CA2169585C

CA2169585C - Concrete cladding panel system

Info

Publication number: CA2169585C
Application number: CA 2169585
Authority: CA
Inventors: Peter Kuelker
Original assignee: Stonetile Canada Ltd
Current assignee: Stonetile Canada Ltd
Priority date: 1996-02-15
Filing date: 1996-02-15
Publication date: 2004-02-03
Anticipated expiration: 2016-02-15
Also published as: CA2169585A1

Abstract

A cladding panel system comprises concrete panels having bevelled side edges, such that when the panels are installed on a supporting wall, the bevelled edges of adjacent panels form a V-joint with its apex at the rear surfaces of the panels. The bevelled edges of adjacent panels provide a localized crush zone that absorbs thermal expansion stresses without significant damage to the panels, thus eliminating the need for expansion joints. Flexible grout such as urethane caulking is applied in the V joints between the panels to prevent entry of water. The panels are formed with perimeter caulking grooves to facilitate application of the flexible grout. The grout may have a coating such as silica sand for protection against ultraviolet radiation. Each panel includes hangar means, which may comprise one or more hangers embedded in the panel, for securing the panel to the supporting wall using screws or other common fasteners.

Description

This invention relates to a method and apparatus for producing building panels, and in particular concrete panels for exterior use on buildings. This new cladding system is a radical departure from any commonly used systems.
Thin panels of the type produced in accordance with the present invention are used to simulate natural stones. Because the panels are relatively thin, the cost of producing a simulated stone finish is substantially less expensive than when using artificial or real stones.
Panels of the type described herein are typically produced in separate moulds which is both time consuming and expensive.
Cladding systems such as stucco, brick, stone and artificial stone vaniers are typically installed whereas the mortars are prepared on the building site. The quality of these materials are impaired due to the fact that monitoring of accurate formulas on the building site is difficult.
The quality of these materials is further impaired due to the fact that typically these materials are allowed to air dry without attempting to seal these cementious products for proper curing. Sealing during curing greatly improves cementious products thus making them denser and reducing a condition known as 1fi'~~~
efflorescing, a process that allows calcium to deposit on the surface. Efflorescence is extremely difficult to prevent in presently known masonry cladding installation systems.
Typically with presently known masonry cladding systems it is required to provide mixing equipment on job sites for preparing the cementious products that are required for installation.

In the case of stucco it becomes necessary to install in three or four steps such as: wire installation, first layer of stucco (scratch coat) second layer (float coat) and top layer (finish coat).

The installation of typical masonry products is often hindered by weather conditions, such as rain and freezing conditions usually forcing a work stoppage unless measures are taken to shield the work area.

Typically with stucco or artificia l stone, an inferior cladding system is achieved due to t he fact that no venting space is provided in behind the cladding.

Typically brick and stone cladding systems are very heavy and consideration must be made to support this weight especially to the foundation an d over window and door openings.

