The invention relates to methods of manufacturing an

external wall of a building, and a kit of parts and an assembly for use in such a method. Particularly, but not exclusively, the invention relates to the manufacture of a building facade.

Conventionally, large buildings are constructed by first building the internal structure, including the floors, and then supporting facades on the internal structure. Facades may comprise composite panels which provide insulation and weather tightness. A composite panel typically has a pair of skins, sandwiching an insulating layer, such as mineral wool slabs or rigid foam polymer insulation, therebetween.

Where composite panels are used to carry an outer cladding layer in a building facade, the load bearing arrangement to carry vertical loads of the composite panel and any outer cladding are typically metal brackets cantilevering

outwardly from the outside of the building structure to carry the horizontal and vertical loads of the facade. Since the skins of the composite panels provide strength mainly in tension, and the insulating core provides strength mainly in compression, and with limited sheer carrying capacity, it is necessary for the brackets to extend past the inward- facing skin of the composite panel to the outward-facing skin of the composite panel. Alternatively, multiple metal screws may be used to connect the inward facing and outward facing skins to aid the resistance of shear loads. Accordingly, each bracket or screw provides a thermally- conductive pathway from the inside of the building to the outside of the building thereby diminishing the building's insulation .

This problem is exacerbated by the nature of conventional brackets for backing walls comprising composite panels, which are often simply configured as thick flanged plates. There is therefore a need in the art to provide an external building wall that provides improved insulation and greater bearing capacity.

According to the invention, there is provided: a kit of parts for forming a panel assembly for an external wall of a building; an assembly for forming an external wall of a building; a bracket for supporting a building facade; a method of manufacturing a panel assembly; and a method of installing an outer wall on a part-constructed building, as defined in the appended claims.

The inventor has realised the possibility of using panel assemblies comprising one or more composite panels for a backing wall of a building facade. The backing wall may span from one structural floor slab to the structural floor slab above in a framed building, and can perform the

function of providing a weather tight, insulated envelope, to which can be attached an outer cladding layer, such as rain screen cladding or an outer leaf of masonry. Embodiments of the invention can provide a way of supporting a plurality of composite panels such that they collectively define an outer wall (or a portion thereof) of a building. In the following discussion, reference is made to a panel, which is a sub-component of a panel assembly. The panel may be a single unitary panel for each panel assembly, or may be multiple sub-panels that lie in the same plane and

collectively form a single greater panel. The panel (or sub- panels thereof) preferably comprise an insulating core sandwiched between an inner skin and an outer skin, with the inner and outer skins defining first and second major surfaces of the panel. A first aspect of the invention is the provision of a pair of frames for each panel. The first frame may include perimeter frame members that surround the perimeter of the first major surface of the panel that defines an inward- facing surface with respect to the building, while the second frame may include perimeter frame members that surround the perimeter of the second major surface of the panel that defines an outward-facing surface. The first and second frames may each include vertically extending rails, which extend between the opposing horizontal members of the respective perimeter frames. The perimeter frame members and the rails of the first and second frames are preferably arranged correspondingly. That is, each perimeter frame member and each rail of the first frame may be arranged on the first major surface of the panel such that it is directly opposite a corresponding perimeter frame member and corresponding rail of the second frame on the second major surface of the panel. The two frames are spaced apart and, thus, not thermally connected. This aspect may be embodied as a constructed panel assembly or as a kit of parts for assembling a panel assembly.

With two such frames, along with the skins of the composite panel, tension and bending (for example, resulting from horizontal loads) can be resisted, and the insulating layer of the panel can resist compression. The insulating layer can only resist shear arising from vertical loads to a limited extent. The inventor has recognised that it is therefore only necessary to support the first and second frames to resist shear forces.

Accordingly, in a second aspect of the invention, a bracket is provided for connecting the two frames. Since the bracket is intended mainly to resist shear (specifically, the shear forces that the composite panel cannot resist), it can be arranged geometrically to act in tension to resist shear forces in the panel and therefore can work in a mechanically efficient way. This means the element of the bracket that bridges the insulating layer can be smaller than that of a prior art cantilevering bracket. This can result in reduced thermal conductivity between the inner and outer skins.

