Note: Descriptions are shown in the official language in which they were submitted.
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WO 200/052276 PCT/AU2004/001672
TITLE: EAVE LI1VING SYSTEM
'Technical Eield
The present invention relates generally to building construction, and more
particularly to the installation of eave linings.
Description of the Prior Art
The invention has been developed primarily for use in the installation of eave
linings, and will be described predominantly with reference to this
application. It will
be appreciated, however, that the invention is not limited to this particular
field of use,
being also applicable to other areas of building and construction.
l0 In the construction industry, the installation of eaves lining is a mufti-
stage
process. Eave sheet used to line the eaves is generally produced in set
lengths and
widths. The sheet must be transported to site, nailed into position on the
building, the
joints set, concealed or connected using joining strips and then the whole
assembly
must be painted. Sometimes, the sheet must be painted more than once with and
undercoat and topcoat.
These finishing processes add greatly to the expense of installing eave
liilings
adding labor and paint and setting costs as well as needing additional time
taken to
paint and/or set the eaves. In addition, eaves are most often situated high up
on
buildings and therefore, generally, additional costs for scaffolding equipment
to
2o elevate the tradesmen during the eave finishing and painting process will
be incurred.
This is a particular problem in the construction of many proj ect, fat and pre-
finished buildings where the only part of the entire building requiring
painting are the
eaves. Accordingly, painters must be brought in specifically and only for that
task.
As such the efficiency is reduced.
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Another problem is the consistency of the painting when done onsite. It is
often
the case that the coverage applied by hand painting eaves is not uniformly
thick. This
may result in patchy protection and/or appearance. Similar comments apply in
relation
to the setting and concealing of various joints where this is required.
It is an object of the present invention to overcome or ameliorate one or more
of
these disadvantages of prior art, or at least to provide a useful alternative.
Brief Summary of the Invention
According to a first aspect, the invention provides an eave lining system for
buildings including:
1 o a fibre reinforced cement eave lining sheet pre-finished on at least one
exposed
surface; and
securing means for affixing said eave sheet to a support surface; wherein
said eave sheet and securing means axe configured such that minimal post
installation
finishing is required.
Is The term "pre-finished" is intended to cover all finishing processes and
includes,
but is not limited to, painting, coating, laminating (e.g. with Formica~ or
Tedlar~), as
v,
well as using pigmented base materials and/or additives so that no, or
minimal, further
finishing is required.
Preferably, the eave sheet is pre-finished prior to sale. However, post
purchase
zo pre-finishing of raw or partially finished sheet is also anticipated.
Desirably, the invention further includes a joining strip for joining a
peripheral
edge of said eave sheet with a
AMEND~~ ~~9E~
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peripheral edge of a like eave sheet; wherein said joining strip is also
preferably
configured and coloured such that minimal post installation finishing is
required.
The phrase "post installation finishing" is used herein to refer to any
relevant
post installation finishing process such as joint setting, painting and the
like.
Preferably, the eave lining system also includes a pre-finished corner trim
system for concealing and finishing the joint between the eave lining sheet
and the
adjacent building surface which in most cases is a wall. In a particularly
preferred
form, the trim system is a two-part system comprising an inner core element,
that is
secured to the eave support structure or adjacent building surface, and an
outer pre-
l0 finished clip on cover element. Ideally, the cover element comprises
standard straight
length sections and custom pre-formed corner pieces. Desirably, the corner
pieces sit
over the straight section cover portions to allow for expansion and reduce the
need for
accurate length cuts on the long sections.
In one form, the inner core trim element has a conventional solid or hollow
15 rectangular, quad, or fillet profile or the like, with rebates formed adj
acent
diametrically opposed corner edges for accepting in-turned lip portions on
corresponding outer trim cover portions having the same general profile as the
exposed portion of the inner element. For regular shaped profiles such as the
square
or rectangular trim element, and any other sections which could be installed
in more
20 than one orientation, rebates are formed on all edges or multiple sets of
corner edges
to reduce the need to carefully orientate the section prior to placement
adjacent the
j oint.