Generally speaking all existing masonry cladding systems are plagued with cracking problems. It is ', ~16~~8~
virtually impossible to prevent this condition.
Furthermore, all existing masonry cladding systems require unsightly expansion joints laterally and vertically. Concealing these joints is virtually impossible.
It is also difficult to maintain uniform minimum thickness of presently known masonry cladding systems.
Presently known artificial stone cladding systems requires surface preparation such as a stucco base coat.
This adds greatly to its expense.
Finally known masonry cladding systems are prone to dirt entrapment.
As is evident from the above discussion of the prior art, what is needed is a cladding system whereas these above mentioned conditions are eliminated or at least minimized.
The object of the present invention is to solve the above mentioned problems by providing a relatively simple, efficient method and apparatus for producing concrete panels.
An object of the present invention is to provide a panel with a peripheral shoulder that, with an adjoining panel, a channel is formed that is most conducive for receiving caulking.
Another object of the invention is that a V-groove between panels is formed that offers a maximum surface for caulking adhesion.
Another object of the invention is to eliminate the need for unsightly expansion joints.
It is a feature of this invention that the bevelled side edges provide a safe crush zone that absorbs thermal expansion without damage to the panel itself.
It is another feature of this invention that each panel has a moulded centre mark. This feature greatly assists in centering the panels during installation.
This mark is located in the side shoulder and becomes covered by the flexible grout.
Another object of this invention is that this masonry product be installed without mortars, glues, nails, or additional brackets.
Another feature of the invention is that each panel has two cast in place hangers that provide several advantages.
A feature of the hanger allows the panel to be simply screwed to a wall.
Another feature of the hanger is that it provides a vent or draining space behind the panel preventing any water from ever contacting the building itself.
Another feature of the hanger is that a kink in the end of the nails prevent pull out and that the point of the nails prevent surface spotting that are normally ~16~~~~
caused by minor temperature differences of metal and curing concrete.
Another feature of this invention is that the plural leg sets of the hangers have spring action and are shaped in such a way that concrete break out during installation is avoided, and that proper panel tension is provided and that adequate strength against cyclonic conditions exists.
It is another feature of the hangers that 4 syphoning bridges are provided on each hanger. These bridges assist in the prevention of concrete travelling into the hanger positioning cavities.
It is another feature of the hanger that the centre section can be cut away and when horizontally screwed to the wall be used as a stabilizing bracket for a single hangered smaller panel.
Another object of the invention is that an unusually thin but relatively ridged thermoformed plastic form be used to greatly reduce mould costs.
Another feature of the form is that hanger positioning cavities are built in allowing the hangers to remain accurately positioned during vibration.
It is a feature of this invention that the forms feature releasing strips, back-up panels, stacking strips and a thin membrane that prevents thermal cracking.

