AU2022204499A1 - Improved prefabricated brick inlay panels - Google Patents

Improved prefabricated brick inlay panels Download PDF

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Publication number
AU2022204499A1
AU2022204499A1 AU2022204499A AU2022204499A AU2022204499A1 AU 2022204499 A1 AU2022204499 A1 AU 2022204499A1 AU 2022204499 A AU2022204499 A AU 2022204499A AU 2022204499 A AU2022204499 A AU 2022204499A AU 2022204499 A1 AU2022204499 A1 AU 2022204499A1
Authority
AU
Australia
Prior art keywords
form liner
planar
planar surface
hollow bulb
liner
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
AU2022204499A
Inventor
Charlie GUBBINS
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Form Brick Pty Ltd
Original Assignee
Form Brick Pty Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from AU2021901930A external-priority patent/AU2021901930A0/en
Application filed by Form Brick Pty Ltd filed Critical Form Brick Pty Ltd
Publication of AU2022204499A1 publication Critical patent/AU2022204499A1/en
Pending legal-status Critical Current

Links

Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04G—SCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
    • E04G9/00—Forming or shuttering elements for general use
    • E04G9/10—Forming or shuttering elements for general use with additional peculiarities such as surface shaping, insulating or heating, permeability to water or air
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B19/00—Machines or methods for applying the material to surfaces to form a permanent layer thereon
    • B28B19/0053—Machines or methods for applying the material to surfaces to form a permanent layer thereon to tiles, bricks or the like
    • B28B19/0061—Means for arranging or fixing the tiles, bricks or the like in the mould
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B7/00—Moulds; Cores; Mandrels
    • B28B7/0064—Moulds characterised by special surfaces for producing a desired surface of a moulded article, e.g. profiled or polished moulding surfaces
    • B28B7/0073—Moulds characterised by special surfaces for producing a desired surface of a moulded article, e.g. profiled or polished moulding surfaces with moulding surfaces simulating assembled bricks or blocks with mortar joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D99/00—Subject matter not provided for in other groups of this subclass
    • B29D99/001—Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings
    • B29D99/0014—Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings provided with ridges or ribs, e.g. joined ribs
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E04F13/0862—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements composed of a number of elements which are identical or not, e.g. carried by a common web, support plate or grid
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E04F13/14—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements stone or stone-like materials, e.g. ceramics concrete; of glass or with an outer layer of stone or stone-like materials or glass
    • E04F13/147—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements stone or stone-like materials, e.g. ceramics concrete; of glass or with an outer layer of stone or stone-like materials or glass with an outer layer imitating natural stone, brick work or the like
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04G—SCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
    • E04G11/00—Forms, shutterings, or falsework for making walls, floors, ceilings, or roofs
    • E04G11/06—Forms, shutterings, or falsework for making walls, floors, ceilings, or roofs for walls, e.g. curved end panels for wall shutterings; filler elements for wall shutterings; shutterings for vertical ducts

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Mechanical Engineering (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Forms Removed On Construction Sites Or Auxiliary Members Thereof (AREA)

Abstract

A form liner for inlaying relief elements onto which concrete is poured to form a precast concrete panel with surface relief texture, the form liner comprising a plurality of spaced-apart elongate strips of resilient protuberances on a planar surface, wherein in use the resilient protuberances sealingly and deformably receive and retain the relief elements on the planar surface. 1/6 \Col \ 1\ C KN K Col N KN \ 'K -- 4--- -- K CK K~ K C1 K KN

