An improved building method, system and components thereof

Abstract

The invention relates to a system for levelling and supporting a building component, the system comprising at least two structure levelling and support devices, the structure levelling and support devices each comprising a cylindrical element including a first aperture extending therethrough, and at least two fixing elements, each fixing element receivable within the first aperture of the at least two structure levelling and support devices, and configured to extend through the cylindrical element of the structure levelling and support device to fixably connect with a building component. Also described are methods for improving thermal performance in a building structure, and components for the installation of insulating material in a building structure, such as a bracket system.

Description

[0001] An Improved Building Method, System and Components Thereof

[0002] 1. FIELD OF THE TECHNOLOGY

[0003] The invention relates to an improved building system for fitting insulation to the exterior of a building structure, together with components for use with the building system, together with methods for the use of the system.

[0004] 2. BACKGROUND TO THE TECHNOLOGY

[0005] There are many building structures, particularly residential housing structures that are inadequately insulated, resulting in homes that are inefficient to heat, damp and both uncomfortable and a health risk for those occupying them. Such homes are usually older and do not meet modern building code requirements.

[0006] Traditionally, improving such houses by adding insultation to the walls, floor and or ceiling space is a time-consuming process that requires the occupants to vacate the home for a period, particularly when wall insulation is required. This is a huge cost burden to both fund the insulation process and to find alternative accommodation for the occupants while the remedial work is undertaken. There are also logistical and emotional costs for the occupants during this period.

[0007] The process of providing improved insulation and upgrading windows involves a range of tools and techniques that are commonly used, for example a sill support bar is a known use for supporting window frames, particularly those over 600mm wide. Commonly used sill support bars can be difficult to install correctly and require a level installation of horizontal support members. Adjustment of sill support members after installation to remedy incorrect alignment is very inconvenient and if installed incorrectly, can lead to leaking, or increased risk of window failure.

[0008] The systems used for the installation and fixing of insulation may differ depending on the type and size of insulation used. Often different fixing techniques and components are needed to cater to different systems, which increases costs and time on a building job.

[0009] It would be advantageous to develop a building system and components that could address the varying insulation needs of existing structures, without the occupants needing to evacuate the premises while the work is taking place and improve the ease of such work with improved supporting component and tools.

[0010] 3. OBJECT OF THE TECHNOLOGY

[0011] It is an object of the technology to provide a building system for providing insulating material to an existing building structure.

[0012] Alternatively, it is an object of the technology to provide one or more components that may be used to assist in the application building materials to an existing building structure.

[0013] Alternatively, it is an object of the technology to provide a method for insulating a building or structure having existing cladding.

[0014] Alternatively, it is an object of the technology to at least provide the public with a useful choice.

[0015] 4. SUMMARY OF THE TECHNOLOGY

[0016] According to a first aspect of the invention there is provided a bracket assembly for use in a construction system, the bracket assembly comprising: a bracket comprising two fixing plates connected together substantially perpendicular to each other, each fixing plate comprising at least one aperture extending through the fixing plate; and an elongate attachment member having a first end and an opposing second end, and a plurality of apertures spaced at variable distances from the first end or second end of the elongate attachment member, such that the apertures are spaced to form a curved path along at least a portion of a length of the elongate attachment member; wherein a first fixing plate of the bracket is rotatably connected to the second end of the elongate attachment member via a pivot mechanism.

[0017] In some forms, the apertures are positioned on the elongate attachment member to form a curved path of varying radius. In some forms the attachment member is a curved elongate member, the elongate member curved through a variable radius between the first and second ends of the member. In some forms, the elongate member is curved around a smaller radius closer to the first end of the elongate member and a larger radius closer to second end.

[0018] In some forms, the elongate member has a convex top side edge and an opposing convex bottom edge extending between the first and second ends of the elongate attachment member.

[0019] In some forms, the plurality of apertures are spaced apart on the attachment member to form a curved path along at least a portion of a length of the attachment member.

[0020] In some forms, the first end and second end elongate member are formed with rounded edges.

[0021] In some forms, the elongate member is formed with curved ends having partially circular edges.

[0022] In some forms, the plurality of apertures are located proximal the concave top side edge of the elongate member.

[0023] In some forms the elongate attachment member comprises one or more flanges extending from a side edge of the elongate attachment member.

[0024] In some forms, the elongate attachment member includes one flange extending from a top edge of the elongate member and one flange extending from a bottom edge of the elongate member.

[0025] According to a further aspect of the invention there is provided a method for securing insulating segments between first and second components of a building structure, the method including; providing a bracket assembly for use in a construction system as described above; securing the second fixing plate of the bracket to a first component of a building structure; applying an insulation material directly or indirectly between the first component of a building structure and a second component of a building structure; rotating the attachment member of the bracket system such that at least one aperture of the attachment member aligns with the second component of a building structure; and fixably connecting the attachment member to the second component of the building structure via the at least one aperture.

