cladding is provided at the second, i.e. exterior, side of panel 100. Fig. 6 shows a plurality of wall panels 100 covered with external sheathing boards 180.

* **. Cement particle board may be used as material for the sheathing boards. Other * 35 suitable sheathing materials are known. An exemplary arrangement of nine boards 180a to 1801 is shown, which in combination cover the full panel area except for the window openings 170 and 172. It is understood that this arrangement of sheathing boards is provided for illustrative purposes and that any geometry or arrangement may be used to cover to external side of the panel 100. The size and number of the geometric arrangement may be dictated by regulatory requirements the stability of the sheathing material, or the suitability of the panel lattice structure. Vertical beams 150 or horizontal beams 130, 140 are generally supporting the sheathing boards 180.

As illustrated in Figs. 2-3 and 5-7, openings 170 and 172 may be of essentially the same height but of different width: However they may also be of the same size, There may be fewer or more than two openings. The number, shape, and arrangement of window openings may be varied according to the building requirements. Thereby, window installation can be coordinated with the panel design. In embodiments, the panels may be sized for clerestories or may be dimensioned for carrying bay windows or balconies. One or more openings may be dimensioned to accommodate doors, e.g. for balconies. An opening may comprise an arcuate or tapered portion in the shape of transoms. Prior to installation, an opening may be covered with a temporary sealing sheet to improve weather tightness of the panel 100 until final fittings can be installed.

An opening provided for a door may contain one or more temporary track sections, as explained above, so as to maintain the edge protection functionality during erection and until the final wall component is installed. Thereby, a temporary edge protection functionality can be provided by a panel 100.

Fig. 4 shows a portion of panel 100 equipped with a lifting cleat 190. For practical purposes, lifting cleats 190 may be bolted to top track 120 orto one more of vertical beams 150 near the upper portions of the vertical beams 150-158. These lifting cleats ". : 190 are provided to allow lifting by a typical main site tower crane. At a typical * construction site for medium rise or taller buildings, cranage is readily available.

* Panels 100 will be craned directly into location, e.g. by the main site tower crane.

Lifting cleats 190 allow safe and simple positioning and installation of panel 100. In practice, lifting cleats 190 have holes 192 which may have a particular size, shape and/or dimension in accordance with the specification of the crane or hoist facilities available on site. Standard dimensions for lifting cleats are known in the art. A panel may be fitted with cleat types of different size and dimension, to increase suitability for different lifting equipment. Lifting cleats 190 are bolted to panel 100 by bolts 194.

Cleats 190 may be temporary fittings and thus removed once panel 100 is erected and installed on site.

Some of the vertical beams 150 shown in Fig. 2 are provided with floor adapter cleats 200. Cleats 200 are an integral component of the prefabricated wall panel 100. A typical cleat may measure 150mm 100mm x 6 miii and may be fixed to the panel with Tek screws. Adapter cleats 200 are provided in a generally horizontal alignment parallel to top track 120 at a height level 210 approximately 2/3 of the distance between top track 120 and base track 110, nearer to the top track. Horizontal height level 210 can be interpreted as separating two portions of panel 100, thereby defining a lower wall panel portion 100L and an upper wall panel portion 100U.

The following paragraphs will describe how the panel 100 is fixed to a building structure 50. It will be appreciated that the panels at ground floor level and top floor level will require a different layout which will be explained in more detail further below.

A walling panel 100 can be mounted to a single floor slab 60 of the primary frame 50 from within the primary frame 50. A panel 100 is mounted to a floor slab 60 with adapter cleats 200, the floor slab 60 is generally aligned with height level line 210, as shown in Figs. 5 and 6. When a panel 100 is mounted to a floor slab 60, the upper panel portion 100U will extend above the floor slab 60 and the lower panel portion 100U will extend below the floor slab 60. Because lower panel portion 100L is by design less high than a storey height 5, lower panel portion 100L will not extend to the floor level of the next-lower floor slab. Above height level line 210, upper panel portion 100tJ extends a certain distance above the height level 210. The distance above height level may be more than 70 cm, more than 80 cm, more than 90 cm, more than ". : 1 m, more than 1.1 m, more than 1.2 m, more than 1.3 m, more than 1.4 m, more than 1.5 m, more than 1.7 m, more than 1.8 m, or more than 2 m. However, a typical height a..... * ..