The third aspect of the invention provides a method of manufacturing the building using these components. For a better understanding of the invention, and to show how the same may be put into effect, reference is now made, by way of example only, to the accompanying drawings in which: Figure 1 shows a perspective view of a bracket;

Figures 2 to 5 show perspective views of parts of a panel assembly installed on a building;

Figure 6 shows multiple panel assemblies installed on a building;

Figure 7 shows an alternative panel assembly;

Figure 8 shows an alternative fixing;

Figure 9 shows another view of the fixing of Figure 8; and Figure 10 shows an alternative embodiment of a panel

assembly supported by a structure of a building; and

Figures 11 to 14 show cutaway perspective views of different aspects of the panel assembly of Figure 10. As will be appreciated, some of the figures show some components with other components hidden for reasons of clarity .

As can be seen from Figure 1, a bracket 100 may comprise a first part 120 and a second part 110, which are spaced apart and connected by a rod 130.

The first part 120 may be considered the inner part 120 of the bracket, since it is arranged for attachment to the part-constructed building. The second part 110 may be considered the outer part 110 of the bracket.

The first part 120 and second part 110 have fixing means 115 for attachments to a frame 210, 220. Preferably, the first part 120 has at least two fixing means 115, which may be bores for bolts. The two fixing means 115 are offset in a first direction. When installed as part of a building, the first direction substantially corresponds to the vertical direction .

Similarly, the second part 110 may have at least two fixing means 115, which are also offset in the first direction.

The first and second parts 110, 120 may be generally

elongate members, extending in the first direction. This can allow spacing between the at least two fixing means 115 (if more than one are used) .

The first and second parts 110, 120 may have opposing planar surfaces 111, 121 for abutment with frame members 210, 220 or a panel 250, the planar surfaces being parallel with each other and both extending in the first direction.

The first and second parts 110, 120 are linked by a rod 130. The rod 130 may pass through a bore in each of the first and second parts 110, 120. The rod 130 may have threaded ends via which bolts may secure it to the first and second parts 110, 120. Alternatively, the rod 130 may have enlarged ends, folded ends, crimped ends, notched ends or curved ends. Rod 130 may have any cross-sectional shape, but is shown in Figure 1 as having a circular cross-section.

The first and second parts 110, 120 may have opposing planar surfaces at the ninety degree angle to the axis of the rod 130. The first and second parts 110, 120 may have bores defining the direction through which the rod 130 may

intersect the first and second parts 110, 120. The first and second parts 110, 120 preferably comprise metal. The first and second parts 110, 120 may be

manufactured by casting, pressing, extrusion, and/or may be formed of folded sheets of, e.g. metal and/or polymer.

The rod 130 preferably comprises metal or a fibre reinforced matrix, such as carbon fibre.

Since the panel 250 will be installed in a vertical

orientation and since the bracket 100 is for resisting tensile and shear forces in a panel 250, it is only needed to resist relative movement of the a first and second frames 110, 120 in the first direction. The rod 130 therefore preferably extends at an angle to the first direction. In this way, the first part 120 may be offset from the second part 110.

The rod 130 preferably extends at an angle to the first direction in the range 30° to 60°.

Thus, when installed, the rod 130 may extend downwardly from the building at an angle in the range 30° to 60° from the vertical direction.

The rod 130 preferably has a length in the range 150mm to 500mm.

One or both of the first and second parts 110, 120 may have a length in the range 50mm to 150mm. The width/diameter of the rod 130 does not need to be great enough to resist bending because, when in use, the panel itself resist compression in the direction of the normal to the major surfaces of the panel, preventing the frames 210, 220 from moving towards each other. The rod 130 preferably has a diameter/maximum width in the range 5mm to 20mm.

As shown in Figures 1 and 2, the first part 120 of the bracket 100 may be configured for attachment to part of a building, for example a floor. In this way, the entire panel assembly (which may include the panel 250, the inner and outer frames 210, 220, and the one or more brackets 100) can be supported via the first part 120 of each bracket 100 of that assembly. Alternative ways of attaching the panel assembly to the building are discussed below with reference to Figure 8 and with reference to Figures 10 to 14.

The first part 120 may be generally L-shaped. The L-shaped first part 120 may have a vertical member for attachment to an inner frame 220 and a horizontal member for attachment to the structure of the part-constructed building.

