Cladding System with Expressed Joint

Abstract

A cladding system based on a specially configured base sheet profiled to provide a ship lap expressed joint with an adjacent sheet, which is ideal for use with relatively low-build brushable or rollable texture coatings. The ship lap expressed joint includes within the visible portion of the joint between the outer surfaces of the base sheets, an interface line defined by an inner overlapping edge of one of the base sheets, whereby the interface line is set in from the outer surface of the base sheets. This arrangement enables coated walls, and in particular texture coated masonry look walls, to be created at a much lower cost and using less skilled operators, as it obviates the need to set and finish the joints between adjacent sheets and the problems associated with that process.

1 . A panelised masonry look wall cladding system incorporating broad planar surfaces extending between vertical expressed joints, the wall cladding system comprising:
 a plurality of broad rectangular base sheets secured in a side by side vertical orientation to an underlying structure;   each of the base sheets having an inner surface and a planar generally smooth unfinished outer surface, each base sheet being profiled along at least one longitudinal edge to provide, on installation with an adjacent sheet, broad planar surfaces with an intermediate overlapping vertical ship lap expressed joint, a portion of the joint being clearly visible between the outer surfaces of the base sheets and including an interface line defined by an inner overlapping edge of one of the base sheets, the interface line thereby being set in from the outer surfaces of the base sheets; and   a relatively low build brushable or rollable texture coating applied in situ to the exposed unfinished outer surfaces of the installed base sheets.   
     
     
         2 . A cladding system according to  claim 1  wherein the visible portion of the expressed joint is defined by a channel formation between the outer surfaces of adjacent base sheets, the channel having an outer width between the outer surfaces, and an inner width at a depth set in from the outer surfaces. 
     
     
         3 . A cladding system according to  claim 2  wherein the interface line is set in at the maximum depth of the channel. 
     
     
         4 . A cladding system according to  claim 2  wherein the profiled edges of the base sheets includes some form of straight or curved chamfer along the edges immediately adjacent the outer surface of the base sheets, such that the outer width of the channel is wider than the inner width of the channel. 
     
     
         5 . A cladding system according to  claim 4  wherein the channel has a generally ‘V’ shaped or truncated ‘V’ shaped section. 
     
     
         6 . A cladding system according to  claim 2  wherein the outer width of the channel is up to about 15 mm. 
     
     
         7 . A cladding system according to  claim 6  wherein the outer width is from about 3 mm to about 9 mm. 
     
     
         8 . A cladding system according to  claim 7  wherein the outer width is approximately 7 mm. 
     
     
         9 . A cladding system according to  claim 2  wherein the inner width is up to about 10 mm. 
     
     
         10 . A cladding system according to  claim 9  wherein the inner width is from about 3 mm to about 9 mm. 
     
     
         11 . A cladding system according to  claim 10  wherein the inner width is about 3 mm. 
     
     
         12 . A cladding system according to  claim 2  wherein the maximum depth of the channel is no more than about 6 mm. 
     
     
         13 . A cladding system according to  claim 12  wherein the maximum depth of the channel is from about 3 mm to 4.5 mm. 
     
     
         14 . A cladding system according to  claim 1  wherein some or all of the internal corners and edges are curved or chamfered. 
     
     
         15 . A cladding system according to  claim 1  wherein the base sheets are pre-coated with an appropriate sealer. 
     
     
         16 . A cladding system according to  claim 1  wherein the relatively low-build brushable or rollable texture coating has a thickness of up to about 300 microns when applied. 
     
     
         17 . A cladding system according to  claim 1  further comprising a back sealing tape adapted to span across the edges of the inner surfaces of adjacent base sheets across the joint. 
     
     
         18 . A cladding system according to  claim 1  further comprising a sealant for application between the overlapping surfaces of the ship lap joint between adjoining base sheets. 
     
     
         19 . A cladding system according to  claim 1  wherein each base sheet is profiled on two opposing longitudinal edges. 
     
     
         20 . A cladding system according to  claim 1  wherein the base sheets are made from fibre cement. 
     
     
         21 . A method of installing a panelised masonry look wall cladding system, the method comprising the steps of:
 providing a plurality of broad rectangular base sheets, each of the base sheets having an inner surface and a planar generally smooth outer surface, each base sheet being profiled along at least one edge such that on installation with an adjacent sheet, an overlapping vertical ship lap expressed joint is formed, a portion of the joint being clearly visible between the outer surfaces of the base sheets and including an interface line defined by an inner overlapping edge of one of the base sheets which is thereby set in from the outer surfaces of the base sheets;   securing the base sheets to an underlying structure in a side by side vertical orientation so as to form at least one vertical ship lap expressed joint as described above; and   applying in situ a relatively low-build brushable or rollable texture coating to the exposed unfinished outer surfaces of the installed base sheets.   
     
     
         22 . A method of installing a cladding system according to  claim 21  wherein the base sheets are secured such that the visible portion of the joint defines a channel between the outer surfaces of adjacent base sheets, the channel having an outer width between the outer surfaces, and an inner width at a depth set in from the outer surfaces. 
     
     
         23 . A method of installing a cladding system according to  claim 22  wherein the base sheets are secured such that the interface line is set in at the maximum depth of the channel. 
     
     
         24 . A method of installing a cladding system according to  claim 22  wherein the sheets are configured and selected such that on installation, the cladding system defines a joint including a channel with an outer width up to about 15 mm. 
     
     
         25 . A method of installing a cladding system according to  claim 21  further comprising applying a back sealing tape between the underlying structure and the base sheets, such that the back sealing tape spans across the inner edge surfaces of adjacent base sheets. 
     
     
         26 . A method of installing a cladding system according to  claim 21  further comprising applying a sealant between the overlapping surfaces of the ship lap joints between adjoining base sheets. 
     
     
         27 . A method of installing a cladding system according to  claim 21  wherein the relatively low-build brushable or rollable texture coating is applied in two coats. 
     
     
         28 . A method of installing a cladding system according to  claim 21  wherein the relatively low-build brushable or rollable texture coating is applied to a thickness of up to about 300 microns. 
     
     
         29 . A method of installing a cladding system according to  claim 21  wherein the base sheets are made from fibre cement.