[0026] According to a further aspect of the invention there is provided a structure levelling and support device comprising; a cylindrical element including at least one aperture extending therethrough, one of the at least one aperture extending parallel to but offset from a central axis extending longitudinally though the cylindrical element and shaped to receive an elongate fixing device.

[0027] In some forms, the cylindrical element comprises a front end having a front surface and an opposing rear end having rear surface, and wherein a plurality of holes are formed within and extend fully or partially through the cylindrical element from the rear surface towards the front surface.

[0028] In some forms the plurality of holes extend partially through cylindrical element from the rear surface towards, but not through the front surface.

[0029] In some forms, the plurality of holes are sized and shaped to create one or more spokes that extend radially from a supporting wall surrounding the at least one central aperture, towards an outer wall of the cylindrical element.

[0030] In some forms, an exterior surface of cylindrical element is smooth, textured or partially textured.

[0031] According to a still further aspect of the invention there is provided a system for levelling and supporting a building component, the system comprising; at least two structure levelling and support devices, the structure levelling and support devices each comprising a cylindrical element including a first aperture extending therethrough, the first aperture extending parallel to but offset from a central axis extending longitudinally though the cylindrical element, the first aperture shaped to receive an elongate fixing device for connecting the cylindrical element to a surface; and at least two fixing elements, each receivable within the first aperture of the at least two structure levelling and support devices, and configured to extend through the cylindrical element of the structure levelling and support device to fixably connect with a building component. In some forms, the cylindrical element of each structure levelling and support device comprises two or more apertures extending therethrough, a second of the at least two apertures offset from the first aperture and configured to receive a connection member for connecting the cylindrical element to a surface.

[0032] In some forms, each cylindrical element comprises a front end having a front surface and an opposing rear end having rear surface, and wherein a plurality of holes are formed within and extend fully or partially through the cylindrical element from the rear surface towards the front surface.

[0033] In some forms, the plurality of holes extend partially through cylindrical element from the rear surface towards, but not through the front surface.

[0034] In some forms, the plurality of holes are sized and shaped to create one or more spokes that extend radially from a supporting wall surrounding the first aperture, towards an outer wall of the cylindrical element.

[0035] In some forms, an exterior surface of cylindrical element is textured or partially textured.

[0036] According to a still further aspect of the invention there is provided a method for levelling and supporting a building component, the method comprising the steps of; providing a system for levelling and supporting a building component as described above; inserting a fixing element through the first aperture of the cylindrical element of each levelling and support device; attaching at least two levelling and support devices to a building structure by partial connection of the fixing element to the building structure, the at least two levelling and support devices attached to be spaced apart from each other horizontally on substantially the same horizontal axis; placing a level across an upper surface of the at least two levelling and support devices; rotating one or more of the cylindrical elements of the at least two levelling and support devices until the upper surfaces of the at least two support devices are level; locking the levelling and support devices in the desired position by full connection of the fixing element to the building structure; and placing a building component on the upper surfaces of the at least two levelling and support devices such that the devices support the building component in the desired horizontal position.

[0037] In some forms, the method comprises attaching at least two levelling and support devices to a building structure by partial connection of the fixing element to the building structure, the devices spaced apart from each other vertically on substantially the same vertical axis.

[0038] In some forms, the building component is a window frame and the method is used to accurately install and support window frames and / or doors.

[0039] In some forms, the window and / or door frames have a thermal conductivity of less than 55 W(m.K), more preferably less than 5 W(m.K) and even more preferably less than 0.5 W (m.K).

[0040] In some forms, the window and / or door frames are timber or PVC.

[0041] According to a further aspect of the technology there is provided a method for improvement of thermal performance and / or moisture control in an existing building structure, the method comprising; applying a protection membrane to pre-existing exterior cladding of the building structure; applying an insulation material over the protection membrane; securing the insulation material in position using a plurality of vertically spaced apart battens; applying exterior cladding over the insulation material.

[0042] In some forms, the method includes further initial steps of; measuring the dimensions of the building structure and entering measurements and optionally additional information on the existing building structure into a software product; generating a thermal report based on the information from step i) using the software product; determining the insulation requirements required to bring the existing building structure up to a pre-determined standard.

[0043] According to a further aspect of the technology there is provided a method for improving of thermal performance and / or moisture control in an existing building structure, the method comprising; removing one or more windows from one or more window frames of an existing structure; applying a protection membrane to pre-existing exterior cladding of the building structure; attaching at least one bracket of the bracket system described above to the existing building structure; attaching a system for levelling and supporting a building component as described above directly to indirectly to the one or more window frames; correctly placing one or more new windows in the one or more window frames using the levelling and support system as described above and fixing in place; applying an insulation material over the protection membrane; mounting a plurality of spaced apart battens to the existing building structure over the insulation material; attaching at least one elongate attachment member of the bracket system as described above to the battens to secure the insulation material in position; applying an exterior cladding over the insulation material and securing the exterior cladding to the plurality of battens.

[0044] In some forms the exterior cladding is exterior wall cladding.

[0045] In some forms the protection membrane is a self-adhesive membrane. More preferably, the membrane is a non-porous, vapour permeable membrane.