The first part 120 may comprise a hooked portion 122 and/or an adjusting means 124 (such as a bore for a bolt) .

Accordingly, the first part 120 of the bracket 100 may be attached to fixings 50 located on the building.

Adjusting means 124 provides a stop for setting the height of the bracket 100 relative to the fixing 50, when the bracket 100 and fixing are engaged (for example, via hooked portion 122) . Adjustment means 124 may comprise a bore through first part 120 and a bolt, wherein rotation of the bolt within the bore varies the amount by which it protrudes thereby setting the height of the first part 120.

Fixings 50 may have ridges or ribs for engagement by the hooked portion 122. Fixings 50 may alternatively, or in addition, have another type of fixing means for engagement with the bracket 100.

Components of a first embodiment of a panel assembly can be seen in Figures 3 to 5. The panel 250 is generally

rectangular in shape, and the inner and outer frames 210, 220 comprise both vertically-oriented elongate frame members 210a, 220a and horizontally-oriented elongate frame members 210b, 220b. Whilst the panel 250 may be a single continuous panel, as can be seen in Figure 4, panel 250 may comprise a plurality of sub-panels that together form panel 250.

Preferably, at least one bracket 100 extends between the vertically-oriented inner frame member 220a and the

vertically-oriented outer frame member 210a on either side of each panel assembly. Thus, each panel assembly can be supported in a vertical orientation by a pair of brackets 100 at or near its upper corners. The bracket 100 is attached to the vertically-oriented inner frame member 220a at a first height and is attached to the vertically-oriented outer frame member 210a at a second height, the first height being greater than a second height when the panel assembly is installed. Thus, the outer frame 210 is supported lower than the inner frame 220. In other words, the bracket 100 is preferably attached at a first distance from one end of the vertically-oriented inner frame member 220a and at a second distance from the nearest end of the corresponding vertically-oriented outer frame member 210a, the first distance being smaller than the second distance.

The frames 210, 220 may have fixing means 115, corresponding to fixing means 115 on brackets 100 (e.g., the frames may have the same number of fixing means), which may be bores for bolts. The bracket 100 may be attached to the frames by attaching fixing means 115 on the bracket 100 with

corresponding fixing means 115 on the frames 210, 220. For example, the fixing means 115 may be holes and the bracket 100 may be bolted to the frames 210, 220. As can be seen in Figure 3, some of the frame members of one or both of the inner and outer frames 210, 220 may have a cross-sectional shape that is complementary with the shape of the first and second parts 110, 120 of the bracket 100. For example, the frame members may have channels arranged to receive one of the first or second parts 110, 120 so that the frame members may be attached to the first and second parts 110, 120 on two opposing sides. The frame members may have flat surfaces extending parallel to the plane of the panel 250 for

abutment with the panel 250.

As can be seen from Figure 4, the vertically-oriented inner frame members 220a and horizontally-oriented inner frame members 220b may collectively define an inner perimeter frame. Similarly, the frame vertically-oriented outer frame members 210a and horizontally-oriented outer frame members 210b may collectively define an outer perimeter frame. In Figure 4, there can be seen optional compression struts 320. A plurality of compression struts 320 may be provided along each side of the panel 250. These can provide further strength to the panel assembly by opposing any compressive loads imposed upon the panel core when the bracket 100 is under load.

Compression struts 320 may extend between and abut the inner and outer perimeter frames. Since the compression struts 320 do not need to resist tension, they may comprise solid polymer or fibre reinforced material of low thermal

conductivity and therefore do not provide a conductive path between the frames 210, 220.

The inner frame 220 surrounds the perimeter of a first major surface of the panel 250 (which may comprise multiple sub- panels), the first major surface being inward-facing when installed. Similarly, the outer frame 210 surrounds the perimeter of a second major surface of the panel 250, the second major surface being outward-facing when installed.

The panel 250 (or each sub-panel) preferably comprises an insulating core 254 sandwiched between an inner skin 252 and an outer skin 251, with the inner and outer skins 251, 252 defining the first and second major surfaces, respectively.

The inner and outer skins 251, 252 may comprise metal, for example steel sheet which may optionally have a coating comprising zinc and/or aluminium. The insulating core may comprise mineral wool slabs or rigid foam polymer

insulation . Preferable panels 250 may be rectangular with a depth in the range 100mm to 500mm, a height in the range 2.5m to 6m, and a width in the range lm to 10m.