Description

1/6
\Col \ 1\ C KN K Col
N KN \'K
-- 4--- -- K CK K~ K C1 KKN
IMPROVED PREFABRICATED BRICK INLAY PANELS
Field
[0001] The present invention relates generally to improved prefabricated brick inlay panels.
Background
[0002] The present applicant's international patent application WO 2015/184502 describes a form liner for prefabricating brick inlay panels. The form liner comprises plastic spacers inserted in a grid pattern of slots or recesses formed in a substrate. Brick tiles are laid between the plastic spacers, and concrete is cast over brick tiles to form a prefabricated brick inlay panel.
[0003] While the invention described in WO 2015/184502 is advantageous compared to conventional moulded form liners, it has been discovered that the steps of forming the slots in the substrate, and inserting the plastic spacers into the slots, can be improved upon.
[0004] In view of this background, the present applicant has developed an improvement in the prefabrication of brick inlay panels.
Summary
[0005] According to the present invention, there is provided a form liner for inlaying relief elements onto which concrete is poured to form a precast concrete panel with surface relief texture, the form liner comprising a plurality of spaced-apart elongate strips of resilient protuberances on a planar surface, wherein in use the resilient protuberances sealingly and deformably receive and retain the relief elements on the planar surface.
[0006] The resilient protuberances may comprise bulb seals.
[0007] The bulb seals may each comprise a hollow bulb portion.
[0008] The hollow bulb portion may have a generally pentagonal internal cross section.
[0009] The hollow bulb portion may have a convex top surface and converging inclined side surfaces.
[0010] The hollow bulb portion may comprise gripping projections on the converging inclined side surfaces to grip and retain edges of the relief elements.
[0011] The convex top surface may have gripping projections to grip and retain edges of the relief elements.
[0012] The gripping projections may comprise downwardly inclined projections, such as fir tree projections.
[0013] The hollow bulb portion may be integrally formed on the planar surface.
[0014] Alternatively, the hollow bulb portion may be directly or indirectly mounted on the planar surface.
[0015] The hollow bulb portion may further comprise planar mounting flanges.
[0016] The planar mounting flanges may be attached to a planar mounting strip.
[0017] The planar mounting strip may be attached to the planar surface.
[0018] Planar infill strips maybe attached to the planar surface to fill planar gaps between adjacent planar mounting strips.
[0019] The planar surface may comprise a metal, wood or plastic substrate of formwork or a concrete casting table.
[0020] The relief elements may comprise thin bricks, thin brick sections, ceramic tiles, glazed tiles, or stone.
[0021] The present invention also provides a method of forming a form liner for inlaying relief elements onto which concrete is poured to form a precast concrete panel with surface relief texture, the method comprising providing a plurality of spaced-apart elongate strips of resilient protuberances on a planar surface, wherein in use the resilient protuberances sealingly and deformably receive and retain the relief elements on the planar surface.
[0022] The present invention may further provide a precast concrete panel with surface relief texture made using the form liner or the method described above.
[0023] The precast concrete panel may comprise a precast concrete panel with brick inlays.
Brief Description of Drawings
[0024] Embodiments of the invention will now be described by way of example only with reference to the accompanying drawings, in which: Figure 1 is an exploded perspective view of a form liner for prefabricating brick inlay panels according to an embodiment of the present invention; Figure 2 is an assembled perspective view of the form liner; Figure 3 is an exploded end view of the form liner; Figure 4 is an assembled end view of the form liner; Figure 5 is an assembled end view of another embodiment of the form liner; Figure 6 is an exploded end view of a further embodiment of the form liner; and Figure 7 is a photograph of the form liner with inlaid thin brick sections with end spacers to form simulated vertical mortal joints between the brick sections.
Description of Embodiments
[0025] Referring to the drawings, a form liner 10 for prefabricating a brick inlay panel according to an embodiment of the present invention may be formed by a method comprising adhering bulb seal strips 12 on a substrate 14 for locating courses of brick tiles (or facings) 16 to be laid on the substrate 14. Optionally, planar infill strips 18 may be arranged on the substrate 14 between the bulb seal strips 12 with or without adhesion for supporting the brick tiles 16 in the courses on the substrate 14.
[0026] The bulb seal strips 12 may comprise a bulb portion 12A between laterally extending mount (or foot) portions 12B. In some embodiments, the planar infill strips 18 may be omitted, and the mount portions 12B of the bulb portion 12A may be laterally extended between adjacent bulb seal strips 12 for supporting the brick tiles 16 in the courses on the substrate 14.
[0027] As best seen in Figures 3 and 4, fir tree projections may be provided on opposite sides of the bulb portion 12A of the bulb seal strips 12 for gripping and retaining the brick tiles 16 in the courses on the substrate 14. The bulb portion 12A of the bulb strips 12 may be hollow leaving open free ends 12C. The method may further comprise inserting plugs into the open free ends 12C of the bulb portion 12A of the bulb seal strips 12. The plugs 20 may be fastened to the substrate 12 by screws 22. The substrate 14 may comprise one or more plastic panels, or a table or bench.
[0028] In some embodiments, the mount portions 12B of the bulb seal strips 12 may be self-adhesive with adhesive backing, and the planar infill strips 18 may be self-adhesive with adhesive backing. In other embodiments, the mount portions 12B of the bulb seal strips 12 may be self-adhesive, and the planar infill strips 18 may not be self-adhesive. One or both of the bulb seal strips 12 and the planar infill strips 18 may be formed of a thermoplastic elastomeric material.
[0029] Referring to Figure 5, in some embodiments of the invention, the planar infill strips 18 may be arranged to wholly or partially overlap spaced-apart mount portions 12B of adjacent bulb seal strips 12 with or without adhesion. In one embodiment, the planar infill strips 18 may cover the fixing screws 22 and overlap the foot 12B of the bulb strip 12 without adhesion so as to removably cover the whole area beneath the brick tiles 16 (not shown). The overlapping planar infill strips 18 may be pulled up after each use and replaced for subsequent use, instead of cleaning the form liner 10 with a trowel after each use. The use of these sacrificial planar infill strips 18 may extend the service life of the form liner 10 for high repeat use. The sacrificial planar infill strips 18 may also reduce the cleaning time of the brick inlay panel. Furthermore, the added protection from concrete that the planar infill strips 18 provide to the substrate 14 may allow brick tiles 16 to be inlaid without the expense of waxing them beforehand. For example, the upper side of the planar infill strips 18 may be provided with a non-stick coating.