[0046] In some forms, the step of attaching at least one elongate attachment member of the bracket system to the battens comprises attaching the elongate attachment member to the batten through at least two apertures in the elongate attachment member.

[0047] In further aspects, the method includes the additional step of removing and replacing windows in the existing building structure with double or triple glazed windows. More preferably the step of replacing windows includes using the method of levelling and supporting a building component as described in further detail above.

[0048] In still further aspects, the method includes the step of installing a cavity closer system to the existing building structure. In still further aspects, the method includes the step of securing the insulation material to an existing building structure using the method for securing insulation material to a building structure as described in further detail above.

[0049] Further aspects of the technology, which should be considered in all its novel aspects, will become apparent to those skilled in the art upon reading of the following description which provides at least one example of a practical application of the technology.

[0050] 5. BRIEF DESCRIPTION OF THE DRAWINGS

[0051] One or more embodiments of the technology will be described below by way of example only, and without intending to be limiting, with reference to the following drawings, in which:

[0052] Figure 1 shows a flow chart describing the method for improvement of thermal performance and / or moisture control in an existing building structure in one form of the present invention;

[0053] Figure 2 shows a front perspective view of the bracket system according to a further aspect of the invention;

[0054] Figure 2A shows a rear perspective view of the bracket system of Figure 2;

[0055] Figure 3 shows a blank of the bracket of the bracket system in one aspect of the invention;

[0056] Figure 4 shows the elongate attachment member of the bracket system as shown in Figure 3;

[0057] Figure 4A shows a side view of the bracket system attached to first and second building components;

[0058] Figure 5 shows a side view of the bracket of the bracket system;

[0059] Figure 6 shows a structure levelling and support device according to one example of the invention; Figure 7 shows a front view of the cylindrical element of the levelling and support device in one example of the invention;

[0060] Figure 7A shows a rear view of the cylindrical element of the levelling and support device in one example of the invention;

[0061] Figure 7B shows a side cross-sectional view of the cylindrical element of the levelling and support device in direction A-A as indicated in Figure 7A;

[0062] Figure 8 shows the levelling and support system in use with a window frame in one example of the invention;

[0063] Figure 9 shows a flow chart describing the method for improvement of thermal performance and / or moisture control in an existing building structure according to a further aspect of the present invention with window replacement required; and

[0064] Figure 10 shows a cross section of a building structure following installation an insulation system using one example of the systems and methods of the present invention.

[0065] 6. DETAILED DESCRIPTION OF EXEMPLARY FORMS OF THE TECHNOLOGY

[0066] Bringing older existing homes that lack insulation and double glazing up to current building standards is a time consuming and costly task, with the occupants of the house needed to vacate the premises so internal linings can be removed to add insulation from the inside. The costs are not only incurred in the remedial work, but also in the rehousing of the occupants while the work is completed.

[0067] The method of the present invention is the application of a building insulation system design to be applied externally to varying building wall claddings, minimising the costs associated with removing existing building material and allowing the occupants to remain living in the building while the work is being done.

[0068] The systems and methods of the present invention allow for a range of different insulation thicknesses to be retrofitted over the existing exterior cladding of a house to improve thermal performance and reduce dampness in the home. The exterior cladding may be masonry, weatherboard, fibrolite, plaster, or other known cladding. For the purposes of the examples provided a weatherboard exterior is described, but this not intended to be limiting.

[0069] Prior to installation of the current system, background analysis of the building structure is completed to determine the requirements for bringing the building up to code, including but not limited to thermal imaging, moisture testing, measurement of structure and assessment of current building materials in place. This information is them used to develop a building specific plan, either manually or using a software product. If weathertightness issues are identified that are not related to the insulation or wall structure of the building, for example a lack of eaves, or a flat roof that contributes to moisture issues, these structural problems must be remedied separately and are not part of the claimed invention. The use of known flashings, guttering etc may be utilised with the below method in known fashion to optimise building performance and address weather tightness issues.

[0070] Insulation may be added in roof cavities and under floors as permitted and the wall insulation requirements are met using the method described in more detail below. Different thicknesses of wall insulation will be required for different situations and the method described below accommodates these differences easily.

[0071] The system, methods and devices of the current invention will be described in further detail below with reference to Figures 1 - 10.

[0072] Figure 1 shows a flow chart of an example of the broad method 100 of the invention when installed on an existing wall structure without windows. A weather-resistant building membrane is installed over the existing exterior of a dwelling 110 following manufacturing instructions. In some forms the membrane is a self-adhesive membrane that can adhere to any rigid structure and provides protection to the building from wind, rain, and other external water sources. The building membrane used is preferably diffusion open, allowing trapped moisture to diffuse through the membrane, without permitting external water in. One such example of a suitable membrane is the SOLITEX ADHERO® barrier from building company Proclima, however other similar products available may also be used provided they meet these requirements.