* * . .1 The upper portion 100U serves as an edge protection system during construction of the walling system. In embodiments, particularly where panel 100 is used as a top floor panel, the upper portion 100U may serve as a permanent edge protection or parapet.

Panels are lifted to the designated floor height using a crane, and cantilevered on tap of a previously installed panel 100. The underlying panel assembly supports the weight of panel 100. In this temporary position a team of operatives fix panel 100 to the primary frame 50 with the adapter cleats 200, such that the height level 210 is at approximately the level of floor slab 60. Once the panel 100 is fixed to the floor slab 60, the upper panel portion iootj extending above the floor slab 60 is sufficiently secure to serve as a temporary edge protection system.

Until erection of the edge protection system, i.e. until installation of a panel 100, only those operatives who are tasked with mounting adapter cleats 200 to the primary frame require additional on site securing. However, this securing may be provided in the form of safety harnesses. The number of these operatives can be kept low because panel is pre-assembled Those operatives who attend to securing the lower portion 100U to the top track 120 of the underlying panel are covered by the edge protection provided by the underlying wall panel. It is an advantage of the present invention that no external scaffolding is required for the erection of the continuous walling system because operatives can work within the primary frame. Operatives not covered by the temporary edge protection can be sufficiently secured from within using safety harnesses.

in particular, the number of connectors 200 for a given width lOOw of a walling panel 100 is typically lower than those of other walling solutions, such that the number of fixing points is minimised. For instance, the exemplary panel 100 of Fig. 2 has four adapter cleats 200, and each adapter cleat 200 is fixed to an individual vertical beam at the first side, i.e. inside, of the panel 100. Therefore, the arrangement of pre-mounted adapter cleats 200 allows a walling panel 100 to be mounted to the floor slab 60 of a primary frame 50 with minimal resources, time and effort. it is contemplated that any given time, two operatives can be sufficient to mount the adapter cleats 200 of a single panel 100 to a floor slab 60.

*j Figs. 5 to 7 show a plurality of panels 100 fiUed to a primary frame 50. Panels 100 are provided as centre panels for a continuous walling system. As set forth above, the height of lower panel poion 100L is less than the height of panel 100 and less than storey height S, because panel 100 is designed to sit on top of an underlying panel.

Packs can be provided between panels to prevent any excessive grinding or damage to a seal surrounding perimeter 115. The horizontal alignment of stacked panels can * 35 be controlled by corresponding alignment holes in both panels. Because each panel is desined to be supported by the panel below, a variation of this system is therefore required for the lowest panel at ground-floor lever.

Figs. 5 and 7 show a continuous walling system including a ground-floor level panel 102. Ground floor panel 102 is a variant of the above-described panel 100. Whereas panel 100 has a height 10011 that is similar to the storey height of a building structure, panel 102 has a height 10211 which is generally the panel height 100H plus the height of upper panel portion 100U. Because of its height 102H, panel 102 is high enough to provide walling for the lowest floor and also to provide the edge protection function to the first floor above the lowest floor. The upper portion 102U of ground floor panel 102 will generally have the same height as the upper portion ioou, i.e. a height suitable for providing a temporary edge protection for the above floor level.

Panel 102 will have suitable modifications relative to panel 100, For instance, any window openings can be located at the base of panel 100 for ease of manufacture.

These openings are located at a height suitable for windows on the ground floor panel.

The embodiments of Figs. 5-7 show a primary structure with the same storey height S on each floor including the ground floor level. In practice, buildings may comprise one or more floors of different height, for instance a ground floor entrance hall that is higher than the upper floor levels. In such cases, the respective walling panel height will be dimensioned to provide edge protection and to extend over the full storey height of its respective storey.

The lowest panel, such as ground floor panel 102, requires a full load bearing capacity at the base. Fig. 8 shows the base of a ground floor panel 102 which is also the base of the continuous walling system, constructed from the base concrete slab of the primary frame upwards. The ground floor concrete slab supports the weight of the external walling. Fig. B shows an embodiment in which the ground floor concrete slab * * 30 of the primary frame protrudes further than the floor level slabs. In such a scenario, " each ground floor panel 102 can be anchored onto the ground floor slab of a primary frame, as shown in Fig. 8.