~1~~~~~
These thin fragile forms can be stacked in an unusually small space and support in excess of one ton of loading capacity.
It is a feature of this invention that a multi-layered form stack can be demoulded simultaneously by lifting and pivoting the complete stack 180 degrees. The mould releasing strips gently push on the edges of the form thus releasing all the panels and allowing them to rest on the bottom of the back-up panel, ready for bundling and shipping.
Another object of the invention is to provide a masonry product that can be installed during freezing temperatures without the need for hording.
It is another advantage of this invention that the panels are compact and can be installed with great speed.
Another object of the invention is to provide mortar that is crack resistant. This was achieved with the use of urethane caulking that is then coated with silica sand. Giving the caulking an aesthetically pleasing mortar appearance. This silica sand coating now greatly adds to the resistance of ultraviolet radiation damage of the urethane caulking. And additional coating of dolomite dust avoids the caulking becoming soiled from airborne dust particles.
Another feature of the invention is the bottom and ~~.~9~8~
top "J" channels have perforations to allow the vent space to function and also retain the bottom of the bottom panel and the top of the top panel.
Another feature of the invention is a dispensing apparatus with lateral rollers and tracks and an adjustable chamber equal in volume to a panel.
Another feature of the invention is lateral shock vibration. Jarring air bubbles free instantly and allowing them to travel away from what will be the panel face virtually eliminating all surface air voids.
Another feature of the invention is a tilting stretch wrap bundler greatly reducing shipping breakage.
Another feature of this invention is that the concrete panels can be complimented with a comprehensive line of concrete architectural component that are produced with the same method as described above resulting in a dramatic new look that simulates European architecture at a great COSt saving.
It is another feature of this invention to easily obtain a number of different surface profiles that will offer an unlimited choice of design alternatives.
It is another object of the invention to obtain a glossy concrete surface that is resistant to any surface dirt entrapment. The glossy surface is achieved by high gloss plastic moulds.
_ g _ ~~~~~~5 It is another object of the invention to obtain better quality control because it is prefabricated under controlled conditions dissimilar to other masonry cladding systems like stucco, artificial stone, brick and real stone.
Accordingly, the invention relates to a method of producing a concrete building panel of the type including a thin concrete body and metal hangers embedded in the body for mounting the panel, said method comprising the steps of:
(a) placing hangers for the panel on a form;
(b) loading a transfer dispenser with sufficient concrete to fill the form;
(c) placing the transfer dispenser over the form, to release the concrete into the form; and (d) applying shock vibration to the form to release air bubbles and settle the concrete in the form.
The invention also relates to an apparatus for producing a concrete building panel of the type including a thin, concrete body and metal hangers embedded in the body for mounting the panel, said apparatus comprising:
(a) thin plastic form means defining a cavity including bottom wall means, side wall means and an open top for receiving concrete;
(b) hanger positioning cavity means on said side wall _ g _ ~~~~~t~
means for supporting said metal hangers in the open top of the form;
tc) transfer dispenser means for receiving and dispensing a predetermined volume of concrete into said form means; and td) vibrator means for applying shock vibration to said form to eliminate air pockets in the concrete.
The invention will be described, by way of example only, reference being had to the accompanying drawings in which:
Figure 1 is is a front view of the textured concrete panel produced using the method and apparatus of the invention.
Figure 2 is a side view of the panel of Fig. 1;
Fiaure 3 is a front view of a bevelled concrete panel;
Figure 4 is a side view of the panel of Fig. 3;
Figure 5 is a view of a range of planar and contoured panels and mouldings.
Figure 6 is a rear view of the panels of Figs. 1 and 3;
Figure 7 is a perspective view from below and one end of a hanger used in the panels of Figs. 1 to 6;
Figure 8 is a perspective view of the top portion of the hanger of Fig. 7;

~~~~5~5 Figure 9 is a perspective view of a stabilizing clip;
Figure 10 is a perspective view of the bottom portion of hanger of Fig. 7;
Figure 11 is a bottom view of the hanger of Fig. 7;
Figure 12 is a top view of the hanger of Fig. 7;
Figure 13 is an end view of the hanger of Fig. 7 and 11 as seen from the left of Fig. 11;
Figure 14 is an end view of the hanger of Fig. 7 and 11 as seen from the right of Fig. 11;
Figure 15 is a perspective view of a section of the form and back-up panel and the hanger positioning cavities;
Figure 15(a) is a partially sectional perspective view of the form referencing the formation of the caulking grooves.
Figure 16 is a perspective view of a form filled with concrete complete with hangers located in the hanger positioning cavities;
Figure 17 is a perspective view of the vibrating table and the shock vibrator;
Figure 18 is a cross section of a filled form of Fig. 15;
Figure 19 is a cross section of the form of Fig. 15 with focus on stacking strips and the releasing strips;

~~~~~$5 Figure 20 is a top view cross section of two installed panels as of Fig. 1;

Figure 21 is a side view cross section of two installed panels as of Fig. 1 special focus on interlocking hangers of Fig. 7;

Figure 22 is a cross section of two adjoining panels of Fig. 1 showing detail of the crush zone and the flexible gro ut in the V-joint and the caulking shoulders;

Figure 23 is a cross section of filled forms as of Fig. 15 in stacked formation;
a Figure 24 is a perspective view of a top and bottom installation channels as part of the present invention;

Figure 25 is a perspective view of a stack rotating device used for multiple simultaneous demoulding;

Figure 26 shows a perspective view of the rotating demoulder of Fig. 25 in a loaded state as part of this as invention;

Figure 27 shows a tilting bundle stretch wrapper as part of th is invention. Shown tilted and ready for loading;

Figure 28 shows loaded bundle stretch wrapper level and rotating as of Fig. 27;

Figure 29 shows long cross section of concrete extruder sh own here while extrusion cavity is being filled;

