CA2555945A1 - Prefabricated masonry covered structural wall panel - Google Patents
Prefabricated masonry covered structural wall panel Download PDFInfo
- Publication number
- CA2555945A1 CA2555945A1 CA002555945A CA2555945A CA2555945A1 CA 2555945 A1 CA2555945 A1 CA 2555945A1 CA 002555945 A CA002555945 A CA 002555945A CA 2555945 A CA2555945 A CA 2555945A CA 2555945 A1 CA2555945 A1 CA 2555945A1
- Authority
- CA
- Canada
- Prior art keywords
- cladding
- metallic
- exterior side
- wall panel
- framing members
- 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.)
- Abandoned
Links
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/04—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
- E04C2/049—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres completely or partially of insulating material, e.g. cellular concrete or foamed plaster
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
- E04C2/38—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels
- E04C2/384—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels with a metal frame
Abstract
A prefabricated masonry covered structural wall panel is disclosed, comprising a plurality of framing members extending in a parallel relationship to each other and to which are secured metallic skeletal supports. A perforated metallic cladding, attached to the metallic skeletal supports, is covered with a plurality of thin bricks.
The prefabricated panel can be used as an integral structural part of a building structure or in a curtain wall.
The prefabricated panel can be used as an integral structural part of a building structure or in a curtain wall.
Description
PREFABRICATED MASONRY COVERED STRUCTURAL WALL PANEL
FIELD OF THE INVENTION
The present invention relates to the field of building construction, more precisely to prefabricated brick covered wall panels.
s BACKGROUND OF THE INVENTION
To meet deadlines and cope with spatial constraints, the construction industry has introduced prefabricated wall panels supporting pre-installed or shop installed thin brick sections. By prefabricated, it is meant a factory-assembled panel, as opposed to onsite construction. Manufacturers make these panels and these brick to sections directly in the factory, manually or using mechanized equipment.
As the panels and the sections are manufactured in factories, off site, construction workers can spend less time on construction sites, thus offering a solution to the existing construction worker shortage and an improvement to the quality of the prod uct.
is As prefabricated panels are expected to meet specific requirements in terms of thickness, thermal isolation, weathering, lightness and strength, the construction industry is working on the improvement of existing products and fabrication techniques.
Many decorative masonry covered panels can be found in the prior art. The 2o following patents disclose examples of these prior art decorative panels:
US patent no. 2,825,221 (BROOK), US patent no. 4,407,104 (FRANCIS), US patent no.
5,715,637 (HESTERMAN et al.) and US patent no. 6,240,691 (HOLZKAEMPER et al.). In some of these patents, the thin bricks are mounted on a wood surface, on rigid plastic foam insulation surfaces or on sheet metal surfaces affixed to a 2s wooden structure. Among these patents, there are also provided panels made of fireproof components designed to address the need for non-combustible and fire resistant construction. However, these panels are mostly decorative and, as they are made of light components, they are not designed to be part of the building supporting structure.
US patent no. 6,412,244 (NOLAN) discloses a prefabricated modular wall element s comprising a precast reinforced concrete wall panel having a front face partially embedding a plurality of spaced-apart individual slabs of stone or brick. A
pair of spaced-apart support legs is provided at a bottom of the wall panel for keying into a concrete foundation to support the wall element.
US patent no. 4,642,960 (WALLOVER) also discloses a panel, which is a to structural supporting element in a building construction. WALLOVER provides a panel including a plurality of support members or studs preferably formed by metal channels and a five-strand layer wire mesh. The wire mesh is encapsulated with cement to form a ferrocement panel and decorative facing tiles are secured to an outer face of the ferrocement panel by a layer of grouting. The ferrocement panel is provides the structural load bearing component for the prefabricated panel for supporting the facing tiles and eliminates the need for a separate substrate which heretofore spanned the support members and provided the structural support.
One drawback with these last two panels, which use cement in their structural part, is that the preparation and transportation of cement may involve several Zo constraints, for example, there is always a risk that the panel crack and break during transportation or installation. Cemented panels are also generally heavy components.
Therefore, there is still a need for a prefabricated masonry covered wall panel which can be used as a decorative element of the building as well as a structural Zs element thereof, and which does not present the drawbacks of cement panels.
FIELD OF THE INVENTION
The present invention relates to the field of building construction, more precisely to prefabricated brick covered wall panels.
s BACKGROUND OF THE INVENTION
To meet deadlines and cope with spatial constraints, the construction industry has introduced prefabricated wall panels supporting pre-installed or shop installed thin brick sections. By prefabricated, it is meant a factory-assembled panel, as opposed to onsite construction. Manufacturers make these panels and these brick to sections directly in the factory, manually or using mechanized equipment.
As the panels and the sections are manufactured in factories, off site, construction workers can spend less time on construction sites, thus offering a solution to the existing construction worker shortage and an improvement to the quality of the prod uct.
is As prefabricated panels are expected to meet specific requirements in terms of thickness, thermal isolation, weathering, lightness and strength, the construction industry is working on the improvement of existing products and fabrication techniques.
