A Precast Building Component and Window Frame System and A Method of Manufacturing a Precast Building Component and Window Frame System

A method and a precast building component and window frame system. The method comprising: positioning a window frame within a window opening of a precast building component, wherein the precast building component comprises solidified settable material; forming a void between the window frame and the precast building component, wherein the void surrounds the window frame; wherein barrier material is placed within the gap between opposing surfaces of the window frame and the precast building component to form a boundary of the void; filling the void with a settable adhesive sealant; wherein the settable adhesive sealant, once set, provides a continuous seal that surrounds the window frame and supports the window frame within the window opening.

TECHNOLOGICAL FIELD

Embodiments of the present disclosure relate to a precast building component and window frame system and a method of manufacturing a precast building component and window frame system. Some relate to a precast building component and window frame system and a method of manufacturing a precast building component and window frame system in the construction industry.

BACKGROUND

Previous methods of installing windows in precast building components rely on multiple products cut and bonded onsite which can lead to variants in performance window to window. There is a requirement for a new method of installing windows within precast building components that is consistent, does not rely on highly skilled workmanship and provides the necessary performance in terms of air tightness, water tightness and structural support.

BRIEF SUMMARY

According to various, but not necessarily all, embodiments there is provided a method comprising:positioning a window frame within a window opening of a precast building component, wherein the precast building component comprises solidified settable material;forming a void between the window frame and the precast building component, wherein the void surrounds the window frame; wherein barrier material is placed within the gap between opposing surfaces of the window frame and the precast building component to form a boundary of the void;filling the void with a settable adhesive sealant;wherein the settable adhesive sealant, once set, provides a continuous seal that surrounds the window frame and supports the window frame within the window opening.

In some, but not necessarily all, examples, the seal provides a hermetic seal between the window frame and the precast building component.

In some, but not necessarily all, examples, the settable adhesive sealant is a pourable liquid.

In some, but not necessarily all, examples, the precast building component is laid flat whilst the window frame is positioned and whilst the void is filled with the settable adhesive sealant.

In some, but not necessarily all, examples, the precast building component is stood up whilst the window frame is positioned and whilst the void is filled with the settable adhesive sealant, wherein additional void boundaries are provided to prevent the settable adhesive sealant escaping the void.

In some, but not necessarily all, examples, one or more brackets are fitted to the window frame and the precast building component to provide additional support to support the window frame within the window opening.

In some, but not necessarily all, examples, the method additionally comprises:forming a secondary continuous seal that surrounds the window frame and supports the window frame within the window opening;wherein the secondary continuous seal is formed by:forming a secondary void between the window frame and the precast building component, wherein the secondary void surrounds the window frame; wherein secondary barrier material is placed within the gap between opposing surfaces of the window frame and the precast building component to form a secondary boundary;filling the secondary void with a settable adhesive sealant;wherein the settable adhesive sealant, once set, provides the secondary continuous seal;wherein an air gap and/or the boundary separates the continuous seal and the secondary continuous seal.

In some, but not necessarily all, examples, the void is filled by filling the settable adhesive sealant up to be level with a face of the precast building component.

In some, but not necessarily all, examples, formwork components are placed on a face of the precast building component to form an additional boundary of the void, wherein the formwork is spaced from the gap between opposing surfaces of the window frame and the precast building component so that when the void is filled with the settable adhesive sealant, part of the seal is bonded to at least part of the face of the precast building component.

In some, but not necessarily all, examples, a face of the precast building component comprises a step surrounding the gap between the opposing surfaces of the window frame and the precast building component, wherein the step forms an additional void boundary, wherein when the settable adhesive sealant fills the void it fills the step, such that part of the seal is bonded to at least part of the face of the precast building component.

In some, but not necessarily all, examples, the solidified settable material is cementitious.

In some, but not necessarily all, examples, the solidified settable material comprises concrete.

In some, but not necessarily all, examples, one or more glass panes are secured within the window frame before positioning the window frame within the window opening.

In some, but not necessarily all, examples, one or more glass panes are secured within the window frame after positioning the window frame within the window opening.