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When the floor slabs of a building frame have the same horizontal extension, or for * 35 high rise buildings, a support structure such as in Fig. 9 may be used. Fig, 9 shows a cross-section of a ledger angle 220. A ledger or ligger, as understood in the art is a support structure secured to and lying parallel to the uprights, e.g. the face1 of a building. Ledger angle 220 is typically provided to transfer the vertical load from the panels 100 or panel 102 back to the supporting structure. Ledger angle 220 may be provided as additional support at intermediate storey levels, e.g. every three to four storeys. This may be necessary if the walling height would otherwise be limited due to factors such as cladding weight, storey height, or the size of any openings 170 172.

For higher building heights, intermediate ledger angles 220 or other suitable supports may be provided to ensure that the panels are able to resist any vertical load. Thus.

the process of providing panels for each floor can generally be repeated for each storey. Ledger angle 220 may also be provided at the ground floor level if the on-top anchoring as shown in Fig. 8 is not suitable.

The panel solution provided by the present invention is designed to accommodate on-site tolerances in particular of the primary frame. The exact geometry of a floor slab 60 may vary, within allowable tolerances, vertically and in two horizontal dimensions.

Further, a building structure is not entirely rigid, floor slabs exhibit a considerable degree of deflection during the lifetime of a building. This tolerance of the primary frame has made it hitherto impractical to implement a pre-manufactured continuous walling solution, because the walling system for each floor level has to be adapted to accommodate any frame tolerances at the time of installation.

A further variation of panel 100 is a top floor panel. A top floor panel corresponds essentially to the lower portion iDOL of panel 100. Therefore, a top floor panel is a walling panel without the temporary edge protection portion 100U. Depending on the architecture requirements, a top floor panel may be desired to provide a flush finish with the top level of the primary frame. A top floor panel may not be required for buildings with an accessible roof such as a roof terrace, such that the upper portion * 100U of a regular panel 100 can see as a roof-level parapet. Whether or not a top 30 floor panel forms part of the continuous walling system is therefore dependent on the respective building requirements.

Figs. 10, 11 and 14 show variations of the method and components used to secure adapter cleat 200 to the edge of concrete floor slab 60. Adapter cleat 200 is a component of the inner, frame-facing side of panel 100 and offered to the primary frame when panel 100 is lifted into position. Adapter cleats 200 may be angle cleats, and comprise slots, which may be serrated slots to aid positioning and retention of the cleats during assembly. When bolted to the concrete slab, a slotted cleat anchors panel 100 to the primary frame 50.

The cleats comprise slot groups that allow adjustment of the cleats relative to the floor slab 60 and relative to the vertical beam. For instance, beam 150 may comprise vertical slot channels which allow vertical positioning of the cleat 200 to accommodate a variation in vertical height of the floor slab. The number and length of slots is commensurate with the building requirements. For instance, slots may be provided in pairs. The adapter cleat may comprise horizontal slots where it is connected to the vertical slots of the beam, thus allowing horizontal alignment parallel to the building face. The adapter cleat may further comprise slots where it is connected to the concrete floor slab 60, thus allowing horizontal adjustment of the cleat perpendicular to the floor slab edge. When the cleat 200 is fixed to the top of the floor slab 60, its horizontal slots allow horizontal positioning of the panel. Once positioned and fixed to the floor slab, panel 100 is bolted to the cleat 200, and thus horizontally fixed to the floor slab via the cleat, while being in horizontal alignment with the panel below. The vertical-slotted connection between the panel and the cleat allows for any live load deflection of the primary structure.

