Fiber reinforced concrete stone panel system

Abstract

A method of forming an exterior wall of a building, including the wall, includes the step of mounting a fiber-reinforced panel to the building. The panel has a plurality of masonry units protruding from the face thereof that are spaced from one another with a groove between each of the masonry units. The method includes mounting a second, similar panel to the building spaced from the first panel with a groove therebetween, and injecting mortar into the grooves between the masonry units and the groove between the panels. The mortar covers the grooves between masonry units and the groove between panels to look the same, thereby making it difficult to distinguish the repeat pattern.

Description

BACKGROUND OF THE INVENTION[0001]1. Field of the Invention[0002]This invention relates generally to a wall on the exterior of a habitable building, and more particularly relates to a wall made of a panel of fiber reinforced concrete stones.[0003]2. Description of the Related Art[0004]Most habitable buildings are made of vertical support members, such as wood or metal studs or steel beams. The support members form a substructure to which sheets of sheathing material is attached. Typical sheathing includes plywood, oriented strand board (OSB) or some type of lightweight, insulating material, such as that sold under the trademark CELOTEX.[0005]The conventional method of applying masonry units, such as stones, bricks and artificial stone, to the exterior surface of a building, such as a house, involves many steps. Once the sheathing is in place on the building, a tar-paper or other moisture-impermeable sheet is stapled or otherwise mounted to the exterior surface of the sheathing. The n...

AI Technical Summary

Benefits of technology

[0009]The invention contemplates the use of a wall panel comprising a fiber-reinforced concrete rear plate and a plurality of fiber-reinforced concrete masonry units protruding from a face of the rear plate. Each of the masonry units is spaced from the next adjacent masonry unit by a groove for receiving mortar. Shoulders are formed on the periphery of the panel adjacent each of the masonry units for forming a groove that can receive mortar when the wall panel is mounted to the building. In a preferred embodiment, a flashing is formed on at least one edge of the rear plate for being received under a masonry unit of another wall panel. In a preferred embodiment, at least one rib is formed on a major surface of the rear plate and protruding in a direction substantially opposite the masonry units for positioning the wall panel against the building. The rib prevents rocking of the wall panel when it is aligned against the building.

[0010]The invention permits stone, brick, tile and other modular masonry units to be formed on individual panels before the panels are attached to a building. This may eliminate the need to attach tar paper and screen to the sheathing of the building, and removes much of the room for error in the installation process. Additionally, the finished product is mold-resistant, much stronger than walls made with conventional sheathing materials, and less costly to construct.

Problems solved by technology

A common problem with attaching the screen to the sheathing is securely attaching the screen using enough fasteners to keep the screen in place.

The process of attaching paper, screen and mortar to the sheathing of a conventional building requires substantial skill.

Any problems in constructing the underlying structure may not be apparent to the owner of the building until many years have passed and water has infiltrated the building or large amounts of stucco or stone have fallen off the building.

Additionally, the process of selecting, cutting and attaching stones to a building's exterior is one that requires time and skill in mechanically cutting and aesthetically arranging the stones.

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