[0073] Once adhered to the building surface, the building joints and / or edges are taped to seal the membrane and provide a continuous, airtight barrier. An insulation layer is provided over the protection membrane 120. The preferred insulation used is a self-supporting segment type insulation that allows for free drainage of moisture. One preferred insulation product is Rockwool ® insulation. Rockwool® is a sustainably produced insulation formed using rock (basalt), a natural fire retardant that has good thermal consistency, sound absorption and is free-draining. Other insulation materials may be used that provide similar properties.

[0074] Insulating segments may be held in position by proprietary pins and also restrained by the installation of vertical battens 130 spaced apart (in one form these may be 30mm battens, spaced 600mm apart) and fixed to the existing building structure and through the use of the bracket system as described in further detail below. The vertical battens support the insulation against the existing cladding and provide an anchor for an exterior cladding to be mounted 140. The exterior cladding may be the same or different to the original cladding material.

[0075] Following installation of the above system, the resulting building structure includes the existing wall and exterior cladding structure, with an additional outer blanket of new insulation and cladding to meet building code requirements.

[0076] As part of the above method, several devices and systems have been developed to enable the above method to perform as required. These devices and systems are discussed in further detail with reference to Figures 2-10.

[0077] 6.1. Bracket System

[0078] Figures 2 - 4A show a bracket system 200 designed for restraining the insulation segments between the protection membrane applied to the initial exterior cladding and the vertical battens. In one form the bracket system 200 includes an integrally formed L-shaped bracket 220 comprising a first fixing plate 221, perpendicular second fixing plate 230 (in some forms formed from folded steel) and an elongate attachment member 240. The size of bracket 220 is as small as possible to reduce thermal bridging within the wider building system.

[0079] Second fixing plate 230 includes apertures 231, 232 to enable fixing plate 230 to be attached to the existing exterior wall structure, over the protection membrane. A rubber gasket 236 is preferably used between fixing plate 230 and the exterior wall structure to reduce moisture or air movement. First fixing plate 221 includes a central aperture 222 adapted to receive a connection means such as a nut and bolt 223 to rotatably connect a front or rear surface of attachment member 240 to fixing plate 221 through aperture 241. In use bracket 220 and attachment member 240 are rotatably connected so that once bracket 220 is fixed to an exterior wall, attachment member 240 can be rotated into a required position relative to the fixing plate 221, such that apertures 247-250 in elongate attachment member 240 are located at a desired position for securing against a building structure component.

[0080] In some forms elongate attachment member 240 is a flat elongate member 242 having a front surface 271 and an opposing rear surface 272. Elongate attachment member 240 is preferably curved in shape along its longitudinal axis and comprises a first end 245 and second end 246, each end preferably formed with rounded edges, for example a partial or semi-circular edge defining each end of the elongate member. Elongate member 242 is In some forms curved along its length through a variable radius between the first and second ends, such that elongate member 242 has a convex top side edge 255 and an opposing convex bottom edge 256 extending between the first and second ends. The variable curve along the length of the elongate member is variable such that the elongate member is curved around a smaller radius closer to the first end 245 and a larger radius closer to second end 246.

[0081] In one form particularly suited to building regulations and material sizing common in New Zealand and Australia, the curved elongate member 242 is formed with curved ends having partially circular edges, the first end 245 having an edge with a radius of 4.75mm, and the second end 246 having an edge with a radius of 17.5mm.

[0082] In some forms, elongate attachment member 240 comprises one or more flanges 278 running the length or portion thereof, of top side edge 255 and / or bottom side edge 256, flange 278 extending at least partially perpendicular to, and from, rear surface 272, away from first fixing plate 221. Flange 278 may be straight, stepped or curved, or maybe or varying width across the length of the flange. In some forms, the flange 278 is 4 - 6mm in width. Flanges 278 may be formed on the top edge only, lower edge only or combination of both.

[0083] The flange 278 provides increased strength to elongate attachment member 240, allowing for increased loading on the bracket. Increasing the strength of the bracket allows for fewer brackets to be utilized in a specific system, reducing thermal bridging and improving performance. Elongate member 242 includes a plurality of apertures 247-250 spaced apart and positioned such that the apertures lie on a curved path of varying radius, along at least a portion of a length of the attachment member. The apertures spacing along a curved path may be determined by an imagined or measured line connecting each aperture. Four apertures are included in the example shown in Figure 4, spaced approximately 35mm apart, but any number of apertures and spacings may be used depending on the size of the attachment member used.

[0084] In some forms, the plurality of apertures 248 - 250 are located proximal the concave top side edge 255, such that in use, they are effectively connectable to a vertical batten, without excess material from the elongate member extending outward further than the edge of the batten.

[0085] In some forms, the centre of apertures 248 - 250 are spaced apart from aperture 247 at the first end 245 of elongate member 240, along the longitudinal axis of the elongate member 240 by between 10mm - 100mm. In some preferred forms, aperture 248 is spaced apart 14-15mm from aperture 247 along the longitudinal axis, aperture 249 spaced from aperture 24742-44mm and aperture 250 spaced apart from aperture 247 76-78mm.