Many decorative masonry covered panels can be found in the prior art. The 2o following patents disclose examples of these prior art decorative panels:
US patent no. 2,825,221 (BROOK), US patent no. 4,407,104 (FRANCIS), US patent no.
5,715,637 (HESTERMAN et al.) and US patent no. 6,240,691 (HOLZKAEMPER et al.). In some of these patents, the thin bricks are mounted on a wood surface, on rigid plastic foam insulation surfaces or on sheet metal surfaces affixed to a 2s wooden structure. Among these patents, there are also provided panels made of fireproof components designed to address the need for non-combustible and fire resistant construction. However, these panels are mostly decorative and, as they are made of light components, they are not designed to be part of the building supporting structure.
US patent no. 6,412,244 (NOLAN) discloses a prefabricated modular wall element s comprising a precast reinforced concrete wall panel having a front face partially embedding a plurality of spaced-apart individual slabs of stone or brick. A
pair of spaced-apart support legs is provided at a bottom of the wall panel for keying into a concrete foundation to support the wall element.
US patent no. 4,642,960 (WALLOVER) also discloses a panel, which is a to structural supporting element in a building construction. WALLOVER provides a panel including a plurality of support members or studs preferably formed by metal channels and a five-strand layer wire mesh. The wire mesh is encapsulated with cement to form a ferrocement panel and decorative facing tiles are secured to an outer face of the ferrocement panel by a layer of grouting. The ferrocement panel is provides the structural load bearing component for the prefabricated panel for supporting the facing tiles and eliminates the need for a separate substrate which heretofore spanned the support members and provided the structural support.
One drawback with these last two panels, which use cement in their structural part, is that the preparation and transportation of cement may involve several Zo constraints, for example, there is always a risk that the panel crack and break during transportation or installation. Cemented panels are also generally heavy components.
Therefore, there is still a need for a prefabricated masonry covered wall panel which can be used as a decorative element of the building as well as a structural Zs element thereof, and which does not present the drawbacks of cement panels.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a prefabricated masonry covered structural wall panel fulfilling the above-mentioned need.
According to one aspect of the present invention, that object is achieved with a s prefabricated wall panel, comprising a plurality of structural framing members extending in a substantially parallel relationship to each other. At least one metallic skeletal support has an interior side secured to an exterior side of the framing members. A perforated metallic cladding is attached to an exterior side of the at least one metallic skeletal support and a plurality of thin bricks are secured to an io exterior side of the cladding. The thin bricks are covering the exterior side of the cladding in a predetermined pattern.
By prefabricated panel, it is meant that the panel is manufactured in advance, especially in standard sections that can be easily shipped and assembled, as opposed to onsite construction.
is By structural framing member, it is meant a load-bearing framing member or a framing member that can bear load in a building, as opposed to a framing member used in a solely decorative assembly. As such, the structural framing members as used in the present description also include framing members used in curtain wall assembly.
2o According to another aspect of the invention, there is also provided a method for manufacturing a prefabricated masonry covered structural wall panel including the steps of:
a) providing a plurality of framing members and extending the same in a substantially parallel relationship to each other, each of the framing 2s members having an interior side opposed to an exterior side;
It is an object of the present invention to provide a prefabricated masonry covered structural wall panel fulfilling the above-mentioned need.
According to one aspect of the present invention, that object is achieved with a s prefabricated wall panel, comprising a plurality of structural framing members extending in a substantially parallel relationship to each other. At least one metallic skeletal support has an interior side secured to an exterior side of the framing members. A perforated metallic cladding is attached to an exterior side of the at least one metallic skeletal support and a plurality of thin bricks are secured to an io exterior side of the cladding. The thin bricks are covering the exterior side of the cladding in a predetermined pattern.
By prefabricated panel, it is meant that the panel is manufactured in advance, especially in standard sections that can be easily shipped and assembled, as opposed to onsite construction.
is By structural framing member, it is meant a load-bearing framing member or a framing member that can bear load in a building, as opposed to a framing member used in a solely decorative assembly. As such, the structural framing members as used in the present description also include framing members used in curtain wall assembly.
2o According to another aspect of the invention, there is also provided a method for manufacturing a prefabricated masonry covered structural wall panel including the steps of:
a) providing a plurality of framing members and extending the same in a substantially parallel relationship to each other, each of the framing 2s members having an interior side opposed to an exterior side;
b) providing at least one metallic skeletal support having an interior side and an exterior side, and securing the interior side of the at least one metallic skeletal support to the exterior side of the framing members;
c) securing a perforated metallic cladding to the exterior side of the at least one s metallic skeletal support, the perforated metallic cladding having an interior side and an exterior side; and d) securing a plurality of thin bricks to the exterior side of the cladding for covering the exterior side of the cladding with the bricks in a predetermined pattern.