[0030] In use, the form liner 10 may be secured inside a form orjig (not shown) by screws (not shown) attached to LVL beams of the concrete formwork. The screws may be covered by infill strips (not show). Waxed brick tiles 16 may be located face down in the courses of the form liner 10 defined by the bulb seal strips 12 on the substrate 14, and spaced apart from one another in end-to-end relationship using a measuring stick (not shown). Concrete (not shown) may then be cast over the laid brick tiles 16. The form liner 10 may then be reused multiple times for prefabricating brick inlay panels.
[0031] In some alternative embodiments, the use of one or more separate substrates 14 that are in turn secured to LVL beams of concrete formwork may be omitted, and the bulb seal strips 12 may instead be adhered directly to a horizontal planar surface of a work support, such as a bench or table, provided at a prefabrication factory for laying the brick tiles 16. In this case, the work support may act as the substrate 14 for the purposes of performing the method of the present invention, and the end plugs 20 may be omitted.
[0032] Referring to Figure 6, another embodiment of the present invention may provide a form liner 30 for inlaying relief elements (not shown) onto which concrete is poured to form a precast concrete panel with surface relief texture. The form liner 30 may comprise a plurality of spaced-apart elongate strips of resilient protuberances on a planar surface, wherein in use the resilient protuberances sealingly and deformably receive and retain the relief elements on the planar surface.
[0033] The resilient protuberances may comprise bulb seals 32 arranged in longitudinal rows on the planar substrate corresponding to horizontal courses of the relief elements. The bulb seals 32 may each comprise a hollow bulb portion 34. The hollow bulb portion 34 may have a generally pentagonal internal cross section. The hollow bulb portion 34 may have a convex top surface 36 and converging inclined side surfaces 38. The hollow bulb portion 34 may comprise gripping projections 40 on the converging inclined side surfaces 38 to grip and retain edges of the relief elements. The convex top surface 36 may have gripping projections 42 to grip and retain edges of the relief elements. The gripping projections 40, 42 may comprise downwardly inclined projections, such as fir tree projections.
[0034] The hollow bulb portion 34 may be integrally formed on the planar surface. Alternatively, the hollow bulb portion 34 may be directly or indirectly mounted on the planar surface with or without adhesive and/or fasteners. The hollow bulb portion 34 may further comprise planar mounting flanges 44 for mounting the hollow bulb portion 38 to the planar substrate. The planar mounting flanges 44 may be integrally formed with the hollow bulb portion 34. The planar mounting flanges 44 may be attached, such as bonded or welded, to a planar mounting strip 46. The planar mounting strip 46 may be attached to the planar surface, for example, by a self-adhesive back layer. Planar infill strips 48 may be attached, for example by a self-adhesive back layer, to the planar surface to fill planar gaps between adjacent planar mounting strips 46.
[0035] The planar infill strips 48 may be sized and dimensioned to abut and be co-planar with, and the same vertical thickness as, the planar mounting flanges 44 to thereby provide a substantially planar surface between adjacent hollow bulb portions 34. The planar mounting strip 46 may be sized and dimensioned to be thin in height with a relatively smaller vertical thickness to extend under and go beneath the planar infill strips 48. This prevents the edge of the planar mounting strip 46 lifting and accumulating dust between pours of concrete.
[0036] The planar surface may comprise a metal, wood or plastic substrate of formwork or a concrete casting table.
[0037] The relief elements may comprise thin bricks, thin brick sections, ceramic tiles, glazed tiles, or stone.
[0038] The hollow bulb portion 34 and the planar mounting flanges 44 may be integral extrusions of a thermoplastic elastomeric composition, such as Santoprene©. The planar mounting strip 46 may comprise a thin polypropylene strip with an adhesive back. The planar infill strips 48 may comprise polyethylene foam tape with an adhesive back.
[0039] The resilient deformability of the rows of bulb seals 32 advantageously accommodates variations in the width of individual thin brick sections, for example, those formed from old or recycled bricks. The height or vertical thickness of the rows of the bulb seals 32 may be slightly less than the height or vertical thickness of the thin brick sections so that simulated horizontal mortar joints are formed when concrete is cast onto the form liner 30 to form a precast panel with brick inlays.
[0040] Referring to Figure 7, the form liner 30 may further comprise end spacers (shown in light colour) inserted between adjacent ends of the thin brick sections to space them apart from each other in end-to-end relationship between the rows of bulb seals 32. The height or vertical thickness of the end spacers may be slightly less than the height or vertical thickness of the thin brick sections so that simulated vertical (or perpendicular) mortar joints are formed when concrete is cast onto the form liner 30 to form a precast panel with brick inlays. The end spacers may, for example, comprise polyethylene foam members placed at the end of each thin brick section to space them apart longitudinally.
[0041] The end spacers may be provided in a set of predetermined variable widths to vary the width of the perpendicular mortar joint to accommodate variations in the length of individual thin brick sections. The end spacers may be colour coded, for example yellow, black, etc, based on their predetermined variable widths so that suitable end spacers may be easily identified as the individual thin brick sections are inlaid into the form liner 30. The variable-sized, colour-coded end spacers enable the thin brick sections to be inlaid into the form liner 30 in the same manner as a brick layer does by allowing a standard length, for example 240 mm, for each brick plus mortar joint.
[0042] Embodiments of the present invention provide a method, and a related form liner, that are both generally and specifically useful for high repeat use for prefabricating brick inlay panels.
[0043] For the purpose of this specification, the word "comprising" means "including but not limited to," and the word "comprises" has a corresponding meaning.
[0044] The above embodiments have been described by way of example only and modifications are possible within the scope of the claims that follow.

