Prefabricated building panel and method of making the same
First Claim
1. A prefabricated exterior building panel including:
- (a) a plurality of spaced parallel elongated support members;
(b) a plurality of spacers attached in a spaced relationship to the support members;
(c) a wire mesh attached to the support members and spaced a predetermined distance from said members by the spacers, said mesh being formed by a plurality of interwoven spaced wires arranged at generally right angles providing interstices therebetween and with the total thickness of the mesh consisting of the thickness of five wire strand layers;
(d) a generally planar layer of cement generally encapsulating the wire mesh and having an outer surface and an opposite inner surface with said inner surface abutting the support members;
(e) a layer of grouting applied to the outer surface of the encapsulating cement; and
(f) a plurality of facing elements attached to the outer surface of the cement by the grouting.
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Accused Products
Abstract
An improved prefabricated building panel for mounting on the exterior of a building including a plurality of spaced, parallel support members or studs preferably formed by metal channels. A five strand layer wire mesh formed by a plurality of interwoven wires arranged at right angles to each other is attached to the support members and spaced therefrom by a plurality of spacers. The wire mesh is encapsulated with cement to form a ferrocement panel and decorative facing tile are secured to an outer face of the ferrocement panel by a layer of grouting. The ferrocement panel provides the structural load bearing component for the prefabricated panel for supporting the facing tile and eliminates the need for a separate substrate which heretofore spanned the support members and provided the structural support. The invention also includes the method steps for forming such a prefabricated panel.
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Citations
20 Claims
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1. A prefabricated exterior building panel including:
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(a) a plurality of spaced parallel elongated support members; (b) a plurality of spacers attached in a spaced relationship to the support members; (c) a wire mesh attached to the support members and spaced a predetermined distance from said members by the spacers, said mesh being formed by a plurality of interwoven spaced wires arranged at generally right angles providing interstices therebetween and with the total thickness of the mesh consisting of the thickness of five wire strand layers; (d) a generally planar layer of cement generally encapsulating the wire mesh and having an outer surface and an opposite inner surface with said inner surface abutting the support members; (e) a layer of grouting applied to the outer surface of the encapsulating cement; and (f) a plurality of facing elements attached to the outer surface of the cement by the grouting. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13)
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14. A prefabricated exterior building panel including:
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(a) a plurality of spaced parallel elongated support members; (b) a plurality of spacers located at spaced intervals along the support members; (c) a wire mesh attached to the support members and spaced from said members by the spacers, said mesh being formed by a plurality of interwoven spaced wires arranged at generally right angles providing interstices therebetween and with the total thickness of the mesh consisting of the thickness of five wire strand layers; (d) a plurality of fasteners attaching the spacers and wire mesh at spaced intervals to the support members; (e) a layer of cement generally encapsulating the wire mesh; (f) a layer of grouting applied to the encapsulated wire mesh; and (g) a plurality of facing elements attached to the encapsulated wire mesh by the grouting.
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15. A method of forming an exterior building panel including the steps of:
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(a) arranging a plurality of elongated support members in a parallel spaced relationship; (b) attaching a plurality of spacers on each of the support members; (c) securing a wire mesh to the support members spaced a predetermined distance from said members by the spacers, said mesh being formed by a plurality of interwoven spaced wire strands arranged at right angles providing interstices therebetween whereby the total thickness of the mesh consists of the thickness of five wire strand layers; (d) encapsulating the wire mesh with a generally planar layer of cement providing an outer surface and an opposite inner surface with said inner surface abutting the support members; (e) applying a layer of grouting to the outer surface of the encapsulating cement; and (f) attaching a plurality of facing elements to the grouting. - View Dependent Claims (16, 17, 18, 19)
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20. A method of forming an exterior building panel including the steps of:
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(a) arranging a plurality of elongated support members in a parallel spaced relationship; (b) placing a plurality of spacers at spaced intervals along each of the support members; (c) attaching the spacers and a wire mesh to the support members with a plurality of fasteners with the wire mesh being spaced from said support members by the spacers, and with said mesh being formed by a plurality of interwoven spaced wire strands arranged at right angles providing interstices therebetween whereby the total thickness of the mesh consists of the thickness of five wire strand layers; (d) encapsulating the wire mesh with cement; (e) applying a layer of grouting to an outer surface of the encapsulated wire mesh; and (f) attaching a plurality of facing elements to the encapsulated wire mesh by the grouting.
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Specification