In a second form, the inner core trim element has a thin walled profile
defining
only one or more suxfaces for connection to the eave sheet or adjacent wall
and means
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[AMENDED PAGE]
to secure thereto a cover element of the desired external profile. In one form
the trim
element has two perpendicular arms where the ends of each arm are configured
to accept
and retain outer trim portions having the same or a different general profile
to the inner
element.
s Preferably, the securing means is selected from the group of screws, nails,
staples,
plugs, and glues and tapes and may include any combination thereof.
Preferably, the screws, nails and plugs are colour coordinated with the eave
sheet
or include colour coordinated caps.
In a preferred form particularly suited for use with externally clad timber
framed
l0 building structures one or more components of the system such as the eave
sheets, the
sheet joining strips and/or the trim components, may include openings or
perforations
configured to provide a predetermined amount of ventilation to selected parts
of the
building stntcture such as the roof or wall cavities.
According to a second aspect of the invention there is provided a method of
15 installing an eave lining system including the step of pre-finishing at
least one exposed
surface of a fibre reinforced cement eave sheet prior to installation. This
step may be
._
conducted on or off site.
In preferred forms of the invention the method also includes the steps of
securing
the pre-finished eave sheets using some or all of the various securing and
fixing
2o elements of the second aspect of the invention.
According to a third aspect of the invention there is provided a two part trim
system for concealing joints in building structures, said trim system
including:
a base securable over or adjacent a joint to be concealed; and
a cover element connectable to said base to conceal said joint.
AM~NI~~~ ~~;~:
.wpaA // f
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In various preferred forms the two part system is configured as per the
embodiments foreshadowed and described herein with reference to an eaves
corner
joint which is defined by two intersecting planes. However, other variations
are
contemplated which are configured to conceal joints which occur in a single
plane as
may occur with cladding sheets and the like. In such embodiments the trim
cover
elements have exposed external surfaces viewable over 180° rather than
90° as with
the corner trim elements described hereW .
Brief Description of the Drawings
A preferred embodiment of the invention will now be described, by way of
to example only, with reference to the accompanying drawings in which:
Figure 1 is a sectional side view of a building showing a first embodiment
eave
system in accordance with the invention;
Figure 2 is sectional plan view of the system shov~rn in Fig. 1;
Figure 3a is a nail in accordance with the invention;
Figure 3b is a screw in accordance with the invention;
Figure 3c is a quick fix fastener plug in accordance with the invention;
Figure 4 is a view showing a first embodiment protective hammer pad in
accordance with the invention;
Figure 5 is a view showing a second embodiment hammer protector cap in
2o accordance with the invention;
Figure 6 is a sectional view of an abutment join "on frame" between two eave
boards in accordance with the invention;
Figure 7 is a sectional view of an abutment join "off frame" between two eave
boards in accordance with the invention;
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Figure 8 is a sectional side view of part of a building showing a second
embodiment eave lining system in accordance with the invention having an
alternative
two part trim system;
Figure 9a shows a first embodiment straight inner trim section of the kind
shown
in Figure 8;
Figure 9b shows an alternative embodiment straight inner trim section of the
kind shown in Figure 8;
(;.
Figure 10 shows a first embodiment straight outer trim section for use with
the
inner trim section of Figure 9;
to Figure 11 shows a partly assembled system using the inner and outer trim
sections of Figures 9 and 10 along with a custom outer external comer piece;
Figure 12 shows a variety of alternative profiles for the two part trim system
of
Figures 8 to 11; and
Figure 13 shows a third embodiment eave lining system in accordance with the
invention that incorporates a vented eave panel and/or eave panel trim
arrangement.
Figure 14 is a detailed view of the vented eave panel trim arrangement shown
in
Figure 13;
Figure 15 shows a ventilated eave panel end join strip particularly suited
for, but
not limited to use with the system of Figure 13.