Preferably, the frame members 210a, 210b, 220a, 220b of the perimeter frames have a generally L-shaped cross-section. Preferably, each frame member 210a, 210b, 220a, 220b extends across at least a portion of the corresponding major surface of the panel 250 and extends across at least a portion of the depth of the panel 250 (in the direction perpendicular to the two major surfaces of the panel 250) .

The frame members 210a, 210b, 220a, 220b preferably comprise one or more of: metal (e.g., pressed, rolled or extruded), polymer, reinforced polymer.

Preferably, at least one, and more preferably both, of the inner frame members 220a, 220b and the outer frame members 210a, 210b have channels formed therein for receiving seal members 300a, 300b. Preferably, the channels are formed in the part of the frame members 210a, 210b, 220a, 220b that extend in the depth direction of the panel 250.

Each frame assembly provides a portion of an external wall of the building. A plurality of abutting frame assemblies may abut substantially vertically or horizontally in a vertical, or substantially vertical, plane and together span the outer surface of the building. As can be seen in Figure 5, a plurality of seal members

300a, 300b may be provided. Each seal member 300a, 300b may be located in the channels of two neighbouring frames 210, 220, such that when neighbouring panel assemblies abut, the seal members 300a, 300b interlock with the channels of the neighbouring panels and thereby prevent air and/or moisture from passing therebetween. Thus, the seal members 300a, 300b may improve insulation and/or waterproofing.

It is preferable that the horizontally-extending seal assemblies 300b extend continuously across neighbouring panel assemblies and the vertically-extending seal

assemblies 300a extend between, and abut and/or overlap with, horizontally-extending seal assemblies 300b.

The seal assemblies 300a, 300b are preferably flexible strips, and may comprise one or more of: polymers, rubber, synthetic rubber, EPDM (ethylene propylene diene monomer rubber) .

Panel interlocks 310 may be provided continuously along the edges of each panel 250 or as spaced apart members along the edges of each panel 250. The panel interlocks 310 may penetrate each panel 250 or perimeter frame to aid in locating each panel assembly in relation to its neighbour. Although only depicted along the upper edge of the panel 250 or frame, the panel interlocks 340 may be provided along each edge.

Figure 5 also shows that panels 250 may be provided with apertures for forming windows or doors of the building.

Inner and outer aperture frames 231, 232 (which can be similar, or the same, in structure to inner and outer frames 210, 220) may be provided to reinforce such apertures. The aperture frames 231, 232 may be considered part of the corresponding frame 210, 220.

The outer frame 210 may include further frame members 340. For example these may be for supporting further components of a building facade. For example, a plurality of rails 340 may be affixed to the perimeter frames (either directly, or via intermediate materials or components) . When panel 250 is formed of separate sub-panels, these may be supported between inner and outer rails 340.

The outer frame 210 can be used to support elements of the building facade. For example, supported on the outer frame 210 may be any known form of rain screen or visual cladding, such as: brick slip cladding; metal panel, plank and sheet cladding; high pressure laminate cladding; timber cladding; terracotta cladding; back painted glass cladding; cement particle board cladding; and/or fibre reinforced concrete cladding .

When installed on a building, inner rails 340 may be used for supporting internal linings such as plasterboard.

Figure 6 shows a plurality of abutting panel assemblies forming part of an external wall of a building. As can be seen, different panel assemblies may have different

configurations and shapes (some may have apertures, others not), but each has an inner frame 220 and a complementary outer frame 210, spaced apart and between which extends one or more bracket(s) 100. As can be seen from Figure 7, the inner (not shown) and outer frames 210, 220 may comprise vertical members 340 (e.g. rails) in addition to the perimeter members 210a, 210b, 220a, 220b. As in the embodiment above, for each member of the first frame 220 (whether it be a perimeter member 210a, 210b, 220a, 220b or a rail 340) there is provided a corresponding member of the outer frame 210 so that the panel 250 is sandwiched between corresponding frame members .

Whilst in the embodiment above, the brackets 100 extend between the vertical members of the inner and outer

perimeter frames, the brackets 100 may instead, or

additionally, extend between a plurality of corresponding rails 340. Such an embodiment is discussed below with reference to Figures 10 to 14.