[0086] In the transverse axis substantially perpendicular to the longitudinal axis, the centre of apertures 248 - 250 are spaced apart from aperture 247 at first end 245 by 20 - 50mm. In some preferred forms, aperture 248 is spaced apart 30-32mm from aperture 247 along the transverse axis, aperture 249 spaced from aperture 24744-46mm and aperture 250 spaced apart from aperture 24748-5mm.

[0087] The curved spacing of apertures 247 - 250 relative to one another allows for the attachment member to be rotated through a range of positions, the apertures providing a variety of attachment points to allow connection at different positions. As seen in Figure 4A, this aperture positioning enables use of the bracket to span different distances between an existing exterior wall and vertical battens.

[0088] Figure 4A shows a cross section of an existing building exterior wall 600, insulation segment 700 and vertical batten 800 in accordance with method 100 described above, with different examples of insulation segment size 701 -705 installed between the original cladding 600 and battens 800.

[0089] Insulation segment 701 is 50mm thick, 702 is 75mm thick, 703 is 100mm thick, 704 is 125mm thick and segment 705 is 150mm thick. In use, bracket system 200 is connected through the cladding to the structural frame of the existing building structure 600 via second fixing plate 230 using screws or similar connection mechanism as required. In some forms, if the original cladding is weatherboard or other wooden cladding mounted on an angle from vertical, second fixing plate 230 may be mounted on an angle against the weatherboard, or if the finish is plaster, it may be mounted vertically. Once the second fixing plate is attached to the original building structure or cladding, attachment member 240 is then rotated around bolt 223 and one or more of apertures 247-250 aligned with a side face of batten 800. Attachment member 240 is then secured in position against batten 800 through relevant apertures using a screw or other connection mechanism, fixing the bracket system in place between the original cladding and outer batten, with elongate member 242 supporting the insulation segment in position.

[0090] As seen in Figure 4A the curved form of elongate member 242 is designed with first end 245 shaped to a curved point that has a smaller radius than second end 246 of attachment member. This shape allows for attachment member 240 to lie flush against a batten having 30mm sides (for example) without extending out further than the batten on either side, and without any protruding corners or edges. The curve of member 242 and aperture placement is such that at least two apertures may be aligned with and receive connections to batten 800, preventing further rotation of the bracket system 200.

[0091] Bracket system 200 may be formed with both left and right-side versions. Figures 2 and 2A show an example of a left side version of bracket system 200. A right side version may also be provided, whereby elongate attachment member 240 and first fixing plate 221 extend from the opposite side of second fixing plate 230, and flange 278 extends from top side edge 255 and bottom side edge 256, away from first fixing plate 221.

[0092] 6.2. Levelling and Support Device

[0093] Typically, method 100 will be applied to buildings such as residential houses that include a number of windows or doors located in the walls. When upgrading the building, single glazed windows are ideally replaced with double or triple-glazed windows to improve the overall insulation of the building and reduce thermal bridging. As an external insulation system, method 100 requires the windows and doors of a building to be installed outside the framing line to allow for continuous insulation to be applied. To support the windows / doors outside the framing line, a levelling and support device as shown in Figures 6-8 may be used. Replacement windows and / or doors are preferably framed with timber or PVC, as these materials have low thermal conductivity, improving the thermal performance of the building. Other materials with low overall thermal conductivity may be used, such as fiberglass or thermally broken aluminum. Ideally, materials with a thermal conductivity lower than 1 W(m.K) are used, and this leads to the preference for timber (~0.12W(m.K) ) or PVC (~0.17W(m.K)).

[0094] A structure levelling and support device 400 has been developed to aid in the installation of new windows or doors during the application of method 100. As seen in Figures 6 - 8, levelling and support device 400 comprises a cylindrical element 410 including at least one aperture 420 extending therethrough.

[0095] Aperture 420 extends through the body of cylindrical element 410 and may have a diameter of 5mm - 25mm, parallel to but offset from the central cylinder axis. Aperture 420 is shaped 418 to receive an elongate fixing device such as a washer head screw that extends through the cylindrical element 410 and is fixable to a building frame or structure.

[0096] Cylindrical element 410 is rotatable around the screw, and the offset aperture creates a cam mechanism such that on rotation of cylindrical element 420, an upper surface 450 created by cylindrical element 410 is raised or lowered. Cylindrical element 410 may further include apertures or holes 430 that do or do not extend through the entire body of cylindrical element 410 as seen in Figures 10 and 10A showing a front view and rear view respectively. These apertures 430 may be formed to improve structural integrity, or to keep manufacturing costs down. Cylindrical element 410 in some forms comprises locking aperture 433 extending through of cylindrical member 410 along the longitudinal axis, parallel to aperture 420. Locking aperture 433 is configured to receive a connection member such as a screw to enable a further fixing of the structure levelling and support device 400 to be securely fastened in a final position, once initial positioning has been achieved via rotation of the cylindrical element 410 around a fixing element received within aperture 420.