2o Detailed Description of the Invention
In general terms the invention provides a pre-finished eave system for
buildings
such that post installation, no additional painting or finishing of the eaves
is required.
In this embodiment, the eave sheets are fibre reinforced cement (FRC),
classified as Type A Category 3 in accordance with AS/NZS 2908.2 'Cellulose-
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Cement Products'. However, in alternative embodiments, the sheets may be of
other
suitable material. For instance, it will be appreciated that sheets formed of
(wood,
metal or plastics etc) might replace the FRC sheets of this preferred
embodiment and
are within the scope of the invention.
Whichever material, the sheets are produced iil a variety of standard widths
and generally will be a standard tluckness so that the sheets will be flush on
installation. The table lists the preferred product sizes however, it will be
appreciated
f,
that the product may be produced in any size or thickness as required.
The sheets may also be perforated through their thickness with a
predetermined number and arrangement of slots or holes. These slots or holes
provide
a predetermined amount of airflow through the sheet, in turn providing
ventilation to
the roof or wall cavity when the sheet is installed.
In this embodiment, the sheets are pre-painted on at least one side with a
protective paint or coating. Paintuzg is normally an automated process
conducted at a
purpose built production facility and may be applied using conventional
techniques,
such as spraying, roll coating, curtain coating, or powder coating. The paint
may be
cured by thermal means or by radiation or a combination thereof. The paint may
be
2o applied in one or more coats with or without an undercoat layer, depending
on the
type and colour of paint or thickness of paint layer required.
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The sheets may also be pre-finished using durable laminates (e.g. Formica
high pressure laminates) or durable polymeric films (e.g. Tedlar ~
fluoropohymer
films). Such laminates are applied to the surface of the sheet with a suitable
adhesive,
such as a polyurethane adhesive. The sheets may also be coloured using organic
or
inorganic pigments incorporated directly into the fibercement. The sheets may
also be
coated with treatments to prevent the accumulation of mildew and fungus which
may
form during storage and when installed. Other possible coatings maybe applied
to
help fire retardation, repel insects or provide insulation characteristics.
These coatings
may be applied under or on top of the paint layer or may be additives to the
paint
l0 itself.
While it is preferred that the sheets be painted in a factory and in a form
which
is substantially or totally pre-finished, it will be appreciated that the
invention may be
applied to sheets that are raw or unpainted and unfinished at purchase.
To prevent damage to the eaves during storage and shipment, the finished eave
sheet may be prepared by covering the surfaces of the sheet with a one or more
removable protective coatings or laminates. This process is described in
detail by the
applicant's corresponding, co-pending United States Application No. 10/620,711
filed
16 July, 2003. Alternatively, the removable protective coating may be spray-
applied
or applied as a transfer film from a backing material
The laminate forms a barrier preventing the surface of the eaves being
damaged, marked or scratched. Once at the building site, the protective layer
is
stripped off either before, after or during installation. In one embodiment,
the
removable protective layer is preferably stripped after installation is
complete, in order
to protect the pre-finished panel surfaces from fingerprints, scratches and
the like.
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Referring to the drawings, as is known in the art, the eave sheets 1 are
attached
to the eaves support structure 4. As shown in Figures l and 2, the support
structure 4
is generally a frame work of eave battens 4. These battens are most commonly
steel
or timber. In alternative embodiments, the eave sheets maybe attached to a
substrate
rather than the more common framework.
As can be seen in a first embodiment shown in Figure 1, the outer edge of each
eave sheet fits into a groove 5 in an eave fascia board 6 and pre-finished
trim 7 is used
at the inner edge to fill the corner between the board and the exterior wall.
The trim can be a conventional wooden beading element, or instead could be
an extruded plastic strip or similar, with or without pre-made straight
section and/or
corner connectors, the latter obviating the need to produce mitre cuts on
site.
Alternatively, a preferred two part trim system can be used as discussed below
in
reference to Figures 8 to 11. In either embodiment the trim may also be a
fibrecement
material.