1o One advantageous feature of the present invention is that the prefabricated panel forms a structural wall section that can be integrated in the building construction structure, as a component of the supporting structure. This panel is also easy to transport and install, as it is less likely to crack, than the corresponding cemented portion in the cement-made panels of the prior art.
is Another advantageous feature of the present invention is that it provides a solution to evacuate the water stagnating between the layer of brick and its skeletal support. Indeed, thanks to the perforations in the support of the cladding, water that may seep through the layer of brick exits through the perforations and is then evacuated out of the building facade.
2o Also thanks to the fact that the panel is shop-assembled, the masonry work is greatly simplified. Indeed, the installation of the bricks can be done while the metallic support and cladding are laid flat on a horizontal surface. This reduces the risks that the bricks unstuck and facilitates the work of the mason.
Furthermore, when the framing members are made of metal, the panels of the 2s invention also have the advantage of being considered incombustible.
Other features and advantages of the present invention will be better understood upon reading preferred embodiments thereof with reference to the appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
s FIG. 1 is a perspective view showing the construction of a building using prefabricated panels according to a preferred embodiment of the invention.
FIG. 2 is a cross-sectional view of the prefabricated panel shown in figure 1.
DESCRIPTION OF A PREFERRED EMBODIMENT OF THE INVENTION
Referring to FIG. 1, the construction of a building using prefabricated wall panels to (10) according to a preferred embodiment of the invention is shown. As can be appreciated, the panels (10) are shipped from the shop to the site of construction where they are lifted vertically by means of a crane (40) and placed side-by-side along with foundations (60) initially built in the ground for receiving the panels.
Prior to the shipment of the panels (10), I-beams (50), joists (52) and columns (54) is are assembled to form the framework of the building. When the panels (10) are shipped to the site of construction, they are placed adjacently and secured to the structure (50, 52 and/or 54). As can be appreciated from FIG. 1, a prefabricated masonry panel (10) according to the invention can be used in a building structure such as a multi-stories residential or commercial building as an element of the 2o structure of the building. It is however worth mentioning that the wall panels can still be used as a curtain wall to be affixed to a pre-existing building structure. The panels (10) according to the present invention can also be used in combination with other type of wall panels (11 ), such as corrugated metal sheet.
Turning now to FIG. 2, the wall panel (10) comprises a plurality of structural 2s framing members (16), two of these are illustrated in FIG. 2. The number of framing members (16) in a panel (10) depends on the width of the panel to be manufactured. As apparent to any person in the art, the wider the panel, the greater is the number of framing members to be used. The panel (10) also comprises at feast one metallic skeletal support (20) secured to the framing members (16) and a perforated metallic cladding (14) attached to the skeletal s support (20). The cladding (14) is covered with a plurality of thin bricks (24). Each of these components of the panel (10) will now be described in more detail.
The framing members (16) extend in a substantially parallel relationship to each other, and when the panel (10) is installed, they are extending in a vertical direction. They are preferably made of metal. In such a case, they are particularly io advantageous for use in non-combustible and fire-resistant constructions.
Any metallic upright posts such as studs or columns of hot-rolled structural steel can be used for the framing members (16).
The at least one metallic skeletal support (20) preferably consists of vertical bars having a generally Z-shaped cross section. In the embodiment illustrated, each is skeletal support (20) is associated with a respective framing member (16), and has an interior side secured to an exterior side of the framing members (16) by means of mechanical fasteners. It is worth mentioning that interior side and exterior side both refer respectively to the inside and outside of the building. The mechanical fasteners are screws (30) or bolts. In another embodiment of the invention, not 2o illustrated, the at least one metallic skeletal support (20) comprises a corrugated metallic sheet with the corrugations extending in a vertical direction. In that particular case, the bottom of some grooves of the corrugated metallic sheet is secured to a respective framing member (16) by means of mechanical fasteners such as screws or bolts. By metallic skeletal supports, it is meant supports capable 2s of supporting the load of the layer of brick. In another embodiment, not illustrated, and used mainly in residential and commercial constructions, the skeletal support is made of metal tracts and furring.
Although not clearly illustrated in the figures, the perforated metallic cladding (14) is attached to the exterior side of the metallic skeletal supports (20) by means of mechanical fasteners such as screws or bolts. The cladding (14) is preferably pre-painted and has a thickness of about 20 ga.
s The thin bricks (24) are secured to the exterior side of the cladding (14) and cover the same in a predetermined pattern. The thin bricks (24) are secured to the cladding (14) by means of a glue layer (25) which fills at least a portion of the perforations of the cladding (14) and forms protuberances (26) that project on the interior side of the cladding (14), thereby opposing a mechanical resistance to a to detachment of the glue layer (25). Since the panel (10) is completely assembled in shop, the installation of the thin bricks (24) can be performed while the cladding (14) is laid flat on a horizontal surface. This reduces the risks that the bricks unstuck and facilitates the work of the mason. As for conventional brick walls, the spaces between the bricks (24) can be filled with mortar that advantageously can is match the colour of the bricks (24). This filling step is also greatly facilitated by the fact that it is performed while the cladding (20) is laid flat.
