A brick slip
The prefabricated modular cladding panel with glass-reinforced concrete and undercut grooves addresses labor and waste issues, enabling quick, low-carbon installation of brick slips with enhanced mechanical attachment.
Patent Information
- Application Number
- GB2025004352
- Authority / Receiving Office
- GB · GB
- Patent Type
- Applications
- Current Assignee / Owner
- Filing Date
- 2025-03-25
- Publication Date
- 2026-11-04
AI Technical Summary
Existing methods for installing brick slips on building surfaces are labor-intensive, require skilled labor, generate construction waste, and have high embodied carbon due to metal mounting rails, and lack factory-controlled quality assurance.
A prefabricated modular cladding panel using glass-reinforced concrete with embedded brick slips and preformed female fasteners, featuring undercut grooves for enhanced mechanical attachment, reduces the need for skilled labor, minimizes waste, and lowers embodied carbon.
Facilitates quick installation, reduces construction waste, and lowers embodied carbon while ensuring structural integrity and quality through factory-controlled production.
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Abstract
Description
FIELD The present teachings relate to a brick slip, a prefabricated modular cladding panel, and to a method of assembling a prefabricated modular cladding panel. BACKGROUND Brick slips are thin sections of brick that are provided on external (or internal) surfaces of a building structure (i.e. a wall). Such brick slips are traditionally manufactured either via an extrusion process, or they are cut from a traditional brick in order to cover a wall surface. An array of brick slips are typically mounted onto a wall surface, so as to provide a traditional 'brick' wall finish. One method of covering a wall surface with brick slips is to mount them directly onto the wall surface, e.g. using an adhesive. An alternative method of covering a wall surface with brick slips is to provide a wall cladding system frame at or on the wall surface. The brick slips are then mounted onto the frame, so as to cover the wall surface. A further method of covering a wall surface with brick slips is to mount them is to mount them onto a cladding panel, which is then in turn mounted onto the wall surface. The present teachings seek to overcome or at least mitigate one or more problems associated with the prior art. SUMMARY The present teachings provide a brick slip, a prefabricated modular cladding panel, and to a method of assembling a prefabricated modular cladding panel as defined in the appended claims. The brick slip and cladding panel provides multiple advantages over known systems, such as: • Quick installation and does not require highly skilled labour, helping to address the shortage of skilled workers; • Sustainable product with low embodied carbon, as the metal brick carrier is replaced with premix glass-reinforced concrete; • Reduces construction waste, as all panels are engineered and manufactured to standard and coordinated brick sizes; • Fully structurally calculated and tested engineering solution; and • Factory-controlled production, ensuring all cladding panels are constructed under strict QA procedures. According to a first aspect, there is provided a brick slip for a cladding panel, the brick slip comprising: a front face and a rear face spaced apart from the front face to define a thickness therebetween; a upper face and a lower face extending between the front face and the rear face and defining a height therebetween; first and second side faces extending between the front face and the rear face and defining a length therebetween; and a mounting formation comprising at least one groove on the rear face, wherein the at least one groove is at least partially arranged at a non-zero angle relative to an axis extending between the front and rear faces to define an undercut portion. The undercut groove provides an overhanging lip or region that is interposed between the concrete in the groove and the concrete of the backing panel arranged behind the brick slip, in use, which helps to increase mechanical attachment of the brick slip to the cladding panel. Optionally, the at least one groove comprises two spaced apart grooves. This further increases adhesion of the brick slip to the cladding panel. Optionally, the two grooves are symmetrical. To ensure the bricks are mechanically retained by the panels, the two grooves provide flexibility during installation, reduce the number of panel types, and optimise the manufacturing process. For example, the panels can be rotated 180 degrees for use in opposite-hand or alternative configurations. Optionally, the two grooves are spaced apart along the height of the brick slip. Optionally, the at least one groove extends between the first and second side faces. Optionally, the lower face, upper face and the first and second side faces are substantially planar and / or wherein the front face is substantially planar. Optionally, the at least one groove extends in a substantially linear direction. Optionally, the at least one groove comprises a dovetail recess. Optionally, the at least one groove extends in a substantially curved