In other embodiments such as maybe used in the US where grooves are not
usually provided in the fascia board, the eaves sheet is nailed to a support
and the
fascia is installed aftewards. Any gap in the eaves sheet and the fascia is
then
caulked or covered by a trim piece which can be of the kinds discussed above.
The sheets are affixed to the supporting structure by a variety of methods.
2o Such methods may include, nails 8, screws 9, plugs 10, staples, glues or
adhesive
tapes alone or in combination. However, it is preferable that the fixing
method and
procedure does not damage the eave board surface so that the need for any
painting or
touch up painting after installation is eliminated or kept to a minimum.
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For instance, screws and nails are fitted with coloured or painted heads to
match the eave board finish. Accordingly, as shown in Figure 4 special hammer
pads
11 are provided so that the heads of the nails are not marked and the sheet
not
damaged. In an alternative embodiment shown in Figure 5, a soft plastic or
rubber
hammer protective cap l la is provided along with a sleeve 11b that allows the
protective cap to be fitted to hammers having a smaller head size. Another
method is
to use coloured caps in conjunction with screws and nails to cover the exposed
head.
Touch up may be required if non-prefinished fixers are used e.g. when
stainless steel
nails are specified in coastal areas.
1o As seen in Figures 6, 7, and 15, joining strips 12 are provided to
facilitate
joining of abutting boards. The joining strips may be extruded plastic or
another
suitable material such as timber, rubber or a molded material. Preferably, the
strips
are colour coordinated with the boards and do not require painting. The strips
maybe
used for joints between sheets either on frame as shown in Figure 6 or off
frame as
shown in Figure 7. Alternatively, a strip may be pre-attached to one sheet
with a
suitable adhesive. While these strips are of a generally "H'' shaped profile,
typically
one internal leg is extended to facilitate attachment to the support structure
as shown
in Figure 6. H-moulds may have an extended width and contain perforations to
provide venting as per the example shown in Figure 15.
Referring next to Figures 8 to 1 I, there is shown an alternative and
preferred
two part trim system for finishing and concealing the corner between the eave
sheets
and the adjacent wall. This system uses an inner trim section which in the
form
illustrated in Figure 9a shows a first embodiment comprising a solid elongate
core
member 13a of generally rectangular section, having rebates 14 adjacent to
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diametrically opposed corner edges as shown. An alternative embodiment 13b is
shown in Figure 9b which has rebate on all four edges so that the section can
be
installed in multiple orientations thereby simplifying the installation
process. This
modification can be applied to any profile that could be installed in more
than one
configuration. These inner trim cores can be made of wood or a wood based
composite like most of the conventional beadings and trim sections used in the
building industry. However, any other firm nailable material would be suitable
including, for example, polymeric expanded foam materials or the like.
W other forms (not illustrated), the core element may be of a simple thin
to walled structure effectively defining a base plate which can be secured to
the eave
sheet and/or the adjacent building surface and which includes retaining means
to
which a clip on cover can be connected. Such a base plate may be of a standard
generally L shaped section and it is each cover element only which is
configured to
the desired external profile.
The second part of the system comprises a pre-finished outer cover element
15a that is adapted to sit over the inner core element 13. In the example
provided, the
outer core at a cover element has in-turned lip formations 16 along its outer
edges,
such that the cover 15 can be "snapped on" to the core element and be retained
thereby engagement of the lip formations 16 with the corresponding rebates 14.
This
2o cover element can again be made of any material that would provide a
requisite
resilience to effect a simple "snap-on" or "push-on" connection. Suitable
materials
may include various moulded or extruded polymers or pre-coated steel or
aluminum
sections.
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Also, optionally forming part of the cover element portion of this trim system
are pre-formed and pre-finished corner pieces such as 1 Sb shown in Figure 11.
The
comer pieces can be made available in all common configurations such as
90°
(internal and external) and 135° external for bay windows and the Iike.
Preferably, the
custom corner sections are configured to sit over the straight section cover
elements.
This eliminates the need for accurate length cutting on the long sections and
allows for
expansion and contraction which can be a problem over long lengths.