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Figure 30 shows extruder with closed doors and full extrusion cavity;
Figure 31 shows extruder during form filling cycle;
Figure 32 shows short cross section of concrete extrude of Fig. 29.
Referring to Figs. 1 to 6, the method and apparatus of the present invention are designed to produce a concrete panel generally indicated at 1. The panel includes a thin rectangular body 2, typical dimensions of which are 12" x 18" x 5/8", however, irregular shapes as shown in Fig. 5 may also be formed. The body 2 has a textured, bevelled or irregular outer or front surface 3, sloping, tapered sides 5 and 6 and a rough, planar inner or rear surface 7. A groove 9 or caulking ledge extends around the side periphery of the panel. Figs. 3 and 4 show a similar panel to that of Figs. 1 and 2 but with smooth face 3A & 2A. A pair of hangers 10 are embedded in the rear surface 7 of the panel. The hangers 10 (Fig.
6) are used to mount the panel 1 on plywood backing or other suitable backing shown in Fig. 20 and 21 when finishing a wall. A flexible grout is provided between the panels to complete the exterior wall.
As shown in Fig. 7 to 10, each hanger 10 includes an elongated, galvanized metal body 12 (or other suitable materials such as plastic) defining a central channel 13 zm~~~~
with a generally U-shaped cross section extending outwardly from the edges of the channel 13. A locating hole 16 (Fig. 11 and 12) is provided in one end of the body 12, and a pair of diverging spring arms 17 are provided on the other end of the body. The arms 17 are extensions of the flanges 14. Slits are cut in the flanges 14 near each end thereof, and the thus formed prongs 18 are bent at approximately 45 degrees to the flanges 14 for anchoring the hanger 10 in the concrete body 2 of the panel 1. Prongs 18 also include sharp pointed tips 23 which are also bent at 24; this prevents surface spotting; also shown in Fig. 7 are bottom and top syphoning bridges 19 and 19A respectively, these aid in transfer of concrete around hangers 10 and more specifically prevent concrete from flowing into hanger positioning cavities.
Numerals 25 and 26 (Figs. 8 and 10) indicate top and bottom hanger parts, which when separated from the main hanger body 12 permit use as separate hanger part portions. Numeral 28 (Fig. 11) indicates the cut, to sever top and bottom hanger parts, and numeral 29 indicates cut to sever stabilizing clip (Fig. 9).
Referring to Figs. 15 to 19, and Figs. 29 to 32, panels 1 are produced using a form and an extruder 100 generally indicated at Figs. 29 to 32, respectively.

~~~~~~5 The form 30 shown in part section in Fig. 15(a) is defined by a thin, molded, polystyrene sheet 33, which includes a plurality of cavities 35 for receiving concrete. A flat ledge 34 tFigure 15) is provided around the top periphery of each cavity 35. Pairs of hanger positioning cavities 40 and 41 are moulded, these cavities 40 and 41 formed in the ledge 34 on opposite sides of each cavity are intended to support the ends of the hangers 10 during vibration.
The finished panel as shown in Figures 1 - 4, and more clearly in Figure 22, has tapered edges 9(a) and a further groove or recess 9 which is referred here as a caulking groove. In Figure 15(a) it will be seen that the mold as form 30 is configured to provide the tapered sides and the groove the latter being formed by the projection 37a.
As best shown in Figs. 15 and 23, each form 30 includes releasing strips 38 stacking strips 39.
As best shown in Figs. 19 and 23, the vertical formation of the stacking strips 39 are separated by the releasing strips 38 and form edges 34, thus causing the back-up panels 32 to become load bearing, and allow curing concrete panels to be stacked in this suspended position, the releasing strip 38 being bonded to form 30.
The stacking strip 39 is bonded to the back-up panels 32.

~~.~~~8~
The extruder 100 shown in Figs. 29 to 32 is used to transfer concrete from a source thereof to the cavities 35 in the form 30.
In order to produce panels 1 of the type shown in Fig. 1 to 6, concrete is poured into form 30 and hangers are placed over each form cavity 35.
As best shown in Fig. 16, the hangers 10 rest in the hanger positioning cavities 40 and 41 and are aligned end to end to adjacent cavities. The form 30 with the 10 hangers 10 thereon is placed on a vibrating table which includes motor 47, table frame 48, shown in Fig. 17 the top surface of which should be as clean as possible to avoid damage to the form by hard particles.