direction. Optionally, an arcuate surface extending between the two grooves. Optionally, the groove defines a depth in the range 5mm to 8mm, for example approximately 7mm, and / or a width in the range 4mm to 6mm, for example approximately 5mm. According to a second aspect, there is provided a modular prefabricated cladding panel comprising: a cementitious backing panel defining front and rear panel faces, said cementitious backing panel formed from concrete; a plurality of brick slips partially embedded in the front face of the cementitious backing panel; a mounting arrangement for mounting the cladding panel to a wall structure, wherein the mounting arrangement comprises a female fastener at least partially embedded in the cementitious backing panel and exposed at the front face of the panel. Typically, brick slips are mounted to mounting rails that are attached to walls / buildings. By replacing the aluminium mounting rails with a cementitious material, the embodied carbon of the cladding assembly is reduced. Moreover, providing the cladding panel with a preformed female mount in the backing panel facilitates mounting the panel to a wall structure. Optionally, the female fastener comprises an internally threaded sleeve configured for receiving a male fastener therein. Optionally, the sleeve comprises a flanged projection extending from an outer surface thereof, said flanged projection at least partially embedded in the backing panel. This increases the strength of the attachment between the sleeve and the backing panel, and so between the cladding panel and a wall structure. Optionally, the flanged projection comprises a plate surrounding the sleeve. Optionally, the plate is substantially square, circular, or rectangular. Optionally, the plate comprises one or more apertures therein. Advantageously, the apertures increase the mechanical attachment between the cementitious backing panel and the sleeve. Moreover, the apertures reduce the weight of the plate, and so of the cladding panel, which facilitates handling of the cladding panel. Optionally, comprising at least one reinforcing rib extending between the projection and the sleeve. Optionally, a front portion of the female fastener is interposed between first and second adjacent brick slips to define a spacing therebetween. Optionally, the female fastener extends from the front face to the rear face of the backing panel. Optionally, the female fastener is formed from a metallic material, for example steel. Optionally, the concrete is glass fibre reinforced concrete. Optionally, the brick slip is a brick slip according to the first aspect. According to a third aspect, there is provided a method of manufacturing a modular prefabricated cladding panel, the method comprising the steps of: providing a mould comprising a base defining a plurality of spaced apart recesses therein; arranging a plurality of brick slips in the plurality of recesses such that a front face of each brick slip is seated on a base of the mould; arranging a female fastener in the mould between two adjacent brick slips; filling the mould with a concrete material such that the plurality of brick slips are partially embedded in the concrete material; and curing the cementitious material form a backing panel. BRIEF DESCRIPTION OF THE DRAWINGS Embodiments will now be described with reference to the accompanying drawings, in which: Figure 1 is a front view of a wall structure according to an embodiment; Figure 2 is a cross-sectional side view of the wall structure of Figure 1; Figure 3 is an enlarged view of a part of Figure 2; Figure 4 is a schematic front view of a fastener of the wall structure of Figure Figure 5 is a cross-sectional side view of a embodiment; Figure 6 is a cross-sectional side view of a embodiment; and Figure 7 is a cross-sectional side view of a brick slip according to an brick slip according to an brick slip according to an embodiment. DETAILED DESCRIPTION OF EMBODIMENT(S) In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of various embodiments and the inventive concept. However, those skilled in the art will understand that: the present invention may be practiced without these specific details or with known equivalents of these specific details; that the present invention is not limited to the described embodiments; and, that the present invention may be practiced in a variety of alternative embodiments. It will also be appreciated that well known methods, procedures, components, and systems may not have been described in detail. References to vertical and horizontal in the present disclosure should be understood to be in relation to the machine when stood on horizontal ground in a non-working condition. The term axial is generally used in relation to the longitudinal axis of the machine. The term width is generally used in relation to the longitudinal length, that is, transverse to the length. Referring firstly to Figures 1 and 2, a wall structure is illustrated and indicated generally at 10. Although not illustrated, it will be appreciated that the wall structure may or may not form part of a building structure. The wall structure 10 has one or more modular prefabricated cladding panels 12 on a face thereof to partially or