The thin bricks (24) preferably have a thickness of about %2 inch and are made of clay or any other appropriate material such as concrete. It is understood that the term "brick" may also refer to stones of various kinds used on the facade of 2o buildings. Although the bricks (24) shown in the illustrated embodiment have a traditional rectangular shape, it is understood that the present invention could make use of bricks of any shape as may be selected to obtain a particular visual appearance of the finished building. It is also understood that the bricks of a same panel do not need to be all of the same shape or appearance.
2s The panel (10) with the framing members (16), the metallic skeletal support (20) and the perforated metallic cladding (14) covered with the bricks form a metallic support or wall section meant to be an integral part of the building structure capable of supporting structural elements, for example roofs, floors, etc. The panel (10) is integrated in the building construction structure, as a component of the supporting structure. 1n a preferred embodiment, a plurality of such panels (10) is installed side-by-side in order to form a visually continuous facade. It will be understood by a person skilled in the art that various techniques may be used in s order to ensure visual continuity at the joints between neighbouring panels.
These panels (10) can also be used in combination with other types of prefabricated wall panels, for example with panels having an outer finish made of corrugated metal sheets.
Still referring to FIG. 2, a water resistant support sheet (18), or substratum and a io rigid insulating layer (32) are preferably provided between the framing members (16) and metallic skeletal support (20).
It is worth mentioning that if the panel is to be used as a curtain wall panel, it is composed of lighter components capable of structurally supporting the weight of the panel and securing the same to the pre-existing structure of the building.
The is panels are then installed on site according to the desired architectural result.
The perforated metallic cladding (14) provides a solution to evacuate the water stagnating between the layer of brick and its skeletal support. Water that may seep through the layer of brick exits through the perforations and is then evacuated out of the building facade.
2o A panel according to the invention is manufactured according to the following method which comprises the steps of:
a) providing a plurality of framing members (16) and extending the same in a substantially parallel relationship to each other, b) securing at least one metallic skeletal support (20) to an exterior side of the 2s framing members (16), preferably by means of mechanical fasteners such as screws or nuts;
c) optionally, extending a water resistant layer (18) between the framing members and the metallic skeletal support (20);
d) securing a preferably pre-painted perforated metallic cladding (14) to the exterior side of the metallic skeletal support (20);
s e) optionally, extending a rigid insulating layer (32) between the water resistant layer (18) and the perforated metallic cladding (14);
f) securing a plurality of thin bricks (24) to an exterior side of the cladding (14), preferably by laying a glue layer on the exterior side of the cladding (14), for covering the exterior side of the cladding with the bricks in a predetermined io pattern; and g) preferably filling at least a portion of the perforations of the cladding (14) and forming protuberances that project on the interior side of the cladding (14), thereby opposing a mechanical resistance to a detachment of the glue layer.
is Although a preferred embodiment of the present invention has been described in detail herein and illustrated in the accompanying drawings, it is to be understood that the invention is not limited to this precise embodiment and that various changes and modifications may be effected therein without departing from the scope or spirit of the present invention.
c) securing a perforated metallic cladding to the exterior side of the at least one s metallic skeletal support, the perforated metallic cladding having an interior side and an exterior side; and d) securing a plurality of thin bricks to the exterior side of the cladding for covering the exterior side of the cladding with the bricks in a predetermined pattern.
1o One advantageous feature of the present invention is that the prefabricated panel forms a structural wall section that can be integrated in the building construction structure, as a component of the supporting structure. This panel is also easy to transport and install, as it is less likely to crack, than the corresponding cemented portion in the cement-made panels of the prior art.
is Another advantageous feature of the present invention is that it provides a solution to evacuate the water stagnating between the layer of brick and its skeletal support. Indeed, thanks to the perforations in the support of the cladding, water that may seep through the layer of brick exits through the perforations and is then evacuated out of the building facade.
2o Also thanks to the fact that the panel is shop-assembled, the masonry work is greatly simplified. Indeed, the installation of the bricks can be done while the metallic support and cladding are laid flat on a horizontal surface. This reduces the risks that the bricks unstuck and facilitates the work of the mason.
Furthermore, when the framing members are made of metal, the panels of the 2s invention also have the advantage of being considered incombustible.
Other features and advantages of the present invention will be better understood upon reading preferred embodiments thereof with reference to the appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
s FIG. 1 is a perspective view showing the construction of a building using prefabricated panels according to a preferred embodiment of the invention.
FIG. 2 is a cross-sectional view of the prefabricated panel shown in figure 1.
DESCRIPTION OF A PREFERRED EMBODIMENT OF THE INVENTION
Referring to FIG. 1, the construction of a building using prefabricated wall panels to (10) according to a preferred embodiment of the invention is shown. As can be appreciated, the panels (10) are shipped from the shop to the site of construction where they are lifted vertically by means of a crane (40) and placed side-by-side along with foundations (60) initially built in the ground for receiving the panels.