A centre mark 42 (Fig. 15) is positioned in the form side wall 37. This centre mark becomes cast into each concrete panel making installation much easier.
As best shown in Fig. 17 the form 30 is placed on top 46 of the vibrating table 45. The table is equipped with four rubber shock absorbers, or dampeners 54, a vibrator motor 47, and frame 48.
A shock vibrator 50 with hydraulic motor 52 is also mounted to the frame 48. Lateral vibrating shock action is produced by an eccentric wheel 53 and transferred to the vibrating table 45 through the shock vibrator connector arm 51. This lateral shock action of ~1~~~~' approximately 200 shocks per minute jars air bubbles free from the form cavity bottom 36 instantly and allows them to travel to the surface or the back of the panel 7. As part of this invention it was discovered that 'rotary vibrating action at high RPM's, eg. 10000 RPM and the lateral shock action is extremely effective in a speedy air bubble elimination.
As best shown in Fig. 18, the syphoning bridges 19 and 19A aide in minimizing the undesirable effect of concrete liquids from travelling along the hanger body 12 during vibration and settling in the hanger positioning cavities 40 and 41.
As best shown in Fig. 20, when panels are installed over the building substrate 56 a venting or draining gap 55 is formed, preventing water from accumulating behind the panels.
As best shown in Fig. 21, when installing the next row of panels the arms 17 interlock behind the previously installed row of panels and hold the panels firmly to the building substrate. The spring action of arms 17 have the dual purpose of holding the bottom panel firmly into place and also reducing the risk of over tension which would result in concrete breakout.
As best shown in Fig. 22 a crush zone 60 is formed when two adjoining panels are installed on a house wall.

2i6~~~~
This crush zone 60 absorbs thermal expansion pressures of installed panels without harm to the individual panels and without resulting in compounded expansion.
As best shown in Fig. 22 a V-joint 61 results when 2 adjoining panels 1 are installed. This V-joint along with the caulking shoulders 9 is most conducive to installing a good quality and speedy caulking joint. The caulking shoulders 9 are greatly assisting in guiding the caulking gun tip (not shown), resulting in caulking beads that require no tooling except for minor tooling on V-joint intersections.
Also shown in Fig. 22 is a silica sand coating 58 on the surface of the caulking bead, or flexible grout 59.
This silica sand coating is applied with a mini spray hopper or brush (not shown), the result is a flexible grout seam that is crack resistant and U.V. resistant.
As best shown in Fig. 23, forms 30 can be stacked preferably to a minimum height of 5 feet. In practice, each form located at the bottom is capable of load bearing weight in excess of one ton. A thin watertight membrane 63 is collated between each form and thus serving a triple function of sealing the concrete and preventing thermal shrinkage cracks, preventing the back up panel from warping due to water absorption and protecting the underside of the back-up panel from ~16~~~~
scratches during the demoulding process.
As best shown in Fig. 24, a bottom 65 and a top 64 galvanized J-channel are utilized to assist installation of the panel on a building. The face 67 of these J-channel are coated with silica sand to match other flexible grout seams 59. The bottom J-channel 65 features bottom perforations 66 allowing for air circulation behind the panels and also water is allowed to drain from these holes. Panels installed in the top channel have adequate air spaces and no further perforations are required.
As best shown in Figs. 25 and 26, a multi-layered form demoulder 70 is provided which receives a stacked pallet of full forms 30 between upper movable forks 71 and lower fixed forks 74. The movable forks 71 are lowered and the locking side doors 73 hinged at 72 are firmly locked in place. The lifting mechanism 75 is activated to gain clearance for a 180 degree turn of the rotating back plate 76. This action results in the simultaneous demoulding of a multi-layer stack.
As best shown in Figs. 27 and 28, a tiltable bundle shrink wrapper 80 is part of this invention. Unlike other building panels or tiles, the panels 1 have metal protruding at the top and bottom resulting in an unchallenged difficulty in transporting these panels.