According to various, but not necessarily all, embodiments there is provided a precast building component and window frame system, comprising:a precast building component, the precast building component comprising solidified settable material and a window opening;a window frame supported within the window opening;wherein the window frame is surrounded by a continuous seal, wherein the continuous seal supports the window frame within the window opening;wherein the continuous seal comprises a settable adhesive sealant that has set.

In some, but not necessarily all, examples, the seal provides a hermetic seal between the window frame and the precast building component.

In some, but not necessarily all, examples, the system additionally comprises one or more brackets, fitted to the window frame and the precast building component, to provide additional support to support the window frame within the window opening.

In some, but not necessarily all, examples, the system additionally comprises a secondary continuous seal comprising settable adhesive sealant that has set, wherein the secondary continuous seal surrounds the window frame and supports the window frame within the window opening;wherein an air gap and/or the boundary separates the continuous seal and the secondary continuous seal.

In some, but not necessarily all, examples, one end of the seal is level with a face of the precast building component.

In some, but not necessarily all, examples, part of the seal is bonded to at least part of a face of the precast building component.

In some, but not necessarily all, examples, a face of the precast building component comprises a step surrounding the gap between the opposing surfaces of the window frame and the precast building component, wherein the seal is bonded to the step.

In some, but not necessarily all, examples, the system additionally comprises one or more membranes that cover at least part of a surface of the window frame, one end of the continuous seal, and at least part of a face of the precast building component.

In some, but not necessarily all, examples, the solidified settable material is cementitious.

In some, but not necessarily all, examples, the solidified settable material comprises concrete.

In some, but not necessarily all, examples, one or more glass panes are secured within each window frame.

According to various, but not necessarily all, embodiments there is provided examples as claimed in the appended claims.

DETAILED DESCRIPTION

The FIGs and examples illustrated below provide example methods and systems that provide a window frame230supported within a window opening220of a precast building component210.

For example,FIG.1illustrates an example method100. The method comprises in block110, positioning a window frame230within a window opening220of a precast building component210. The precast building component210comprises solidified settable material213.

The method100comprises, in block120, forming a void between the window frame and the precast building component. The void surrounds the window frame. Barrier material is placed within the gap between opposing surfaces of the window frame and the precast building component to form a boundary of the void.

The method comprises, in block130, filling the void300with a settable adhesive sealant. The settable adhesive sealant, once set, provides a continuous seal240that surrounds the window frame230and supports the window frame230within the opening220.

The continuous seal240can provide both structural support for the window frame230along with all necessary air and water performance, whereas in previous methods multiple components were required. For example, previous methods of installing a window frame within a precast building component included mounting the window frame to the precast building component using brackets to provide structural support and providing sealing by sealing strips fitted to the gaps between the window frame and the precast building component.

In previous methods, sealing strips needed to be applied to the front side of the window frame and the rear side of the window frame to provide necessary air and water performance. In some examples, the continuous seal240provides all the necessary sealing for air and water performance and so this reduces the complexity of the installation of the window frame into the precast building component.

By providing a continuous seal240around the window frame230that supports the window frame240within the window opening230, this can even out the load points on the window frame230and the precast building component210, producing less localized stress compared to if the window frame230was supported in the precast building component210with only brackets spaced around different parts of the window frame230.

FIG.2Aillustrates an example precast building component and window frame system200. The system200comprises: a precast building component210. The precast building component210comprises solidified settable material213and a window opening220. The system200additionally comprises a window frame230supported within the window opening220. The window frame230is surrounded by a continuous seal240. The continuous seal240supports the window frame230within the window opening220. The continuous seal240comprises a settable adhesive sealant that has set.

FIG.2Billustrates the precast building component210before the window frame230has been positioned within the window opening220. The precast building component210with one or more window openings220can be referred to as a doughnut precast building component.

FIG.3illustrates part of an example precast building component and window frame system200.FIG.3illustrates a cross-section of part of the system200.FIG.3illustrates the system200prior to the settable adhesive sealant having filled the void300.

As illustrated inFIG.3the barrier material310has been placed within the gap between opposing surfaces232,212of the window frame230and the precast building component210. The barrier material310forms a boundary of the void300. In this example at least part of the surfaces232,212provide other boundaries of the void300.