Prior to the shipment of the panels (10), I-beams (50), joists (52) and columns (54) is are assembled to form the framework of the building. When the panels (10) are shipped to the site of construction, they are placed adjacently and secured to the structure (50, 52 and/or 54). As can be appreciated from FIG. 1, a prefabricated masonry panel (10) according to the invention can be used in a building structure such as a multi-stories residential or commercial building as an element of the 2o structure of the building. It is however worth mentioning that the wall panels can still be used as a curtain wall to be affixed to a pre-existing building structure. The panels (10) according to the present invention can also be used in combination with other type of wall panels (11 ), such as corrugated metal sheet.
Turning now to FIG. 2, the wall panel (10) comprises a plurality of structural 2s framing members (16), two of these are illustrated in FIG. 2. The number of framing members (16) in a panel (10) depends on the width of the panel to be manufactured. As apparent to any person in the art, the wider the panel, the greater is the number of framing members to be used. The panel (10) also comprises at feast one metallic skeletal support (20) secured to the framing members (16) and a perforated metallic cladding (14) attached to the skeletal s support (20). The cladding (14) is covered with a plurality of thin bricks (24). Each of these components of the panel (10) will now be described in more detail.
The framing members (16) extend in a substantially parallel relationship to each other, and when the panel (10) is installed, they are extending in a vertical direction. They are preferably made of metal. In such a case, they are particularly io advantageous for use in non-combustible and fire-resistant constructions.
Any metallic upright posts such as studs or columns of hot-rolled structural steel can be used for the framing members (16).
The at least one metallic skeletal support (20) preferably consists of vertical bars having a generally Z-shaped cross section. In the embodiment illustrated, each is skeletal support (20) is associated with a respective framing member (16), and has an interior side secured to an exterior side of the framing members (16) by means of mechanical fasteners. It is worth mentioning that interior side and exterior side both refer respectively to the inside and outside of the building. The mechanical fasteners are screws (30) or bolts. In another embodiment of the invention, not 2o illustrated, the at least one metallic skeletal support (20) comprises a corrugated metallic sheet with the corrugations extending in a vertical direction. In that particular case, the bottom of some grooves of the corrugated metallic sheet is secured to a respective framing member (16) by means of mechanical fasteners such as screws or bolts. By metallic skeletal supports, it is meant supports capable 2s of supporting the load of the layer of brick. In another embodiment, not illustrated, and used mainly in residential and commercial constructions, the skeletal support is made of metal tracts and furring.
Although not clearly illustrated in the figures, the perforated metallic cladding (14) is attached to the exterior side of the metallic skeletal supports (20) by means of mechanical fasteners such as screws or bolts. The cladding (14) is preferably pre-painted and has a thickness of about 20 ga.
s The thin bricks (24) are secured to the exterior side of the cladding (14) and cover the same in a predetermined pattern. The thin bricks (24) are secured to the cladding (14) by means of a glue layer (25) which fills at least a portion of the perforations of the cladding (14) and forms protuberances (26) that project on the interior side of the cladding (14), thereby opposing a mechanical resistance to a to detachment of the glue layer (25). Since the panel (10) is completely assembled in shop, the installation of the thin bricks (24) can be performed while the cladding (14) is laid flat on a horizontal surface. This reduces the risks that the bricks unstuck and facilitates the work of the mason. As for conventional brick walls, the spaces between the bricks (24) can be filled with mortar that advantageously can is match the colour of the bricks (24). This filling step is also greatly facilitated by the fact that it is performed while the cladding (20) is laid flat.
The thin bricks (24) preferably have a thickness of about %2 inch and are made of clay or any other appropriate material such as concrete. It is understood that the term "brick" may also refer to stones of various kinds used on the facade of 2o buildings. Although the bricks (24) shown in the illustrated embodiment have a traditional rectangular shape, it is understood that the present invention could make use of bricks of any shape as may be selected to obtain a particular visual appearance of the finished building. It is also understood that the bricks of a same panel do not need to be all of the same shape or appearance.
2s The panel (10) with the framing members (16), the metallic skeletal support (20) and the perforated metallic cladding (14) covered with the bricks form a metallic support or wall section meant to be an integral part of the building structure capable of supporting structural elements, for example roofs, floors, etc. The panel (10) is integrated in the building construction structure, as a component of the supporting structure. 1n a preferred embodiment, a plurality of such panels (10) is installed side-by-side in order to form a visually continuous facade. It will be understood by a person skilled in the art that various techniques may be used in s order to ensure visual continuity at the joints between neighbouring panels.
These panels (10) can also be used in combination with other types of prefabricated wall panels, for example with panels having an outer finish made of corrugated metal sheets.
Still referring to FIG. 2, a water resistant support sheet (18), or substratum and a io rigid insulating layer (32) are preferably provided between the framing members (16) and metallic skeletal support (20).