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The device 80 is placed in its tilting position by activating foot pedal 87 which allows the device to tilt.
A locking pin 89 aided by a spring 88 holds the device firmly when tilted.
Panels 1 are loaded against the retention forks 81 on the turntable 83. The stacking guides 82 aid in achieving an orderly bundle. The device is now placed in its level position by simply pulling it forward. The stretch wrap 90 is started as best shown in Fig. 28. The knee switch 85 activates the motor 84 and turns the turntable 83.
As best shown in Figs. 29 to 32, concrete is filled from a continuous concrete source through 92 into the extruder hopper 93. The hopper slides on wheels 91 horizontally. Two augers 94 moves the concrete to the prefill cavity 95. The telescope door 96 is then opened and the concrete falls into the adjustable extruder cavity 97. The telescoping door is then closed again.
The extruder cavity door 99 is actuated by an hydraulic cylinder 98.
Finally, Fig. 31 shows the extrusion of concrete from the cavity 97 into form cavities 35. Upon completion of the vibration and shock vibration step, the concrete is allowed to cure completing a panel.
It will be appreciated that the invention disclosed ~~fi~~~5 above is not in any way limited by the structure described herein and the scope of the invention will be defined by the accompanying claims in which:-

Claims

1. A concrete panel system comprising a plurality of concrete panels arranged in adjacent fashion on a supporting wall, each said panel having:
(a) a panel body having a front surface and a rear surface and a plurality of side edges, at least one said side edge being a bevelled side edge forming an acute angle with said rear surface; and (b) a caulking groove connecting each bevelled side edge with said front surface;
wherein:
(c) the bevelled side edges of adjacent panels form a V-joint therebetween, said V-joint having its apex at the rear surfaces of the adjacent panels; and (d) said panel system further comprises a seam of flexible grout in the V-joint.

2. The concrete panel system of Claim 1, wherein at least one of the bevelled side edges is straight.

3. The concrete panel system of Claim 1, wherein at least one of the bevelled side edges is curvilinear.

4. The concrete panel system of Claim 1, 2, or 3, wherein at least one bevelled side edge of one of the panels is in contact with a corresponding bevelled side edge of an adjacent panel at a crush zone formed in the adjacent panels at the apex of the V-joint therebetween, for absorbing thermal expansion of the panels after installation.

5. The concrete panel system of Claim 1, wherein the flexible grout comprises a urethane caulking material.

6. The concrete panel system of Claim 1, further comprising a coating on the exposed surface of the flexible grout bead, for protecting the flexible grout from ultraviolet light.

7. The concrete panel system of Claim 6, wherein the coating comprises a silica sand.

8. The concrete panel system of Claim 1, wherein each panel includes hanger means for securing the panel to the supporting wall.

9. The concrete panel system of Claim 8, wherein the hanger means comprises a hanger embedded in the panel and projecting from the rear surface thereof.

10. A concrete panel system comprising a plurality of concrete panels arranged in adjacent fashion on a supporting wall, each said panel having:
(a) a panel body having a front surface and a rear surface and a plurality of side edges, at least one said side edge being a bevelled side edge forming an acute angle with said rear surface;
(b) a hanger embedded in the panel and projecting from the rear surface thereof, for securing the panel to the supporting wall; and (c) a caulking groove connecting each bevelled side edge with said front surface;
wherein:
(d) the bevelled side edges of adjacent panels form a V-joint therebetween, said V-joint having its apex at the rear surfaces of the adjacent panels; and (e) at least one bevelled side edge of one of the panels is in contact with a corresponding bevelled side edge of an adjacent panel at a crush zone formed in the adjacent panels at the apex of the V-joint therebetween, for absorbing thermal expansion of the panels after installation;
said panel system further comprising:
(f) a seam of flexible grout in the V-joint;
(g) a bead of flexible grout in the V-joint between adjacent panels; and (h) a coating on the exposed surface of the flexible grout, for protecting the flexible grout from ultraviolet light, said coating comprising a silica sand.