Precast concrete veneer panel system

Abstract

A pre-cast concrete veneer panel system for attaching to a wall surface. The pre-cast concrete veneer panels comprise a surface having simulated stone regions surrounded by simulated mortar regions. The concrete veneer panels are sized and shaped to allow the panels to interconnect both vertically and horizontally in a manner which results in a wall facade having a random pattern of unique stones.

Description

BACKGROUND OF THE INVENTION [0001] The present invention relates to a veneer system for attachment to an interior or exterior wall. In particular, the present invention relates to concrete veneer panels which can be placed next to one another to form a wall facade which resembles a wall made from stones. [0002] For a variety of applications, it is desired to create a wall or other structure from stone. Because each stone is unique, the stone wall has a highly pleasing appearance due to the variation in the stones used and the random pattern in which the stones are placed. However, building such a wall using either natural or cut stones is not always a practical option. Constructing a wall made of stone is often very expensive, labor intensive, and requires highly skilled laborers. In addition, specialized equipment and tools may be required. [0003] As an alternative, a variety of simulated stone wall products have been developed which allow a user to make a wall which resembles one ...

AI Technical Summary

Benefits of technology

[0012] The present invention relates to a system of concrete veneer panels placed together to form a wall surface which appears to have a random pattern unique stones. Each of the veneer panels is multi-sided, and is shaped to allow the panels to easily interconnect vertically and horizontally with other panels. The shape of the veneer panels also allows for a unique pattern of stones to be present on the front surface, and better masks the location of any joints or seams which occur where adjacent panels meet. The ease with which the panels interconnect also makes it easy to install the panels to obtain a realistic wall having a random pattern, without requiring the use of an installation plan or diagram.

[0013] To allow the veneer panels to be installed on a wall surface, the panels have a back mounting surface. The front surface of the veneer panels comprises a pattern of simulated stones surrounded by simulated mortar regions. Preferably, the veneer patterns are formed of a fiber reinforced concrete (FRC). Making the veneer panels of FRC results in the panels having a thickness which allows the panels to be hung using standard mounting methods, such as sheet rock screws. Using FRC also results in the veneer panels having the necessary strength and robustness to survive shipping and to resist cracking during installation. Further, FRC is a highly durable material which is suitable for use in exterior settings, as well as interior settings.

Problems solved by technology

However, building such a wall using either natural or cut stones is not always a practical option.

Constructing a wall made of stone is often very expensive, labor intensive, and requires highly skilled laborers.

In a pour in place application, problems arise in making the wall so that the finished product looks natural.

It is particularly difficult to make the wall so that the finished product resembles a random pattern of unique stones.

When the seams are visible in the wall, the resulting effect detracts greatly from the attempt to create a realistic simulated stone wall.

Just as it is difficult to ensure a poured in place wall appears to have a random pattern of unique stones, it is difficult to ensure that pre-cast wall sections result in the desired random pattern.

Further, not all applications are appropriate for pour in place concrete, leaving precast systems as the more appropriate choice.

However, many of these veneer systems, particularly those made of vinyl products, are not realistic in texture or feel.

In addition, the same problems arise in the inability to create a random pattern of unique stones using a minimum number of veneer panels.

Veneer systems are particularly susceptible to “paneling out”, wherein it becomes obvious that the pattern is repeating and non-random.

However, forming a veener system using concrete has been impractical to date.

In particular, concrete veneers may be thick, making them heavy and unwieldly and difficult to install.

In addition, when made thin enough to be more practical, the concrete may crack or break very easily, such as during shipping or during the installation process.

A further difficulty in forming a simulated stone wall is ensuring that while the number of form liners, precast, or veneer pieces is reduced, the observer of the finished wall is not able to pick out certain stones because they are so unique in their surface texture.

Further, it is desired to form each stone in a manner which reduces its distinctiveness relative to the other stones, to make it more difficult for the human eye to pick out the stone as it repeats in the wall.

Images