It is worth mentioning that if the panel is to be used as a curtain wall panel, it is composed of lighter components capable of structurally supporting the weight of the panel and securing the same to the pre-existing structure of the building.
The is panels are then installed on site according to the desired architectural result.
The perforated metallic cladding (14) provides a solution to evacuate the water stagnating between the layer of brick and its skeletal support. Water that may seep through the layer of brick exits through the perforations and is then evacuated out of the building facade.
2o A panel according to the invention is manufactured according to the following method which comprises the steps of:
a) providing a plurality of framing members (16) and extending the same in a substantially parallel relationship to each other, b) securing at least one metallic skeletal support (20) to an exterior side of the 2s framing members (16), preferably by means of mechanical fasteners such as screws or nuts;
c) optionally, extending a water resistant layer (18) between the framing members and the metallic skeletal support (20);
d) securing a preferably pre-painted perforated metallic cladding (14) to the exterior side of the metallic skeletal support (20);
s e) optionally, extending a rigid insulating layer (32) between the water resistant layer (18) and the perforated metallic cladding (14);
f) securing a plurality of thin bricks (24) to an exterior side of the cladding (14), preferably by laying a glue layer on the exterior side of the cladding (14), for covering the exterior side of the cladding with the bricks in a predetermined io pattern; and g) preferably filling at least a portion of the perforations of the cladding (14) and forming protuberances that project on the interior side of the cladding (14), thereby opposing a mechanical resistance to a detachment of the glue layer.
is Although a preferred embodiment of the present invention has been described in detail herein and illustrated in the accompanying drawings, it is to be understood that the invention is not limited to this precise embodiment and that various changes and modifications may be effected therein without departing from the scope or spirit of the present invention.
Claims (16)
1. A prefabricated masonry covered structural wall panel, comprising:
- a plurality of structural framing members extending in a substantially parallel relationship to each other, each of said framing members having an interior side opposed to an exterior side;
- at least one metallic skeletal support having an interior side and an exterior side, the interior side of said at least one metallic skeletal support being secured to the exterior side of the framing members;
a perforated metallic cladding attached to the exterior side of the at least one metallic skeletal support, said perforated metallic cladding having an interior side and an exterior side; and - a plurality of thin bricks being secured to the exterior side of the cladding, and covering said exterior side of the cladding in a predetermined pattern.
- a plurality of structural framing members extending in a substantially parallel relationship to each other, each of said framing members having an interior side opposed to an exterior side;
- at least one metallic skeletal support having an interior side and an exterior side, the interior side of said at least one metallic skeletal support being secured to the exterior side of the framing members;
a perforated metallic cladding attached to the exterior side of the at least one metallic skeletal support, said perforated metallic cladding having an interior side and an exterior side; and - a plurality of thin bricks being secured to the exterior side of the cladding, and covering said exterior side of the cladding in a predetermined pattern.
2. The prefabricated wall panel according to claim 1, comprising a plurality of said metallic skeletal supports each including a vertical bar having a generally Z-shaped cross section.
3. The prefabricated wall panel according to claim 1, wherein the at least one metallic skeletal support comprises a corrugated metallic sheet.
4. The prefabricated wall panel according to claim 1, wherein the interior side of the at least one metallic skeletal support is secured to the exterior side of the framing members by means of mechanical fasteners selected from the group consisting of screws and nuts.
5. The prefabricated wall panel according to claim 1, wherein the plurality of thin bricks is secured to said cladding by means of a glue layer laid on the exterior side of the cladding.
6. The prefabricated wall panel according to claim 5, wherein the glue layer fills at least a portion of the perforations of said cladding and forms protuberances that project on the interior side of the cladding, thereby opposing a mechanical resistance to a detachment of the glue layer.
7. The prefabricated wall panel according to claim 1, wherein the cladding is attached to the exterior side of the at least one metallic skeletal support by means of mechanical fasteners selected from the group consisting of screws and nuts.
8 The prefabricated wall panel according to claim 1, wherein the perforated metallic cladding has a thickness of about 20 ga.
9. The prefabricated wall panel according to claim 1, further comprising a water resistant layer extending between the exterior side of the framing members and the interior side of the at least one metallic skeletal support.
10. The prefabricated wall panel according to claim 9, further comprising a rigid insulating layer extending between the water resistant layer and the perforated metallic cladding.
11. A method for manufacturing a prefabricated masonry covered structural wall panel including the steps of:
a) providing a plurality of structural framing members extending in a substantially parallel relationship to each other, each of said framing members having an interior side opposed to an exterior side;
b) providing at least one metallic skeletal support having an interior side and an exterior side, and securing the interior side of the at least one metallic skeletal support to the exterior side of the framing members;
c) securing a perforated metallic cladding to the exterior side of the at least one metallic skeletal support, said perforated metallic cladding having an interior side and an exterior side; and
a) providing a plurality of structural framing members extending in a substantially parallel relationship to each other, each of said framing members having an interior side opposed to an exterior side;
b) providing at least one metallic skeletal support having an interior side and an exterior side, and securing the interior side of the at least one metallic skeletal support to the exterior side of the framing members;
c) securing a perforated metallic cladding to the exterior side of the at least one metallic skeletal support, said perforated metallic cladding having an interior side and an exterior side; and
12 d) securing a plurality of thin bricks to the exterior side of said cladding for covering the exterior side of the cladding with said bricks in a predetermined pattern.