It will be appreciated that any suitable arrangement of slot groups and slot orientations can be used, e.g. instead of the above-described arrangement, the vertical slots may be provided on the cleat whereas horizontal slots are provided at the beam. Slots may be provided at the inner face of beam 150 that is facing towards the concrete slab or at a side of beani 150. Further, a combination of two or more cleats may be used where a single cleat would complicate the connection arrangement, *.* Thus, an arrangement of three slot groups allows adjusting the position of slotted cleat * 30 200 in three dimensions. Through this arrangement, a reliably anchored yet adaptive " connection between the panel 100 and the primary frame is ensured. At the same time, panel 100 is reliably horizontally aligned with both the primary frame and the support panel or panels of the lower floor level. The slotted cleat portion that fixes back * panel 100 allows for the vertical deflection of the primary frame that is expected during * 35 the lifecycle of the structure.

The cleats 200 as shown in Fig. 10 are fixed to the top of the floor slab 60. These are designed to remain in place for the lifetime of the building structure, but are not intended to remain uncovered because both the cleat and any fixings will be lost under the subsequently fitted floor screed or floating floor. However, if the arrangement of Fig. 10 is not desired, then an alternative arrangement as shown in Fig. 11 is equally suitable for installation of an adapter cleat 200 that accommodates tolerances in both horizontal and the vertical dimension. The adapter cleat 200 of Fig. 11 is conceptually identical to that if Fig. 10 and is installed in the same way as that of Fig. 10. However, floor slab 60 comprises a formed pocket 62 in which adapter cleat 200 is set down.

Pocket 62 may be sealed together with floor 60 during a subsequent power floated finish.

Fig. 12 shows a cross-section of an embodiment incorporating the arrangement of Fig. 10. Fig. 12 shows and embodiment using a second adapter cleat 230 to allow for vertical deflection by virtue of three vertical slots.

Figs. l3to 16 show an alternative embodiment for fixing panel 100 to a floor slab 60 by virtue of an adapter cleat 200. As in Figs. 10 to 12, the cleat arrangement allows deflection in a vertical and two horizontal dimensions. However, the adapter cleat 200 is not fixed to the top of floor slab 60, but to the edge face of floor slab 60. For reference, this construction variant is also illustrated in Figs. 5 and 7. A channel 64 is cast into the edge of the concrete slab 60. A cast-in channel 64 is advantageous because the adapter cleats 200 can be accessed from the top of the slab, with operatives wearing fall arrest harnesses. As shown in Figs. 16 to 17, adapter cleats have horizontal slots to allow for the final tolerance and positioning of the panels. *. .

The face-fixed arrangement of Fig. 14 allows reducing the time during which a given * ***** * panel 100 requires crane support. This is because a temporary restraint angIe 62 as shown in Fig. 13 is used for temporarily fixing the panel 100 in position as soon as it rests on an underlying support structure. The temporary restraint angles 62 have slotted holes to allow for fine alignment of the verticality of the panel 100, even though the panel is no longer supported by a crane. Temporary restraint angle 63 fulfils a restraining function, rather than a panel load support function. The horizontally slotted holes of the permanent adapter cleat 200 allow for further fine alignment once the panel has been finally positioned vertically. Then the cleat lock nuts can be tightened and the panels are fixed through the centre of the vertical slotted holes. it is contemplated that the cleats are fixed to the channels 64 with Conventional tek screws with washers, engaging with M12 T-Head bolts. Tek screws facilitate the final vertical alignment of the panel.

The length of the slots of the slotted cleats may be dimensioned in accordance with on site requirements. For instance, the typical tolerance variation observed in for a primary frame is in the region of +1-20 mm. Therefore, the slots may be dimensioned to allow tolerances of +1-10mm, +/ 20 mm, +/-30 mm, +/-40mm1 or more than +1-mm, It is believed that this level of tolerance is sufficient for medium rise buildings.

The inventors have found that the adjustable adapter system of the present invention provides sufficient structural support for the walling panels while allowing leeway for variations in slab dimensions. Thus, the adjustment feature enables the provision of a pre-assembled modular panelling system. In particular, an advantage of adaptively fixing each panel to a floor slab ensures that the walling panels remain aligned although each floor slab may require different building tolerances.

In this context it should be noted that "weather tightness" or air tightness" of a building shell is a milestone in a building project. Once weather tightness is achieved, interior fitting can commence, and less stringent health-and-safety requirements apply.