entirely cover said face. It will be understood that the face of the wall structure 10 may be an external face or an internal face of the wall structure 10 or building structure. In some embodiments, the wall structure may include insulation 14, as is illustrated. In other embodiments the insulation may be omitted. The wall structure 10 includes one or more mounting members 16 for mounting a cladding panel 18 thereto. The mounting members 16 are illustrated on an external face of the wall structure 10, but may be arranged on any face of a wall or surface that is to be covered by the cladding panels 12. In the illustrated embodiment, the mounting members 16 are provided in the form of an array of horizonal battens to which the cladding panels 12 are secured. The battens may be formed from wood. In the illustrated example, the mounting members include vertical counter battens 16-1, but these may be omitted. The counter battens may be spaced apart at regular intervals, for example approximately 60cm. In other embodiments, the mounting members 16 may be provided in the form of metal top hat structures, for example formed from aluminium or steel. Whilst the mounting members 16 have been illustrated as being horizontal and vertical, it will be appreciated that they may be arranged in any other suitable orientation in other embodiments. Moreover, it will be understood that in some embodiments, the mounting members 16 may be omitted and the cladding panels 12 may be mounted directly to a surface or a wall structure or may be attached by any other suitable means. Referring now to Figure 3, the cladding panel 12 is a modular prefabricated cladding panel. The cladding panel 12 is assembled offsite, for example in a factory, before being transported to a desired location to be installed on the wall structure 10. Multiple modular panels 12 are then arranged on said wall structure 10 to partially or entirely cover the face of the wall structure 10. This offsite assembly enables quick installation of the cladding panels, helps to reduce waste as the panels are engineered and manufactured to standard and coordinated brick sizes, and enables factory-controlled production. The cladding panels 12 include a backing panel 18. The backing panel 18 is formed from a cementitious material. In the present example, the backing panel 18 is formed from cementitious material. In some embodiments, the backing panel 18 may be formed from reinforced concrete. The reinforced concrete may be glass fibre reinforced concrete, known as GRC or GFRC, although other reinforcement may be incorporated into the concrete in other embodiments. In the present embodiment, the concrete is premix GRC, but may be sprayed GRC in other embodiments. The premix GRC is formed by mixing cement, water, fine aggregate, and reinforcing fibres. The mixture is then poured into mould. In the present example, sand is generally used as the fine aggregate. The concrete mixture may include sand in the range 40kg to 60kg, for example approximately 50kg. The concrete mixture may include cement in the range 40kg to 60kg, for example approximately 50kg. The cement may be Portland cement, or any other suitable cement. The concrete mixture may include water in the range of 12 litres to 20 litres, optionally in the range 14 litres to 18 litres, for example approximately 16 litres. The concrete mixture may include reinforcing fibres in the range 1 wt.% to 5 wt.%, optionally in the range 2 wt.% to 4 wt.%, for example approximately 3 wt.%. It will be understood that different compositions of the concrete may be used in other embodiments. The backing panel 18 defines a front face 20 and a rear face 22. A plurality of brick slips 24 are partially embedded in the cementitious backing panel 12. In particular, the plurality of brick slips 24 are partially embedded in the front face 20 of the cladding panel 12. Typically, brick slips are mounted to metal mounting rails that are attached to walls / buildings. By replacing the metal mounting rails with a cementitious material, the embodied carbon of the cladding assembly may be reduced. A spacing or distance between the rear face 22 of the backing panel 18 and a back or rear of each brick slip may be in the range 8mm to 12mm, for example approximately 10mm. As will be discussed in more detail below, the brick slips 24 are provided with a gripping or mounting formation on a rear face thereof to increase mechanical attachment between the brick slip 24 and the backing panel 18. The cladding panel 12 includes a mounting arrangement 26 for mounting the cladding panel 12 to a wall structure 10. The mounting arrangement 26 includes a preformed female fastener 26 in the backing panel 18. Providing the cladding panel 12 with a preformed female fastener 26 in the backing panel 18 facilitates mounting the cladding panel 12 to the wall structure 10. The female fastener 26 is provided in the form of a sleeve 28. A part 30 of the sleeve 28 is exposed at the front face 20 of the backing panel 18. This arrangement enables a fastener 31 to be inserted into the sleeve 28 from the front of the cladding panel 12, which facilitates mounting the cladding panel 12 to the wall structure 10. In the present embodiment, the female