12. The method according to claim 11, comprising the step of securing the interior side of the at least one metallic skeletal support to the exterior side of the framing members by means of mechanical fasteners selected from the group consisting of screws and nuts.
12. The method according to claim 11, comprising the step of securing the interior side of the at least one metallic skeletal support to the exterior side of the framing members by means of mechanical fasteners selected from the group consisting of screws and nuts.
13. The method according to claim 12, comprising the step of securing the plurality of thin bricks to said cladding by laying a glue layer on the exterior side of the cladding.
14. The method according to claim 13, comprising the step of filling at least a portion of the perforations of said cladding and forming protuberances that project on the interior side of the cladding, thereby opposing a mechanical resistance to a detachment of the glue layer.
15. The method according to claim 11, comprising the step of extending a water resistant layer between the exterior side of the framing members and the interior side of the at feast one metallic skeletal support.
16. The method according to claim 15, comprising the step of extending a rigid insulating layer between the water resistant layer and the perforated metallic cladding.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US70718105P | 2005-08-11 | 2005-08-11 | |
| US60/707,181 | 2005-08-11 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2555945A1 true CA2555945A1 (en) | 2007-02-11 |
Family
ID=37744722
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002555945A Abandoned CA2555945A1 (en) | 2005-08-11 | 2006-08-09 | Prefabricated masonry covered structural wall panel |
Country Status (2)
| Country | Link |
|---|---|
| US (1) | US20070039265A1 (en) |
| CA (1) | CA2555945A1 (en) |
Families Citing this family (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US20050210811A1 (en) * | 2004-02-17 | 2005-09-29 | Nasvik Paul C | Precast concrete veneer panel system |
| US20090188180A1 (en) * | 2008-01-29 | 2009-07-30 | Cmi Limited Company | Integrated wall system |
| US20100185249A1 (en) * | 2009-01-22 | 2010-07-22 | Wingeier Brett M | Method and Devices for Adrenal Stimulation |
| US8419317B2 (en) * | 2009-05-12 | 2013-04-16 | Cmi Limited Company | System and method for installing sheet piles |
| US9556619B2 (en) * | 2011-10-21 | 2017-01-31 | Old Mill Brick Incorporated | Fiber enforced thin brick sheet and process |
| NZ630423A (en) | 2014-07-14 | 2016-04-29 | Illinois Tool Works | Improvements relating to lifting of building units |
| WO2017074425A1 (en) * | 2015-10-30 | 2017-05-04 | Boral Ip Holdings (Australia) Pty Limited | Wall panel with rain screen |
| CN106760157A (en) * | 2016-12-14 | 2017-05-31 | 浙江远成精工科技有限公司 | A kind of improved fireproof heat-preservation sandwich board |
Family Cites Families (30)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US2825221A (en) * | 1952-12-18 | 1958-03-04 | Brouk Joseph John | Wall embodying masonry panels |
| US3533206A (en) * | 1968-07-16 | 1970-10-13 | James K Passeno Jr | Building block holder for fabricating veneer walls |
| US3660214A (en) * | 1969-04-21 | 1972-05-02 | Merry Co Inc | Concrete block or the like with multiple brick facing and method of making the same |
| US3654742A (en) * | 1970-01-26 | 1972-04-11 | John A Wilnau | Method of forming a concrete building component |
| US3646715A (en) * | 1970-04-06 | 1972-03-07 | Du Pont Canada | Prefabricated building panel |
| US3701228A (en) * | 1970-07-23 | 1972-10-31 | Frank Taylor | Decorative wall facing |
| US3621625A (en) * | 1970-08-17 | 1971-11-23 | Robert S Medow | Brick siding |
| US3775916A (en) * | 1972-03-20 | 1973-12-04 | Dev Co America | Prefabricated wall panel |
| US3882218A (en) * | 1973-07-11 | 1975-05-06 | Jr Charles G Bixel | Brick textured building panels and their method of manufacture and installation |
| US4031682A (en) * | 1975-04-14 | 1977-06-28 | Metropolitan Industries | Prefabricated building panel and method of making |
| US3965635A (en) * | 1975-04-14 | 1976-06-29 | Metropolitan Industries, Inc. | Prefabricated building panel and method of making |
| US4011702A (en) * | 1975-04-18 | 1977-03-15 | Matyas Andrew M | Building wall constructions |
| US4235054A (en) * | 1977-11-14 | 1980-11-25 | Angeles Metal Trim Co. | Building wall structure |
| US4407104A (en) * | 1980-10-02 | 1983-10-04 | Francis Gerald T | Brick panel insulation with load bearing clip |