The advantages of the two part firmer and outer trim system are significant,
in
that the need for a skilled carpenter is eliminated and a simplified fixing
process
to should be fairly quick to install. In this regard, the inner core sections
can be
conveniently cut using, for example, suitable plier type cutters and nailed
into position
without the need to ensure a clean and accurate mitre join at the corner. The
straight
section cover elements can then be cut approximately to length in the same way
and
"snapped" onto the core elements. Finally, the corner pieces can be clipped on
top of
the adjacent straight section cover portions and the finishing processes
complete.
There is no need to finish or touch up joins, and no special skills are
required as there -
are no mitre joints to be cut and accurate length cutting at the straight
sections is not
needed.
As can be seen from Figure 12, the two part inner and outer trim system can be
2o configured to any desired profile and is not limited to the examples shown,
nor is it
limited to the use of solid core elements as shown in this illustration.
Additional
advantages are that the hidden fixings of the two part trim section removes
the need
for touch up of nails or screws. Furthermore the snap on trim sections allow
for
thermal expansion of the building and the eaves components that is not
possible using
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a I piece trim as is found in traditional eaves installation methods. This
ability to
accommodate thermal expansion provides a significant advantage over prior art
systems. For example, for a fully fixed trim that can't accommodate thermal
expansion, buckling of the trim can occur if the thermal expansion of the trim
is
greater than the wall resulting in an unsightly finish and possible nail pull
out of the
trim. Alternatively, if the wall/substrate/etc expands more than a fully fixed
trim, the
corner joints of the trim can open up and cause a deterioration in performance
of the
eaves system. These potential problems are avoided with the preferred system
described above.
It will also be appreciated that while this two part trim system is
particularly
suited to use in eave lining systems as described, it is equally applicable to
other
building applications where comer or indeed planar joints need to be concealed
in a
simple manner that minimises the need for highly skilled labour.
Turning finally to Figures 13, 14 and 15 there are shown further variations to
the invention that incorporate venting means for enabling air and moisture
vapour to
flow from the wall and/or roof cavity to atmosphere. The arrangement shown in
the
accompanying figures is particularly well suited to externally clad timber
frame
structures. However, the concept is not limited to this particular type of
building
structure.
In order to provide ventilation to the wall cavity, a vented trim system is
optionally provided. While the illustrated form is based on the preferred t<vo
part trim
system, an equivalent single part trim component could also be used. The
functional
modification resides in the provision of a trim wall extension strip 17 which
has
ventilation apertures 18 provided therein.
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In use, the vented eaves sheets are secured in the usual manner and an opening
19 is left between the external wall cladding and the sheet and/or eaves
bearer. The
modified trim element including the trim wall extension strip 17 is then
secured to the
eave sheet so that the extension strip bridges over the opening 19 as shown.
If
separate or additional ventilation is required into the roof cavity, then a
suitably
vented eaves sheet can also be used. Alternately, a roof space may be
ventilated by
using a similar strip and re-orienting it so that the vented extension strip
bridges a gap
between the eaves sheet and the eaves support structure. The eaves sheets,
whether
ventilated or un-ventilated, can also be joined using a ventilated end join
strip 12 such
l o as the kind shown in figure I S which further enhances the ventilation and
also
provides an easy means of providing ventilation without using perforated eave
panels
which may not be aesthetically acceptable.
It will be appreciated that all aspects of the invention provide significant
advantages over the prior art by minimising or at least significantly reducing
the
amount of time consuming and expensive in-situ post installation finishing
required.
This enables faster and more economical installation of eaves, particularly
where '
scaffolding would have normally been required. Furthermore, the trim
arrangement
incorporating overlapping corner and end finishing components overcomes
problems
that can readily occur with fixed trim systems where there is some form of
differential
2o expansion between the trim and the adjacent sheets or elements of the
building
structure.
Although the invention has been described with reference to specific examples
it will be appreciated by those skilled in the art that the invention may be
embodied in
many other forms.