The barrier material310can be provided by any suitable material that prevents the settable adhesive sealant from passing through when the void300is filled. For example, the barrier material310can be provided by one or more polystyrene backers, such as polystyrene backer rods. In other examples the barrier material310is provided by expanding foam tape. In the examples where the barrier material310is provided by polystyrene backer rods, these can be removed after the settable adhesive sealant has set. In examples where the barrier material310is expanding foam tape this can be retained in place after the settable adhesive sealant has set to form a finishing surface for the continuous seal240. In examples where the barrier material310is expanding foam tape, the expanding foam can be checked to ensure it is secured to the surfaces232,331so that it retains the settable adhesive sealant in place when it is placed within the void30.

FIG.4illustrates an example system200after the void300has been filled with the settable adhesive sealant, in accordance with block130of method100. In this example the void300is filled with the settable adhesive sealant up to be level with a face211of the precast building component210. In this example the face211is the rear face211of the precast building component210.

The settable adhesive sealant, once set to form the continuous seal240, bonds the window frame230to the precast building component210.

The continuous seal240can provide a hermetic seal between the window frame230and the precast building component210. This means that air and water cannot pass from the front face233of the window frame230through the gap between surfaces232,212to the rear face231of the window frame230, or vice versa.

The settable adhesive sealant can be a pourable liquid, which can make it easier to form a seal between the window frame230and the precast building component210compared to, for example, using sealing strips, which require more skilled workmanship.

In some examples the precast building component210is laid flat whilst the window frame230is positioned and whilst the void300is filled with the settable adhesive sealant. In these examples, the precast building component210is laid flat so that the rear face211of the precast building component210is at least substantially parallel to the ground.

By laying the precast building component210flat, this provides an easy way to fill the void300with the settable adhesive sealant, as gravity will naturally force the sealant against the barrier material310and against the surfaces232,212and easily allows a level surface of the top end241of the continuous seal240as illustrated inFIG.4.

The integrity of the seal240and assurance that the adhesive sealant has bonded to all necessary surfaces can be checked by ensuring the settable adhesive sealant fills the void300according to the specific design of the seal240and that the settable adhesive sealant has not run through to the other side of the boundary material310. This method of checking, which can form part of the method100, has the benefit of enabling checking of the integrity of a seal before the precast building component is installed in the associated building.

Any suitable props, brackets and other supports can be used to position the precast building component210and the window frame230as required and secure them in the correct position to prevent any movement.

In some examples the precast building component210is laid flat on a table. In some examples the precast building component210is supported so that the window opening220is free from obstructions for positioning of the window frame210.

In some examples the precast building component210is stood up whilst the window frame230is positioned and whilst the void300is filled with the settable adhesive sealant. In these examples, additional void boundaries are provided to prevent the settable adhesive sealant escaping the void300. For example, additional boundaries may be placed next to where the top end241of the seal240is formed. In these examples, to allow access to the void300, the void300may be filled in vertical sections with additional void boundaries placed as the void is filled up vertically.

In some examples one or more brackets are fitted to the window frame230and the precast building component210to provide additional support to the window frame230within the window opening220.

FIG.5illustrates part of an example precast building component and window frame system200. In this example the precast building component210comprises multiple facing building members214, for example brick slips, which are bonded to the solidified settable material213. In this example a pane of glass234is fixed within the window frame230.

FIG.6illustrates a front view of the part of the system200illustrated inFIG.5. The line600with arrows pointing down illustrates the cross-sectional view provided inFIG.7, which looks down from the top of the cross-section. InFIG.7the circle700illustrates what is illustrated inFIG.8.

In this example the rear face211of the precast building component210comprises a step800surrounding the gap between the opposing surfaces232,212of the window frame230and the precast building component210. The step800forms a boundary of void300. The settable adhesive sealant fills the step800when the settable adhesive sealant fills the void, such that part of the continuous seal240is bonded to the rear face211of the precast building component210.

