EP-4739862-A1 - A METHOD FOR CONSTRUCTING A BUILDING WALL AND A BUILDING WALL PRODUCED BY SUCH A METHOD

Abstract

The invention relates to a method for producing a building wall. The method comprises a) constructing an inner core of a building wall comprising a layer of mineral wool insulation batts, fiberglass insulation batts, polymeric foam insulation batts, and/or cellulose fiber insulation batts (130); and b) applying, preferably spraying, a layer of a plaster composition comprising an adhesive (140) onto a portion of said layer of batts (130).

Inventors

• Rasmussen, Tormod Martin Christian
• ALBÉR, Leif
• BOYE, Søren Valdgård

Assignees

• Alber Gypsum LLC

Dates

Publication Date

20260513

Application Date

20240628

Claims (16)

1. 1 . A method for producing a building wall, the method comprising: a) constructing an inner core of a building wall comprising a layer of mineral wool insulation batts, fiberglass insulation batts, polymeric foam insulation batts, and/or cellulose fiber insulation batts; and b) applying, preferably spraying, a layer of a plaster composition comprising an adhesive onto a portion of said layer of batts.
2. 2. The method according to claim 1 , wherein step a) comprises the sub-steps of: a1) providing a plurality of beam members and positioning them with a predefined space between adjacent beam members, said beam members each having a front face, a rear face, and two side faces; and a2) placing a layer of mineral wool insulation batts, fiberglass insulation batts, polymeric foam insulation batts, and/or cellulose fiber insulation batts into the spaces between adjacent beam members.
3. 3. The method according to claim 2, wherein step b) further comprises applying, preferably spraying, a layer of a plaster composition comprising an adhesive onto a portion of said beam members.
4. 4. The method according to any one of the claims 2-3, wherein step a) further comprises the sub-step of: a3) mounting a supporting net to the front and/or rear faces of said beam members and across said layer of batts, and wherein step b) further comprises applying, preferably spraying, a layer of a plaster composition comprising an adhesive onto said supporting net.
5. 5. The method according to any one of the claims 2-4, wherein said beam members’ side face or side faces comprises a support section, such as one or more flanges or pins or spikes, adapted for holding said layer of batts into place.
6. 6. The method according to any one of the claims 2-4, wherein said beam members’ front and/or rear faces comprises a plurality of protrusions adapted for use as anchorage points within said layer of a plaster composition.
7. 7. The method according to any one of the claims 2-5, wherein step b) comprises: b1) mounting a guide rail of plaster, preferably by adhesion, onto the front and/or rear faces of at least two, preferably three or more, of said beam members; b2) spraying a layer of a plaster composition comprising an adhesive onto a portion of said layer of batts and preferably also onto a portion of said beam members; and b3) using said guide rails for controlling the thickness of said layer of plaster composition and/or for straightening said layer of plaster composition, and/or for smoothening said layer of plaster composition.
8. 8. The method according to any one of the claims 1 -6, wherein step b) comprises: b1) mounting a guide rail of plaster, preferably by adhesion, onto the front faces of said layer of batts; b2) spraying a layer of a plaster composition comprising an adhesive onto a portion of said layer of batts; and b3) using said guide rails for controlling the thickness of said layer of plaster composition and/or for straightening said layer of plaster composition, and/or for smoothening said layer of plaster composition.
9. 9. The method according to any one of the claims 6-7, further comprising the step of: c4) allowing said plaster composition to irreversibly bind to said guide rails as it cures or harden.
10. 10. The method according to any one of the claims 1 -8, wherein said layer of batts is of mineral wool insulation batts, and wherein the plaster composition comprises an adhesive suitable for adherence to the layer of mineral wool insulation batts, and preferably also to wood or metal.
11. 11 . The method according to any one of the claims 1 -8, wherein said layer of batts is of polymeric foam insulation batts, and wherein the plaster composition comprises an adhesive suitable for adherence to the layer of polymeric foam insulation batts, and preferably also to wood or metal.
12. 12. The method according to any one of the claims 1 -8, wherein said layer of batts is of cellulose fiber insulation batts, and wherein the plaster composition comprises an adhesive suitable for adherence to the layer of cellulose fiber insulation batts, and preferably also to wood or metal.
13. 13. The method according to any one of the claims 1 -8, wherein the plaster composition comprises an adhesive selected from the group consisting of: adhesives comprising an anionic copolymer dispersion of acrylic acid ester and styrene, polyvinyl acetate adhesives, polyvinyl alcohol adhesives, polyurethane adhesives, phenolic resin adhesives, cyanoacrylate adhesives, adhesives comprising an ethylene/vinyl acetate copolymer, adhesives comprising an ethylene-vinyl acetate-vinyl chloride emulsion, and mixtures thereof.
14. 14. The method according to any one of the claims 1 -12, wherein the plaster composition comprises 6-15% by dry matter weight adhesive.
15. 15. A building wall produced by the method of any one of the claims 1 -13.
16. 16. A building wall comprising: - a plurality of spaced apart beam members; - a layer of mineral wool insulation batts, fiberglass insulation batts, and/or cellulose fiber insulation batts positioned within said space between adjacent beam members; and - a layer of a plaster composition comprising an adhesive, said plaster layer adhering to a portion of said layer of batts and preferably also to a portion of said beam members; wherein said layer of batts comprises a first side and a second side, said second side facing said plaster layer.