[0097] In one form as shown in Figure 7 and 7A, cylindrical element 410 comprises a front end having a front surface 422 and an opposing rear end having rear surface 423. A plurality of holes 430 are formed within and extend partially through a solid cylindrical element 410 from the and are shaped and sized such that a plurality of spokes 425 are formed in rear surface 423 and extend partially longitudinally through cylindrical element 410 towards, but not through front surface 422. Spokes 425 provide additional structural strength to levelling and support device 400, and reduce the material used in manufacture, for example should the device be 3D printed or molded. Holes 430 are sized and shaped to create spokes 425 that extend radially around from a supporting wall 427, surrounding aperture 420, towards an outer wall 428.

[0098] The exterior surface 431 of cylindrical element 410 may be smooth or textured around the curved outer surface of the cylinder, or a combination thereof as shown with side view of Figure 10B. The textured surface can assist in gripping and stabilising a structural device that is to be levelled as it rests On surface 450 during use.

[0099] Cylindrical element 410 has a length along the longitudinal axis of the cylindrical element of 20mm - 200mm and is sized to support and hold the edge of a window and / or frame. In some forms, the length of cylindrical element 410 is 40mm - 80mm, more preferably 60mm.

[0100] The levelling and support device is used in a system comprising at least two levelling and support devices and at least two fixing elements receivable within the aperture of a corresponding levelling and support device and sized to extend through the levelling and support device and enable connection with a building component. The system may comprise additional levelling and support devices to support larger windows, and / or to provide vertical as well as horizontal support.

[0101] Figure 8 shows the levelling and support system in use in the positioning and securing of a new window and frame comprising six levelling and support devices. In an example of use, a first pair of levelling and support devices 400A and 400B are fixed in a horizontally spaced apart placement to a lower structure of window framing 460, such that each device 400A and 400B is at or near the lateral edges of the window frame. For a large window, additional devices 400 may be used between the two outer devices 400A and 400B. A levelling device such as a spirit level is then placed across upper surfaces 450 of both device 400A and 400B to ensure they are level to each other. If the level is out, one or both of devices 400A and 400B are rotated by hand around the central screw to raise or lower the upper surface 450 that the spirit level is resting on until a horizontal level is achieved. Levelling devices 400 are then fixed firmly into position to prevent further rotation by engaging the screw member further into the building structure until no rotation is possible.

[0102] A new window is then mounted into the building frame, the lower edge supported by the upper surface 450 of the levelling and support devices 400. If needed, further minor adjustments may be made to the window level by rotating one or both devices 400. To further support the window in position, additional levelling and support devices 400 may be mounted laterally on either side of a window as seen in Figure 8, with pairs of support and levelling devices 400 C, 400D mounted on the same vertical axis to provide alignment surface 451, supporting the lateral edges of the window frame. As with the horizontally mounted pair of devices 400A and 400B, one or both of the devices are rotate by hand around the central screw until a spirit level resting against surface 451 of each of 400C and 400D is vertical. Levelling devices 400C and 400D are then fixed into position by

[0103] . The system of levelling and support devices 400 can allow for a range of minor adjustments using the cam mechanism to ensure correct placement of windows and to support the frames permanently in position to prevent further rotation by engaging the screw member further into the building structure until no rotation is possible.

[0104] The material used in construction of the levelling and support devices 400 is corrosion resistant and with low thermal conductivity. It can be made from but not limited to, reinforced or unreinforced thermoplastics, resins and the like.

[0105] 6.3. Method of for improvement of thermal performance and / or moisture control in an existing building structure.

[0106] Figures 9 and 10 show the outline of a method for insulating a building or structure having existing cladding in further detail, with Figure 10 showing a cross section of a building structure including all the features of the invention. Features in earlier figures are also referenced below.

[0107] A step-by-step example of the method in use is provided below with reference to these figures.

[0108] One use example of applying the method is on a residential home having a fibre-cement board external cladding, directly mounted on a timber frame, with no wall insulation and single glazed windows.

[0109] Installation of an external insulation and cladding system for improvement of thermal performance and / or moisture control is conducted using method 1000 shown in Figure 9. An initial thermal and moisture inspection is undertaken, and measurements made prior to beginning to determine the optimum insulation and joinery requirements for the building. Insulation is added in roof cavities and underfloor where required.

[0110] Existing single-glazed windows are removed from the existing structure 1010. A self-adhesive protection membrane 650 such as SOLITEX ADHERO® by Proclima is applied to the existing external cladding 630 and all joints are taped to create a continuous, airtight barrier 1020.

[0111] Brackets 220 of bracket system 200 are fixed at regular intervals 1030 vertically and horizontally to the external cladding 630 and / or original timber framing, 600. These are typically placed at 600mm intervals, but this is determined using supplied engineering span tables accounting for aspects including, but not limited to cladding weight and wind zone. Left and right hand brackets systems may be used alternatively, or brackets with a specific orientation may be selected to suit particular building features such as corners. The opposing end of elongate attachment member 240 of the bracket system is not secured at this point.