An embodiment of a method of manufacturing an outer wall of a building comprises the step of providing a plurality of panel assemblies and affixing these to a structure forming a part-complete building.

Each panel assembly is manufactured by: providing a

composite panel; securing an inner frame 220, which includes members that extend around the perimeter of an inside surface of a composite panel 250; securing an outer frame 210, which includes members that extend around the perimeter of an outside surface of a composite panel 250; and

attaching a bracket 100 between a vertically extending member of the inner frame 220a and a vertically extending member of the outer frame 210a. The vertically extending members may be the vertical members of a perimeter frame or rails 340 extending from a horizontal member of a perimeter frame .

Preferably, the panel assemblies can be manufactured prior to installation on the structure of the building (or part- constructed building) . The panel assemblies may be

manufactured on-site, or prepared elsewhere and transported to the building site. The panels may be prepared with outer cladding attached before installation on the structure of the building.

A plurality of fixings 50 may be attached to the structure of the part-constructed building. Preferably, the fixings 50 are attached to the floors of the building.

The inner and outer frames 210, 220 may be affixed to the inside and outside surfaces, respectively, of the composite panel 250 along the length of each of a plurality of frame members, for example by way of screws and/or adhesive.

The plurality of panel assemblies are attached to the structure via the fixings 50. The panel assemblies are preferably hung from the fixings 50. The panel assemblies are preferably supported by the fixings 50 in a vertical or substantially vertical plane. The panel assemblies are preferably rectangular and have an horizontal upper side, a horizontal lower side, and two vertical sides. The neighbouring panel assemblies preferably abut (either directly, or with a seal member therebetween) , such that at least one panel assembly meets other panel assemblies on each of the four sides. Preferably, the neighbouring panel assemblies interlock along each abutting side.

Each of the fixings 50 may be engaged by one or more of the brackets 100 of the panel assemblies. The brackets 100 may be hooked on ridges or ribs formed on the fixings 50. The brackets 100 may be bolted to the fixings 50. As can be seen in Figures 2, 7 and 8, fixings 50 may be discrete items spaced apart or a single continuous strip extending across a portion of an edge or a/each floor.

As shown in Figure 9, the fixings 50 may engage both the upper edge of a first panel assembly, and the lower edge of a second panel assembly (for example, the lower horizontal member 220b of the inner perimeter frame) . Thus, horizontal loads applied to the panel assembly can be resisted by fixings 50 at upper and lower edges thereof. In Figure 9, the first and second panel vertically spaced apart

assemblies abut a fixing 50 level with a floor of the building. However, an alternative arrangement is described below with reference to Figures 10 to 14. In preferable embodiments, the fixings 50 may include means for engaging the lower edge of a panel to resist relative movement in the horizontal direction, whilst allowing at least some relative movement in the vertical direction.

Whilst in Figure 1, the bracket 100 comprises a hook 122 for engaging the fixing(s) 50, as can be seen in Figure 8, means 1050 for engaging the fixing 50 may be a separate component of the panel assembly. Preferably, means 1050 for engaging the fixing 50 may be sandwiched between the first and second parts 110, 120 of the or each bracket 100. Preferably, the panel may be manufactured by drilling or otherwise providing a bore in the one or more composite panels, locating a first part 120 of the bracket 100 on one side of the panel 250; locating a second part 110 of the bracket 100 on an opposite side of the panel 250. The rod 130 may then be inserted through the bore and attached to the first and second parts 110, 120. Advantageously, the bore extends through the panel at an angle to its major surfaces (as set out above) . It is preferably, though not essential, for the frame members to which each bracket 100 is attached to be located between the first and second parts 110, 120. It is preferable, though not essential, that each frame member or rail 340 engaged by a bracket 100 is

sandwiched between the corresponding bracket part 110, 120 and the panel (either directly, or via intermediate

materials or components) . Thus, the frames 210, 220 (or at least some of the members thereof) are preferably attached to the panel 250 before the brackets 100.

Whilst in the embodiments described above the panel

assemblies are arranged vertically, embodiments are

envisaged in which the panels are merely substantially vertical, such as in the range 75° to 90°.