Claims (19)

Claims
1. A form liner for inlaying relief elements onto which concrete is poured to form a precast concrete panel with surface relief texture, the form liner comprising a plurality of spaced-apart elongate strips of resilient protuberances on a planar surface, wherein in use the resilient protuberances sealingly and deformably receive and retain the relief elements on the planar surface.
2. The form liner of claim 1, wherein the resilient protuberances comprise bulb seals.
3. The form liner of claim 2, wherein the bulb seals each comprise a hollow bulb portion.
4. The form liner of claim 3, wherein the hollow bulb portion has a generally pentagonal internal cross section.
5. The form liner of claim 4, wherein the hollow bulb portion has a convex top surface and converging inclined side surfaces.
6. The form liner of claim 5, wherein the hollow bulb portion comprises gripping projections on the converging inclined side surfaces to grip and retain edges of the relief elements.
7. The form liner of claim 6, wherein the convex top surface has gripping projections to grip and retain edges of the relief elements.
8. The form liner of claim 7, wherein the gripping projections comprise downwardly inclined projections or fir tree projections.
9. The form liner of claim 3, wherein the hollow bulb portion is integrally formed on the planar surface.
10. The form liner of claim 3, wherein the hollow bulb portion is directly or indirectly mounted on the planar surface.
11. The form liner of claim 10, wherein the hollow bulb portion further comprises planar mounting flanges.
12. The form liner of claim 11, wherein the planar mounting flanges are attached to a planar mounting strip.
13. The form liner of claim 12, wherein the planar mounting strip is attached to the planar surface.
14. The form liner of claim 13, wherein planar infill strips are attached to the planar surface to fill planar gaps between adjacent planar mounting strips.
15. The form liner of claim 1, wherein the planar surface comprises a metal, wood or plastic substrate of formwork or a concrete casting table.
16. The form liner of claim 1, wherein the relief elements comprise thin bricks, thin brick sections, ceramic tiles, glazed tiles, or stone.
17. A method of forming a form liner for inlaying relief elements onto which concrete is poured to form a precast concrete panel with surface relief texture, the method comprising providing a plurality of spaced-apart elongate strips of resilient protuberances on a planar surface, wherein in use the resilient protuberances sealingly and deformably receive and retain the relief elements on the planar surface.
18. A precast concrete panel with surface relief texture made using the form liner of claim 1 or the method of claim 17.
19. The precast concrete panel with surface relief texture of claim 18, wherein the precast concrete panel comprises a precast concrete panel with brick inlays.
10
16
12 1/6
12A 12B 18 12B 12A
12C 12B 12B 14 12C
22 20 22 Figure 1
AU2022204499A 2021-06-25 2022-06-24 Improved prefabricated brick inlay panels Pending AU2022204499A1 (en)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
AU2021901930 2021-06-25
AU2021901930A AU2021901930A0 (en) 2021-06-25 Prefabricated brick inlay panels
AU2021902476A AU2021902476A0 (en) 2021-08-10 Improved prefabricated brick inlay panels
AU2021902476 2021-08-10

Publications (1)

Publication Number Publication Date
AU2022204499A1 true AU2022204499A1 (en) 2023-01-19

Family

ID=84892499

Family Applications (1)

Application Number Title Priority Date Filing Date
AU2022204499A Pending AU2022204499A1 (en) 2021-06-25 2022-06-24 Improved prefabricated brick inlay panels

Country Status (1)

Country Link
AU (1) AU2022204499A1 (en)

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