fastener 26 includes an internally threaded sleeve 28 configured for receiving the male fastener 31 therein. In the present example, the sleeve 28 is formed from a metallic material, for example steel or aluminium. In other examples, the sleeve 28 may be formed from a polymeric material, or any other suitable material. The sleeve 28 may define a length in the range 30mm to 50mm, for example in the range 37mm to 45mm. The part 30 of the female fastener 26 may be a front part of portion of the sleeve 28. The front portion 30 of the sleeve 28 may be interposed between first and second adjacent brick slips 24. In this way, the front part 30 of the female fastener 26 may be arranged to define a minimum spacing between adjacent brick slips 24. The sleeve 28 extends from the front face 20 of the backing panel 18 to the rear face 22. In some embodiments, the sleeve 28 may extend or project rearwardly from the rear face 22 of the backing panel 18, for example towards the mounting member 16 of the wall structure 10. In the illustrated example, the sleeve 28 extends from the mounting member 16 to the front face of the backing panel 18. In other embodiments, the sleeve 28 may extend only part way through the backing panel 18, and / or may be recessed from the front face 20 of the backing panel 18 while still being accessible from the front of the cladding panel 12. In some embodiments, the female fastener 26 includes one or more engagement features to increase mechanical attachment between the fastener 26 and the backing panel 18. This increases the strength of the attachment between the fastener 26 and the backing panel 18, and so between the cladding panel and a wall structure. In the present embodiment, the female fastener 26 includes a flanged projection 32 extending from an outer surface of the sleeve 28. The sleeve 28 is arranged in the backing panel 28 such that the flanged projection is at least partially embedded in the backing panel. In the present example, the flanged projection 32 is entirely embedded within the backing panel. Alternatively or additionally, it will be understood that in other embodiments the engagement feature may include a roughed surface on the sleeve 28, barbs, or any other suitable configuration. Referring now to Figure 4, in the illustrated example, the flanged projection 32 is provided in the form of a plate. The plate 32 is arranged to surround the sleeve 28. Although the plate 32 is illustrated as being substantially square, it will be understood that the plate may be any suitable shape such as circular, oval, rectangular or triangular, for example. In some embodiments, the plate 32 may be provided with one or more attachment features configured and / or arranged to increase the mechanical attachment between the cementitious backing panel 18 and the sleeve 28. In the present example, the attachment features are provided in the form of one or more apertures 34 therein. The or each aperture may define a diameter in the range 2mm to 8mm, for example in the range 4mm to 6mm, or approximately 5mm for example. Providing aperture sizes of these sizes have been found to enable the glass fibre within the concrete material to flow freely through the perforations, which helps to improve mechanical attachment of the fastener in the panel. The plate 32 may include an array of apertures 34. In some embodiments, the apertures may be arranged to surround the sleeve 28. Providing an attachment feature in the form of one or more apertures has been found to reduce the weight of the plate, and so of the cladding panel, which facilitates handling of the cladding panel. In other embodiments, the plate 32 may include attachment features in the form of one or more barbs, a roughened surface, or any other suitable feature. It will be appreciated that in some embodiments, an external surface of the sleeve 28 may be provided with one or more attachment features, either additionally or alternatively to the attachment features provided on the plate 32. In some embodiments, the female fastener 26 may be provided with a reinforcing arrangement for increasing the strength thereof. In the present embodiment, the reinforcing arrangement is provided in the form of at least one reinforcing rib 36 extending between the projection 32 and the sleeve 28. In the illustrated example, the female fastener is provided with four reinforcing ribs 36. The ribs 36 are equally spaced around the sleeve 28. Each rib 36 may extend between the sleeve 28 and a respective aperture 34 in the plate 32. It will be understood that any suitable number of reinforcing ribs may be provided in other configurations. Referring now to Figure 5, the brick slip 24 of Figure 3 is illustrated in more detail. The brick slip 24 includes a front face 38 and a rear face 40. The front face 38 and the rear face 40 are spaced apart to define a thickness therebetween. The brick slip 24 includes an upper face 42 and a lower face 44. The upper face 42 and lower face 44 extend between the front face 38 and the rear face 40. A spacing between the upper face 42 and the lower face 44 defines a height of the brick slip 24. Although not illustrated, the brick slip 24 includes first and second side faces extending between the