Description

A method for constructing a building wall and a building wall produced by such a method Field of the Invention The present invention relates to walls for buildings. Background of the Invention Many different materials, such as polymeric foams, mineral wool, cellulose fibres, and fiberglass, are known in the art to provide thermal insulation to wall systems. Some of these materials are inherently flammable and some lead to the melting and spread of burning debris. This may lead to sustaining combustion by progressive smouldering even after the actual flames have extinguished. Hence, a building wall is to meet specific fire performance standards and may have to be constructed with fire-resistant protective surfaces, such as one-half inch gypsum board, applied over the insulation. However, it is difficult to provide an airtight protective surface of gypsum board around installations in the wall, such as around electrical outlets, and tubing. Furthermore, it is very timeconsuming to mount the gypsum boards. Object of the Invention The objective of the present invention is to provide a building wall solving at least some of the above problems. This has been accomplished according to this invention by providing a plurality of beam members and positioning them with a predefined space between adjacent beam members, said beam members each having a front face, a rear face, and two side faces. Then a layer of mineral wool batts, fiberglass batts, and/or cellulose batts are placed into the spaces between adjacent beam members, and finally a layer of a plaster composition comprising an adhesive is sprayed or applied onto a portion of said layer of batts and preferably also onto a portion of said beam members. If needed, the layer of plaster composition is smoothened. The plaster composition is then allowed to cure or harden to form a plaster layer. Electrical outlets and tubing are completely sealed along their edges by the plaster composition, thereby improving the fire resistance compared to the use of traditional plaster boards, where holes must be made therein for installation of e.g., electrical outlets. Often these holes are made excessively large, thereby increasing the risk that fire can reach the insulation layer or e.g., beam members of wood or other inflammable materials. Summary of the Invention A first aspect relates to a method for producing a building wall, the method comprising: a) constructing an inner core of a building wall comprising a layer of mineral wool insulation batts, fiberglass insulation batts, polymeric foam insulation batts, and/or cellulose fiber insulation batts; and b) applying, preferably spraying, a layer of a plaster composition comprising an adhesive onto a portion of said layer of batts. The term “mineral wool” generally refers to fibers made from natural or synthetic minerals. Non-limiting examples of synthetic minerals are fiberglass or glass wool; ceramic fibers; and stone wool or rock wool. The terms “mineral wool”, “mineral fibers” may be used interchangeably. In the context of the present disclosure, the term "polymeric foam" is meant to designate a material based on a polymer and which material comprises voids, typically in an amount of at least 5% by volume, typically from 10% to 55% by volume or from 10% to 45% by volume. The voids may be obtained by any of the known methods, such as cells formed by gas. Alternatively, the voids may result from the incorporation of hollow fillers, such as hollow polymeric particles, hollow glass microspheres or hollow ceramic microspheres. The term "insulation batt", as used herein, is defined to mean a sheet, block, or web of an insulation material. In the present context, the terms “plaster” and “gypsum” are used interchangeably and meant to be understood as normally understood in the art, i.e., to cover compositions predominately made from calcium sulfate, preferably predominately comprising calcium sulfate hemihydrate but may also comprise calcium sulfate anhydrate, calcium sulfate dihydrate, as well as calcined gypsum. In one or more embodiments, the plaster composition comprises an adhesive suitable for adherence to the layer of open and/or closed cell foam, and preferably also to wood. In one or more embodiments, the plaster composition comprises an adhesive selected from the group consisting of: adhesives comprising an anionic copolymer dispersion of acrylic acid ester and styrene, polyvinyl acetate adhesives, polyvinyl alcohol adhesives, polyurethane adhesives, phenolic resin adhesives, cyanoacrylate adhesives, adhesives comprising an ethylene/vinyl acetate copolymer, adhesives comprising an ethylene-vinyl acetate-vinyl chloride emulsion, and mixtures thereof. In one or more embodiments, the plaster composition comprises 6-15% by dry matter weight adhesive. In one or more embodiments, the plaster composition comprises an adhesive in the form of a (water) redispersible polymer powder. Redispersible polymer powders are polymer e