Figure 10 shows an alternative embodiment. Whereas Figure 9 shows fixings 50 engaging both the upper edge of a first panel assembly, and the lower edge of a second panel

assembly level with a floor of the building, in some cases (for example, in residential buildings rather than office buildings), this is not desirable. The arrangement shown in Figures 10 to 14 allows the panel assemblies 2250 to be supported at a location offset from the floors of a building using one or more supports 2050 as a fixing 50. This arrangement has features in common with that described above and differs only in the aspects described below, and so related reference numerals have been used to denote like components .

A preferable form of support 2050 is shown in Figure 10 to 14. The support 2050 comprises: a main body 2051 having a planar surface for abutment with a floor of a building structure; an elongate shaft 2053, preferably extending perpendicular to the planar surface; a first hook or slot

2052 extending along the shaft 2053; and a second hook or slot 2054 extending along the shaft 2053. The second hook or slot 2054 is located further from the main body 2051 than the first hook or slot 2052. Optionally, a web may be provided between the main body 2051 and the elongate shaft

2053 for resisting bending. Preferably, the main body is installed on the underside of the floor and so the planar surface may form an upper surface .

Preferably, the main body 2051 is generally plate-shaped.

The main body 2051 may include one or more elongate slots through which bolts or other fixing means 2055 may attach the main body 2051 to a floor of a building structure in such a way as to allow the support 2050 to be adjusted by sliding into and out of the building (in the direction perpendicular to the plane of the panel assembly 2250) while the bolts or fixing means 2055 are engaged but not fully tightened. The bolts or fixing means 2055 when fully

tightened can frictionally engage the main body 2051 with the floor. Washers (in particular, serrated washers) are preferably provided (for example, around the shaft of any bolts 2055) to provide resistance to lateral loads.

The first and second hooks or slots 2052, 2054 extend parallel with the shaft 2053 for engagement with respective retaining rods 2126a, 2126b extending from or through a vertical rail 2220a. A first retaining rod 2126b extends through the lower end of the vertical rail 2220a for

engaging the lower second hook or slot 2054, while a second retaining rod 2126a extends through the lower end of the vertical rail 2220a for engaging the upper first hook or slot 2052. The first and second hooks or slots 2052, 2054 are not intended to support the weight of the panel assembly 2250 in the vertical direction, but merely to prevent the panel assembly 2250 from moving towards and away from the building .

In some embodiments, first and second hooks or slots 2052, 2054 may be formed from one or more flanges extending from the elongate shaft 2053. When vertical rail 2220a forms a channel through which retaining rods 2126a, 2126b extend, the open side of the channel can face the elongate shaft 2053 such that the flanges are inserted into the channel. The flanges may be narrower than the channel to allow the position of the rail 2220a to vary slightly in the direction of the longitudinal extension of the retaining rods 2126a, As with the system described above, the weight of the panel assembly 2250 in the vertical direction can be supported by an adjustment means 2124. Adjustment means 2124 provides a stop for setting the height of the bracket 2100 relative to the support 2050, when the bracket 2100 and support 2050 are engaged. Adjustment means 2124 may comprise a bore through first part 2120 and a bolt, wherein rotation of the bolt within the bore varies the amount by which it protrudes thereby setting the height of the first part 2120. The adjustment means 2124 may abut the planar surface of the main body 2051. The retaining rod 2126a nearest the bracket extending through the vertical rail 2220a for engagement with a first slot 2052 may be spaced from the first part 2120 of the bracket 2100 such that the adjustment means 2124 abuts the planar surface.

A further difference from the embodiment described above is that in the panel assembly 2250 of Figures 10 to 14, the bracket 2120, 2130, 2110 is connected at or near the lower end of the frame members 2220a, 2210a. Optionally, with such a configuration, there may be provided a tension strut 2325 at or near the upper end of the frame members 2220a, 2210a. This can assist the tensile forces in the panel thereby preventing the outer frame from coming away from the inner frame at the upper end.

Yet a further difference from the embodiment described above is that in the panel assembly 2250 of Figures 10 to 14, the bracket 2120, 2130, 2110 is preferably connected to the vertical rails 2220a, 2210a rather than the outer perimeter frames 2300a, 2300b. As with the first embodiment, a compression strut 2320 may be provided. Preferably, this is provided such that it is (vertically) aligned along the length of the respective frame member with the second part 2110 of the bracket 2100.