Weather-tightness or at least preliminary air-tightness can be achieved by in-filling or sealing any gaps between panels, and between the panels and the lower and upper floor siabs. Embodiments carrying cladding or sheathing such as sheathing boards are thought to be particularly suitable for providing early weather tightness. *. 0 * 0e

* Except for certain border panels, each panel has a frame 115 formed of edge beams S.....

* 152, 154, and horizontal tracks 120 which joins to frame of a neighbouring panel 100.

. 30 These external joints can be taped and/or sealed, such that the external elevation provided by the continuous walling system is ready to receive the final cladding. It may be necessary to seal openings 170, 172 using temporary sheaths or covers to achieve early weather tightness. If openings 170, 172 are provided with temporary seals, any F windows can be filled in accordance with the construbtion schedule by contractors, e.g., windows may be fitted and sealed with a suitable material such as ethylene propylene diene monomer rubber (EOPM rubber) following the installation of the panels to the primary frame.

The dry lining to the inside face of the system is practically the same as those known for existing walling systems. The dry lining is provided to adequately fire protect the primary structure whilst making provision for the allowance for any vertical movement.

Figs. 12 and 15 show an exemplary plug 70 used to plug a gap between the panel 100 and an internal structure. For illustration, a suitable material used in the industry is stone mineral wool having a density of 100kg/rn3. Because of allowed tolerances, gaps are expected to exist along the ceiling and floor edges bordering on the installed panel 100.

The above-mentioned tolerance requires each panel to have a tolerance pack at each joint. E.g., for a tolerance of +/-20 mm, a nominal 20 mm pack at each joint would be required. To facilitate early weather tightness the panel edge 115 may carry a compressible strip 80, such as a cornpressible waterproof combiband seal, which would have been provided at the off site manufacturing stage. The compressible seal allows sealing the inter-panel joints when the panels are offered to the building face, as shown in Fig. 18. The compressible seal solution may also be provided at internal and external corners, as shown in Figs. 19 and 20. The elevations of Fig. 2 and Fig. 7 show a schematic seal arrangement.

Fig. 21 shows a schematic sequence of three installation steps. Step 1 shows a wall panel 100, shown in side view, being presented to a floor slab 60 of a building frame.

In Fig. 21, panel 100 is shown with a base track 110, a top track 120, cladding 180 and with adapter cleat 200. In step 2, panel 100 is lifted onto a base level panel 102 such ". : that adapter cleat 200 can be fixed to floor slab 60. In step 3, panel 100 is positioned * on top of a lower panel and fixed to the primary frame. Step 3 of Fig 21 shows a base * track section llOb that 5 removed from within the building after installation of panel :.: 30 l00while permanent sections of basetrack 110 remain in place.

External insulation and cladding that is fitted after installation of the continuous walling system to the primary frame will need to be provided from an external working platform, because access from to the outside face is always going to be required to adequately treat the cladding joints. However the continuous walling system of the present invention allows removing the cladding steps from the critical path, i.e. any cladding work can be undertaken independently of the progress of the internal trades.

Exemplary cladding solutions are brickwork cladding, timber cladding, insulated render, composite panels, or ventilated rainscreens It is believed that the pre-panerised walling system improves cost by reducing the time in which scaffolding and safety platforms are tied to a building project. External scaffolding is not required for the erection of the continuous walling system, because operatives can work from within the building frame. Further, the continuous walling system of the present invention allows taking the scaffolding required for external cladding out of the critical path for interior fitting. The present solution reduces the number of operatives required for construction of the walling on site. The walling system of present invention can therefore accelerate and facilitate the wall construction process. Because panels need not be assembled on site, the manual handling under hazardous circumstances is reduced. Also, a larger proportion of the panel assembly may be undertaken in a controlled factory environment, thereby improving opportunities for quality control and minimising on-site waste.