front face 38 and the rear face 40. A spacing between the first and second side faces defines a length of the brick slip 24. In one example, the brick slip 24 has a thickness of approximately 15mm, a height of approximately 65mm, and a length of approximately 215mm. Whilst the brick slip 24 has been described with exemplary dimensions it will be appreciated that the brick slip 24 may be any size suitable for a particular application. In other examples, the thickness may be in the range 10mm-20mm. The length may be in the range 215mm to 490mm, For example the length of the brick slip 24 may define a length of approximately 290mm, approximately 327mm, approximately 440mm, or approximately 490mm. The height may be in the range 50mm to 300mm. The height may be in the range 50mm to 74mm, 75mm to 109mm, 110mm to 144mm, 145mm to 184mm, 185mm to 219mm, 220mm to 254mm, or 255mm to 300mm. In the illustrated example, the lower face 44, upper face 42, the first and second side faces and the front face 38 may be substantially planar. The rear face 40 may be substantially planar. The brick slip 24 is provided with a mounting formation on the rear face 40. Put another way, the rear face 40 of the brick slip 24 may be substantially planar apart from the mounting formation. In some embodiments, the brick slip 24 may be substantially cuboidal in shape. The mounting formation is provided in the form of at least one groove, recess or channel 46 on the rear face 40 of the brick slip 24. Hereinafter, the groove, recess or channel 46 will be referred to as a groove. The grooves are designed to ensure that the bricks are mechanically retained by the panels, requiring a pull-out force of more than 2kN to disengage them. In the illustrated example each groove may define a depth or length in the range 6mm to 8mm, for example approximately 7mm. Each groove may define a width in the range 4mm to 6mm, for example approximately 5mm. When the cladding panel 12 is assembled, the groove 46 is filled with the cementitious material of the backing panel 18. In this way, the groove 46 increases the mechanical attachment of the brick slip 24 to the backing panel 18. In the illustrated embodiment, the groove 46 extends between the first and second side faces of the brick slip 24. Put another way, the groove 46 extends substantially horizontally across the brick slip 24. The groove 46 extends an entirety of the distance between the first and second side faces (i.e. across the entire width of the brick slip 24) in the present example. However, in other embodiments the groove 46 may extend partially between the first and second side faces. The groove 46 extends from the back face 40 of the brick slip 24 towards the front face 38. The groove 46 is at least partially angled away from a centre of the brick slip to define an undercut portion. Put another way, the groove 46 is arranged at a non-zero angle relative to an axis extending between the front face 38 and the rear face 40. At least a part of the groove 46 may be angled in a direction towards the upper face 42 and / or lower face 44 of the brick slip 24 to define an undercut portion. In the illustrated example, each groove is arranged at an angle in the range 40° to 50°, for example approximately 45°. In other embodiments, the groove 46 may extend between the upper 42 and lower 44 faces and may include a portion that is angled towards one or both of the side faces of the brick slip 24 to define an undercut portion. The undercut groove provides an overhanging lip 48 or region that is interposed between a part of the groove 46 and the back face of the brick slip 24. This arrangement helps to increase adhesion of the brick slip to the cladding panel when the groove 46 is filled with the cementitious material of the backing panel 18. In the illustrated example, the groove 46 is provided in the form of a dovetail recess. This arrangement provides each groove 46 with a pair of overhanging lips 48 on opposing sides of the groove 46. In some embodiments, the at least one groove 46 may include two grooves 46-1, 46-2. In other embodiments, any suitable number of grooves 46 may be provided, for example three, four, five etc. Providing multiple grooves 46-1, 46-2 has been found to further increase adhesion of the brick slip 24 to the cladding panel 12 when the grooves 46 are embedded in the backing panel 18. As described above, the height of the brick slip 24 may be vary. The number of grooves 46 provided on the brick slip 24 may increase as the height of the brick slip increases. For example, a brick slip height in the range 50mm to 74mm may be provided with two grooves; a brick slip height in the range 75mm to 109mm may be provided with three grooves 46; a brick slip height in the range 110mm to 144mm may be provided with four grooves 46; a brick slip height in the range 145mm to 184mm may be provided with five grooves 46; a brick slip height in the range 185mm to 219mm may be provided with six grooves 46; a brick slip height in the range 220mm to 254mm may be provided with seven grooves 46; or a brick slip height in the range 255mm to 300mm may be provided with eight grooves 46. In some embodiments, the grooves 46-1, 46-2 may be arranged on the back face 40 of the