[0112] Levelling and support systems 400 are attached to lower beams of each window framing 1040 using the methods described above and levelled by rotating the cylindrical element 410. A new double or triple-glazed window 500 is fitted using the levelling support system 400, the window resting on the upper surfaces 450 of the levelling and support devices 400 to ensure correct placement and fixed into position using known methods. The self-adhesive protection membrane is mounted to the new window to continue the membrane from the walls, continuing the airtight barrier 1050. Further levelling and support system 400 may be utilised around other areas of the window frame work to support and level the window in position. Support devices 400 are mounted and fixed in to position, and are retained within the framing to support the window. The support devices 400 are in some forms made from molded plastic to reducing thermal bridging.

[0113] A cavity closing member may optionally be attached to a bottom perimeter of the existing building structure 1060. Insulation segments 700 are applied and secured to the walls 1070 with clips over the building membrane 650, the width of the insulation segment determined by the pre-determined thermal requirements of the building. Cavity closing systems may also be mounted at upper or side perimeters of buildings in certain situations. A plurality of vertically spaced battens 800 are mounted to the building outside the insulation segments 700, 1080. Once insulation segments 700 and battens 800 are in position, the elongate attachment member 240 of bracket system 200 is rotated around bracket 220 and inserted through or between (requiring cutting of the insulation material) the insulation segments until elongate attachment member 240 abuts a side face of batten 800. As seen in in Figure 4, the required rotation of the elongate attachment member 240 is dependent on the thickness of the insulating segment used. The positioning of apertures 247 - 250 on the elongate attachment member through a curve having a variable radius allows for the fixation of the bracket system to the batten through at least two of apertures 247 - 250, with a simple adjustment through rotation to select the desired position. Fixation through two apertures (vertically spaced apart) positions and locks the elongate attachment member in position, securing the insulation material and aiding in the stabilisation of the building structure.

[0114] When new vertical weatherboard cladding is required, horizontal cladding rails (not shown) are mounted to the vertical battens 800 to enable fixing of the cladding material 850.

[0115] Following batten 800 installation, a second cavity closing member 300 may be overlapped with the first cavity closing member and secured to the battens, forming a covered channel running the length of the wall, supporting the insulation segments, providing drainage, ventilation, and preventing vermin entry to the building 1090.

[0116] The cavity closing system of the present invention may also be installed in other regions of the building where a cavity needs to be covered and ventilated, for example the head and sill of a window.

[0117] New exterior cladding 850 is then installed on the outside of the new insulation material 1100, using vertical battens and optionally horizontal cladding rails (not shown) as required.

[0118] The method and components of the present invention have a number of advantages over known techniques. The bracket system described above provides a variable fixing device that allows for a single component to be utilised to secure building components in position a range of sizes, while reducing thermal bridging associated with the use of bulkier devices. The bracket design provides significant time and cost savings over known fixing techniques. The structure and levelling device and system may be used with the present methods of insulation application and thermal improvement of existing building structures but may also be used independently in new builds to ensure correct levelling and support of window systems. The use of structure and levelling devices allows for independent rotation of each component for simple correction of misaligned frames, while the frame weight remains supported, a far simpler technique than the use of traditional sill supports that must be level before the window frame is mounted. The use of non-conductive material in the structure and levelling devices reduces thermal bridging, improving overall building performance.

[0119] Unless the context clearly requires otherwise, throughout the description and the claims, the words "comprise", "comprising", and the like, are to be construed in an inclusive sense as opposed to an exclusive or exhaustive sense in the sense of "including, but not limited to".

[0120] The entire disclosures of all applications, patents and publications cited above and below, if any, are herein incorporated by reference.

[0121] Reference to any prior art in this specification is not, and should not be taken as, an acknowledgement or any form of suggestion that that prior art forms part of the common general knowledge in the field of endeavour in any country in the world.

[0122] The technology may also be said broadly to consist in the parts, elements and features referred to or indicated in the specification of the application, individually or collectively, in any or all combinations of two or more of said parts, elements or features.

[0123] Where in the foregoing description reference has been made to integers or components having known equivalents thereof, those integers are herein incorporated as if individually set forth.

[0124] It should be noted that various changes and modifications to the presently preferred embodiments described herein will be apparent to those skilled in the art. Such changes and modifications may be made without departing from the spirit and scope of the technology and without diminishing its attendant advantages. It is therefore intended that such changes and modifications be included within the present technology.

Claims

7. CLAIMS1. A system for levelling and supporting a building component, the system comprising; at least two structure levelling and support devices, the structure levelling and support devices each comprising a cylindrical element including a first aperture extending therethrough, the first aperture extending parallel to but offset from a central axis extending longitudinally though the cylindrical element, the first aperture shaped to receive an elongate fixing device for connecting the cylindrical element to a surface; and at least two fixing elements, each fixing element receivable within the first aperture of the at least two structure levelling and support devices, and configured to extend through the cylindrical element of the structure levelling and support device to fixably connect with a building component.

2. The system for levelling and supporting a building component of claim 1, where in the cylindrical element of each structure levelling and support device comprises two or more apertures extending therethrough, a second of the at least two apertures offset from the first aperture and configured to receive a connection member for connecting the cylindrical element to a surface.