The continuous walling system of the present invention avoids the problems with misalignment and delays in achieving a weather-tight structure that are associated with variations and tolerances of primary structures while providing a larger amount of off-site assembly than hitherto possible. Thus, the pre-panelised walling system of the present invention facilitates providing early weather tightness of a building structure. It is believed that the weather tightness may further assist compliance with thermal, acoustic, fire, and air-tightness. 0 * * * * * * * * *. * * * * . 0 **

Claims (23)

1. CLAIMS: 1. A exterior wall panel for mounting to a building frame, the building frame comprising at least one horizontal floor structure dividing two storeys of the building; wherein the wall panel is adapted to be mounted to the outside of said building frame so as to extend from below to above said horizontal floor structure; and comprises: a top structure for supporting another wall panel; and an adapter for securing the wall panel to said building frame.
2. 2. The wall panel according to claim 1 wherein the adapter is provided for securing the wall panel to the horizontal floor structure of the building frame.
3. 3. The wall panel according to any one of claims 1 or 2 wherein the adapter is provided for securing the wall panel to the building frame from within the building frame.
4. 4. The wall panel according to any one of the preceding claims wherein the adapter allows adjustment of the panel position relative to the building frame.
5. 5. The wall panel according to claim 4 wherein the adapter allows the adjustment from within the building frame when the wall panel rests on a lower panel mounted to the building frame below.
6. 6. The wall panel according to any one of claims 4 or 5 wherein the adapter allows the adjustment in a horizontal direction parallel to the face of the building frame.
7. 7. The wall panel according to any one of claims 4 to 6 wherein the adapter allows the adjustment in a horizontal direction perpendicular to the face of the building frame.
8. 8. The wall panel according to any one of claims 4 to 7 wherein the adapter allows : : the adjustment in a vertical direction. * . * *
9. 9. The wall panel according to any one of claims 4 to S wherein the adapter allows the adjustment in a vertical direction when the adapter is horizontally fixed to the building frame.
10. 10. The wall panel according to any one of the preceding claims having a first panel surface facing the building structure when the panel is mounted to the building structure wherein the first panel surface comprises a plurality of adapters.
11. 11. The wall panel according to claim 10 wherein the plurality of adapters is horizontally aligned.
12. 12. The wall panel according to any one of the preceding claims wherein the or each adapter is located at less than the full height of the wall panel.
13. 13: The wall panel according to any one of the preceding claims wherein the or each adapter is located more than 70 cm, more than 80 cm, more than 90 cm, more than 1 m, more than 1.1 m, more than 1.2 m, more than 1.3 m, more than 1.4 m, more than 1.5 m, more than 1.7 m, more than 1.8 m, or more than 2 m below the top edge of the wall panel.
14. 14. The wall panel according to any one of the preceding claims having a height of more than 1.8 m, more than 1.9 m, more than 2 m, more than 2.1 m, more than 2.2 m, more than 2.3 m, more than 2.4 m, more than 2.5 m, more than 2.6 m, more than 2.7 m, more than 2.8 m, more than 2.9 m, more than 3 m, more than 3.2 m, more than 3.4 m, more than 3.6 m, more than 3.8 m, more than 4 m, or more than 4.5 m.
15. 15. The wall panel according to any one of the preceding claims further comprising * a temporary base protection track. * ** * . *
16. 16. The wall panel according to any one of the preceding claims further comprising a compressive sealing at the panel edge faces. *

    *:.
17. 17. The wall panel according to any one of the preceding claims further comprising one or more lifting cleats.
18. 18. The wall panel according to any one of the preceding claims comprising a second panel surface having a surface finish.
19. 19. An exterior wall panel system for mounting to a building frame! comprising one or more panels as defined in claim 1 and a top panel, wherein the top panel is adapted to rest on top of a lower panel mounted to the building frame below, and to extend from the top of said lower panel to a top level of said building structure.
20. 20. A method of erecting an outer wall of a building! comprising the steps of: providing a building frame that comprises at least one horizontal floor structure dividing two storeys of the building; securing a base panel to the building frame wherein the base panel is supported on a ground base and extends upwards a floor structure of said frame to a height above said horizontal floor structure; and securing an upper panel to the building frame from within the building frame, the upper panel resting on a top structure of said base panel.
21. 21. The method according to claim 20 wherein the step of securing the upper panel to the building frame comprises securing said upper panel to said building frame using an adjustable adapter.
22. 22. A wall panel substantially as hereinbefore described with reference to Figure 2.
23. 23. A wall panel system substantially as hereinbefore described with reference to Figures 3,5,6,71 18, 19,20 or2l. * *...