brick slip 24 to be symmetrical. In some embodiments, the grooves 46-1, 46-2 may be spaced from the centreline along the length of the brick slip by a distance I the range 10mm to 12mm, for example approximately 11mm. The grooves 46-1, 46-2 extends in a substantially linear direction from the rear face 40. In the present example, the two grooves 46-1, 46-2 are arranged to oppose each other on the back face 40 of the brick slip 24 about a centre point of the brick slip 24. The grooves 46-1, 46-2 may be spaced apart along the height of the brick slip 24. A portion 40-1 of the rear face 40 of the brick slip 24 extends between the two groves 46-1, 46-2. In the illustrated example, this portion 40-1 is substantially planar. The portion 40-1 may be co-planar with the other parts of the rear face 40 of the brick slip 24. In other embodiments, the portion 40-1 may be at least partially curved. Referring to Figure 6, an alternative embodiment of brick slip is illustrated and indicated generally at 124. Corresponding features of this embodiment with respect to the embodiment of Figure 5 are labelled with the prefix '1' and only differences are discussed. In the illustrated example, the two grooves 146-1, 146-2 on the rear face 140 of the brick slip 124 are provided in the form of grooves or slots 146-1, 146-2. In the present example, the grooves 146-1, 146-2 are symmetrical, but in other embodiments the grooves 146-1, 146-2 may be arranged to be substantially parallel. In the illustrated example, the groove 146 is provided in the form of a dovetail recess. This arrangement provides each groove 146 with a pair of overhanging lips 48 on opposing sides of the groove 146. Referring to Figure 7, an alternative embodiment of brick slip is illustrated and indicated generally at 224. Corresponding features of this embodiment with respect to the embodiment of Figure 5 are labelled with the prefix '1' and only differences are discussed. In the illustrated example, the two grooves 246-1, 246-2 on the rear face 240 of the brick slip 224 are provided in the form of grooves or slots 246-1, 246-2. In the present example, the grooves 246-1, 246-2 are symmetrical, but in other embodiments the grooves 246-1, 246-2 may be arranged to be substantially parallel. The grooves 246-1, 246-2 extend in a substantially curved direction from the rear face 240. In the illustrated example, the portion 240-1 of the rear face 240 of the brick slip 224 that extends between the two groves 246-1, 246-2 is at least partially curved or arcuate. In other embodiments, the portion 240-1 may be substantially planar. It will be understood that the brick slips 124, 224 illustrated in Figures 6 and 7 may be incorporated into the cladding panel 12 and wall structure illustrated in Figures 1 to 3. A method of manufacturing the modular prefabricated cladding panel 12 will now be discussed with reference to the Figures. The method may be carried out offsite. A mould is provided that includes a base and a plurality of side walls extending from the base to define a cavity. In some embodiments, the base of the mould includes a plurality of spaced apart recesses therein, where each recess is configured to receive a brick slip 24, 124, 224 therein. A brick slip 24, 124, 224 may be arranged in each of the plurality of recesses. However, in some embodiments, one or more of the recesses may not have a brick slip 24, 124, 224 placed therein. The brick slips 24, 124, 224 are arranged in the recesses such that a front face 38, 138, 238 of each brick slip 24, 124, 224 is seated on a base of the mould. In other embodiments, it will be understood that the recesses may be omitted from the base and the brick slips 24, 124, 224 may be arranged on the base to be spaced apart. A female fastener 26 is arranged in the mould. The female fastener may be an internally threaded sleeve 26 configured for receiving a male fastener therein, as has been described above. The female fastener 26 is arranged to at least partially extend into the space between two adjacent brick slips 24, 124, 224. Put another way, the female fastener 26 is arranged in the mould such that a part 30 of the sleeve 28 is exposed at the front face 20 of the backing panel 18, when the backing panel has been formed. The mould is then filled with a cementitious material such that the plurality of brick slips 24, 124, 224are partially embedded in the cementitious material. The cementitious material is then cured to form the backing panel 18. Following this curing, the cladding panel 12 is then removed from the mould. Following the removal of the cladding panel 12 from the mould, it is then ready to be mounted to a wall structure, as illustrated in Figures 1 to 3. The cladding panel 12 is placed on the surface of the wall structure 10 and a male fastener (not shown) is inserted into the female fastener 26 from a front of the cladding panel. After mounting the cladding panel 12 to the wall structure 10, the front portion 30 of the female fastener may be covered with grouting. The one or more embodiments are described above by way of example only and it will be appreciated that the variations are possible without departing from the scope of protection afforded by the appended claims.