| US4589241A (en) * | 1983-09-29 | 1986-05-20 | American Siding Discount Distributor, Inc. | Wall construction |
| US4642960A (en) * | 1984-12-12 | 1987-02-17 | Wallover Iii Edwin M | Prefabricated building panel and method of making the same |
| US4912902A (en) * | 1986-07-14 | 1990-04-03 | Weaver Elvin W | Simulated brick covering and wall construction |
| US4920716A (en) * | 1988-06-09 | 1990-05-01 | Coffey Jess R | Veneer construction and method of achieving same |
| US5501049A (en) * | 1992-09-28 | 1996-03-26 | Francis; Steven R. | Thin brick panel assembly |
| US5787666A (en) * | 1994-12-23 | 1998-08-04 | Sherry; Edward B. | Thin masonry veneer panel system and the fabrication thereof |
| US5715637A (en) * | 1995-04-27 | 1998-02-10 | Pan-Brick, Inc. | Prefabricated composite building panel with improved fire retardancy |
| CA2206671C (en) * | 1996-06-21 | 2000-02-15 | Rolf C. Holzkaemper | Prefabricated composite building panel |
| DE69931439T2 (en) * | 1998-09-03 | 2006-12-28 | Nolan, Edward, Ballysax | Modular wall element |
| US7121051B2 (en) * | 2001-02-12 | 2006-10-17 | Garrick Hunsaker | Panel for thin bricks and related systems and methods of use |
| EP1273729A3 (en) * | 2001-07-02 | 2003-12-03 | Carmine Franco Valente | Element of brick material for making prefabricated panels for the construction industry |
| US6701683B2 (en) * | 2002-03-06 | 2004-03-09 | Oldcastle Precast, Inc. | Method and apparatus for a composite concrete panel with transversely oriented carbon fiber reinforcement |
| US6898908B2 (en) * | 2002-03-06 | 2005-05-31 | Oldcastle Precast, Inc. | Insulative concrete building panel with carbon fiber and steel reinforcement |
| US6951086B2 (en) * | 2002-05-20 | 2005-10-04 | James Kenneth Passeno | Method and apparatus for making thin brick wall facing |
| CA2400122A1 (en) * | 2002-08-28 | 2004-02-28 | Paul Baillargeon | Prefabricated thin wall concrete panel |
| CA2433505A1 (en) * | 2003-06-24 | 2004-12-25 | John Mcgrath | Rock facade panel and methods of manufacturing a rock facade panel |
-
2006
- 2006-08-09 CA CA002555945A patent/CA2555945A1/en not_active Abandoned
- 2006-08-09 US US11/502,068 patent/US20070039265A1/en not_active Abandoned
Also Published As
| Publication number | Publication date |
|---|---|
| US20070039265A1 (en) | 2007-02-22 |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| US5697189A (en) | Lightweight insulated concrete wall | |
| US20080196349A1 (en) | Connected structural panels for buildings | |
| US20070039265A1 (en) | Prefabricated masonry covered structural wall panel | |
| CA2888614A1 (en) | Methods, systems and components for multi-storey building construction | |
| US6405509B1 (en) | Lightweight structural element, especially for building construction, and construction technique thereon | |
| IES20060907A2 (en) | Construction of buildings | |
| EP2175088B1 (en) | Method of installation on site of a prefabricated semi-resistant module for construction | |
| WO2002066757A1 (en) | A load bearing building panel | |
| KR101361959B1 (en) | A modular cell block through the integration of interior and exterior finishing materials and its construction method using modular cell blocks | |
| US20080295430A1 (en) | Thin shell cementitious coated shear wall structural panel assembly and method of manufacture | |
| ZA200901736B (en) | Improved construction system for buildings | |
| JP2022505592A (en) | Underground modular assembly | |
| US7700024B1 (en) | Corrugated concrete wall panel form and method of construction thereof | |
| CN110593397A (en) | Multilayer assembled plate type building | |
| CN110593449A (en) | Assembly type light vertical bar plate type bearing wall structure and construction method thereof | |
| US20080196336A1 (en) | Fiber reinforced concrete exterior wall system | |
| US20080196354A1 (en) | Fiber Reinforced Concrete Exterior Wall System | |
| US4227357A (en) | Construction blocks | |
| CN211200814U (en) | Assembled light vertical bar plate type bearing wall structure | |
| CN211200692U (en) | Multilayer assembled plate type building | |
| AU2014265071B2 (en) | A building and methods of constructing the building | |
| WO2000047836A1 (en) | Wall construction system | |
| AU2015100472A4 (en) | Constructions having solid load bearing walls | |
| RU2609035C2 (en) | Carcass unit for modular construction of buildings and system of such blocks | |
| AU750020B3 (en) | A load bearing building panel |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| FZDE | Discontinued |