3. The system for levelling and supporting a building component of claim 1 or claim 2, wherein each cylindrical element comprises a front end having a front surface and an opposing rear end having rear surface, and wherein a plurality of holes are formed within and extend fully or partially through the cylindrical element from the rear surface towards the front surface.

4. The system for levelling and supporting a building component of claim 3, wherein the plurality of holes extend partially through cylindrical element from the rear surface towards, but not through the front surface.

5. The system for levelling and supporting a building component of claim 4, wherein the plurality of holes are sized and shaped to create one or more spokes that extend radially from a supporting wall surrounding the first aperture, towards an outer wall of the cylindrical element.

6. The system for levelling and supporting a building component of any one of claims 1 to 5, wherein an exterior surface of cylindrical element is textured or partially textured.

7. A method for levelling and supporting a building component, the method comprising the steps of; providing a system for levelling and supporting a building component as claimed in any one of claims 1 to 6; inserting a fixing element through the first aperture of the cylindrical element of each levelling and support device; attaching at least two levelling and support devices to a building structure by partial connection of the fixing element to the building structure, the at least two levelling and support devices attached to be spaced apart from each other horizontally on substantially the same horizontal axis; placing a level across an upper surface of the at least two levelling and support devices; rotating one or more of the cylindrical elements of the at least two levelling and support devices until the upper surfaces of the at least two support devices are level; locking the levelling and support devices in the desired position by full connection of the fixing element to the building structure; and placing a building component on the upper surfaces of the at least two levelling and support devices such that the devices support the building component in the desired horizontal position.

8. The method of claim 7 further comprising attaching at least two structure levelling and support devices to a building structure by partial connection of the fixing element to the building structure, the structure levelling and support devices spaced apart from each other vertically on the same vertical axis.

9. The method of claim 7 or claim 8, wherein the building component is a window frame and the method is used to accurately install and support window frames and / or doors.

10. A bracket assembly for use in a construction system, the bracket assembly comprising: a bracket comprising two fixing plates connected together substantially perpendicular to each other, each fixing plate comprising at least one aperture extending through the fixing plate; andan elongate attachment member having a first end and an opposing second end, and a plurality of apertures spaced at variable distances from the first end or second end of the elongate attachment member, such that the apertures are spaced to form a curved path along at least a portion of a length of the elongate attachment member; wherein a first fixing plate of the bracket is rotatably connected to the second end of the elongate attachment member via a pivot mechanism.

11. The bracket assembly of claim 10, wherein the apertures are positioned on the elongate attachment member to form a curved path of varying radius.

12. The bracket assembly of claim 10 or claim 11, wherein the elongate attachment member is a curved elongate member, the curved elongate member curved through a variable radius between the first and second ends of the member.

13. The bracket assembly of claim 12, wherein the elongate attachment member is curved around a smaller radius closer to the first end of the elongate member and a larger radius closer to the second end of the elongate member.

14. The bracket assembly of any one of claims 10 to 13, wherein the elongate attachment member has a convex top side edge and an opposing convex bottom side edge, the top and bottom side edges extending between the first and second ends of the elongate attachment member.

15. The bracket assembly of any one of claims 10 to 14, wherein the elongate attachment member is formed with curved ends having partially circular edges.

16. The bracket assembly of any one of claims 14 to 15, wherein the plurality of apertures are located proximate the concave top side edge of the elongate attachment member.

17. The bracket assembly of any one of claims 10 to 16, wherein the elongate attachment member comprises one or more flanges extending from a side edge of the elongate attachment member.

18. The bracket assembly of claim 17, wherein the elongate attachment member includes one flange extending from a top edge of the elongate member and one flange extending from a bottom edge of the elongate member.

19. A method for improving of thermal performance and / or moisture control in an existing building structure, the method comprising; removing one or more windows from one or more window frames of an existing structure; applying a protection membrane to pre-existing exterior cladding of the building structure; attaching at least one bracket of the bracket assembly of any one of claims 10 to 18 to the existing building structure; attaching a system for levelling and supporting a building component as claimed in any one of claims 1 to 8 to the one or more window frames; correctly placing one or more new windows in the one or more window frames using the method for levelling and supporting a building component of claim 9 and fixing the one or more windows in place; applying an insulation material over the protection membrane; mounting a plurality of spaced apart battens to the existing building structure over the insulation material; attaching at least one elongate attachment member of the bracket assembly of any one of claims 10 to 16 to the battens to secure the insulation material in position; and applying an exterior cladding over the insulation material and securing the exterior cladding to the plurality of battens.

20. The method of claim 19, wherein the exterior cladding is exterior wall cladding.

21. The method of claim 19 or 20, wherein the protection membrane is a self-adhesive, non-porous, vapour permeable membrane.

22. The method of any one of claims 19 to 21, wherein the step of attaching at least one elongate attachment member of the bracket assembly to the battens comprises attaching the elongate attachment member to the batten through at least two apertures in the elongate attachment member.

Images