Claims
1. A brick slip for a cladding panel, the brick slip comprising:a front face and a rear face spaced apart from the front face to define a thickness therebetween;a upper face and a lower face extending between the front face and the rear face and defining a height therebetween;first and second side faces extending between the front face and the rear face and defining a length therebetween; anda mounting formation comprising at least one groove on the rear face, wherein the at least one groove is at least partially arranged at a non-zero angle relative to an axis extending between the front and rear faces to define an undercut portion.
2. The brick slip according to claim 1, wherein the at least one groove comprises two spaced apart grooves.
3. The brick slip according to claim 2, wherein the two grooves are symmetrical.
4. The brick slip according to claim 2 or claim 3, wherein the two grooves are spaced apart along the height of the brick slip.
5. The brick slip according to any preceding claim, wherein the at least one groove extends between the first and second side faces.
6. The brick slip according to any preceding claim, wherein the lower face, upper face and the first and second side faces are substantially planar and / or wherein the front face is substantially planar.
7. The brick slip according to any preceding claim, wherein the at least one groove extends in a substantially linear direction.
8. The brick slip according to any preceding claim, wherein the at least one groove comprises a dovetail recess.
9. The brick slip according to any one of claims 1 to 6, wherein the at least one groove extends in a substantially curved direction.10.The brick slip according to claims 2 and 9, comprising an arcuate surface extending between the two grooves.11.The brick slip according to any preceding claim, wherein the groove defines a depth in the range 5mm to 8mm, for example approximately 7mm, and / or a width in the range 4mm to 6mm, for example approximately 5mm .
12. A modular prefabricated cladding panel comprising:a cementitious backing panel defining front and rear panel faces, said cementitious backing panel formed from concrete;a plurality of brick slips partially embedded in the front face of the cementitious backing panel;a mounting arrangement for mounting the cladding panel to a wall structure, wherein the mounting arrangement comprises a female fastener at least partially embedded in the cementitious backing panel and exposed at the front face of the panel.13.The modular prefabricated cladding panel according to claim 12, wherein the female fastener comprises an internally threaded sleeve configured for receiving a male fastener therein.14.The modular prefabricated cladding panel according to claim 13, wherein the sleeve comprises a flanged projection extending from an outer surface thereof, said flanged projection at least partially embedded in the backing panel.15.The modular prefabricated cladding panel according to claim 14, wherein the flanged projection comprises a plate surrounding the sleeve.16.The modular prefabricated cladding panel according to claim 15, wherein the plate is substantially square, circular, or rectangular.17.The modular prefabricated cladding panel according to claim 15 or claim 16, wherein the plate comprises one or more apertures therein.18.The modular prefabricated cladding panel according to any one of claims 14 to 17, comprising at least one reinforcing rib extending between the projection and the sleeve.19.The modular prefabricated cladding panel according to any one of claims 12 to 18, wherein a front portion of the female fastener is interposed between first and second adjacent brick slips to define a spacing therebetween.20.The modular prefabricated cladding panel according to any one of claims 12 to 19, wherein the female fastener extends from the front face to the rear face of the backing panel.21.The modular prefabricated cladding panel according to any one of claims 12 to 20, wherein the female fastener is formed from a metallic material, for example steel.22.The modular prefabricated cladding panel according to any one of claims 12 to 21, wherein the concrete is glass fibre reinforced concrete.
23. The modular prefabricated cladding panel according to any one of claims 12 to 22, wherein the brick slip is a brick slip according to any one of claims 1 to 11.
24. A method of manufacturing a modular prefabricated cladding panel, the method comprising the steps of:providing a mould comprising a base defining a plurality of spaced apart recesses therein;arranging a plurality of brick slips in the plurality of recesses such that a front face of each brick slip is seated on a base of the mould;arranging a female fastener in the mould between two adjacent brick slips; filling the mould with a concrete material such that the plurality of brick slips are partially embedded in the concrete material; andcuring the cementitious material form a backing panel.25.The method according to claim 24, wherein the method steps are carried out offsite in a factory environment.
Citation Information
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