This enables the seal240to use the rear face211of the precast building component as a support. In this example providing the step800also enables the top end241of the seal240to be level with the rest of the rear face211. This can enable easier application of a membrane810to be adhered to at least part of the rear face211, the top end241of the seal240, at least part of the surface232of the window frame and at least part of the surface231of the window frame. The membrane can be, for example EPDM (Ethylene Propylene Diene Monomer) rubber. The membrane810can provide additional protection to the seal240.

In this example the barrier material310has been removed.

FIG.9illustrates part of another example system200.FIG.10shows a front view of the example system200illustrated inFIG.9. The line1000with arrows pointing down illustrates the cross-sectional view illustrated inFIG.11, which looks down from the top of the cross-section. The circle1100inFIG.11illustrates what is illustrated inFIG.12.

In this example part of the seal240is bonded to part of the rear face211of the precast building component210. To provide the seal240illustrated inFIG.12, formwork components are placed on the rear face211of the precast building component210to form a boundary of the void300. The formwork is spaced from the gap between the opposing surfaces232,212of the window frame230and the precast building component210so that when the void300is filled with the settable adhesive sealant, part of the seal240is bonded part of the face211of the precast building component as illustrated inFIG.12. The end1200of the seal240shows the position at which the formwork was placed during the method of manufacturing the system200.

FIG.13illustrates part of another example precast building component and window frame system200.

In this example the system200additionally comprises a secondary continuous seal1300comprising settable adhesive sealant that has set. The secondary continuous seal1300surrounds the window frame230and supports the window frame230within the window opening220. An air gap1310and the barrier material310separates the continuous seal240and the secondary continuous seal1300.

In other examples the barrier material310has been removed and so only the air gap1310separates the continuous seal240and the secondary continuous seal1300.

To form the secondary continuous seal1300, a secondary void is formed between the window frame230and the precast building component210. The secondary void surrounds the window frame230. Secondary barrier material1320is placed within the gap between opposing surfaces232,212of the window frame230and the precast building component210to form a secondary boundary. The secondary void is filled with a settable adhesive sealant. The settable adhesive sealant, once set, provides the secondary continuous seal1300. In some examples the secondary continuous seal1300is formed prior to the continuous seal240.

In the examples illustrated and described, the solidified settable material213can be cementitious. In the examples and illustrations described, the solidified settable material213can comprise concrete.

In the examples described and illustrated, one or more glass panes234can be secured within the window frame230before positioning the window frame230within the window opening220.

In the examples illustrated and described, one or more glass panes234can be secured within the window frame230after positioning the window frame230within the window opening220.

In the examples illustrated and described, the settable adhesive sealant can be any suitable settable adhesive sealant that has a viscosity sufficient to fill the space within the void300to ensure that when the void300is filled the settable adhesive sealant fills the space required and bonds to the window frame230, and the precast building component210.

The void is defined by the boundaries described and an open end which the settable adhesive sealant is filled up to. The settable adhesive sealant can be filled to any indicated level in line with the structural requirements of the design of the window frame and/or the design of the precast building component. For example, the settable adhesive sealant is filled to be flush or raised above the rear face211of the precast building component by a set amount, for example 5 mm.

In some examples a primer is placed upon the surfaces of the window frame230and/or the precast building component210that the settable adhesive sealant is bonded to.

The methods described above can be carried out in a temperature-controlled environment, which can be a dry environment.

The window frame230can comprise, for example, aluminum, timber, or a composite.

The gap between the surfaces232,212of the window frame230and the precast building component210can be, in some examples, in the range of 5 mm to 30 mm.

The settable adhesive sealant can be a curable adhesive sealant, and to set the settable adhesive sealant, the settable adhesive sealant is allowed to cure in accordance with the manufacturer's guidance.

In the examples illustrated and described, the precast building component can form a building panel, for part of a wall of a building. The building can comprise multiple panels for form a wall. The precast building component can comprise multiple window openings210, which each can be filled with any of the window frames230described with any of the continuous seals240,1300described.

The blocks illustrated inFIG.1may represent steps in a method. The illustration of a particular order to the blocks does not necessarily imply that there is a required or preferred order for the blocks and the order and arrangement of the block may be varied. Furthermore, it may be possible for some blocks to be omitted.