EP3875705B1

EP3875705B1 - Method for cladding a wall with stone strips and impression mould and stone strips applied thereby

Info

Publication number: EP3875705B1
Application number: EP21154924.1A
Authority: EP
Inventors: Dimitri Anna A Vervaet
Original assignee: Individual
Current assignee: Individual
Priority date: 2020-03-03
Filing date: 2021-02-03
Publication date: 2023-06-07
Anticipated expiration: 2041-02-03
Also published as: BE1028120A1; BE1028120B1; EP3875705C0; EP3875705A1; BE1028120A9

Description

The present invention relates to a method for cladding a wall with stone strips.
Stone strips are herein understood to mean strips of all types of materials such as, but not restricted to, concrete, epoxy, natural stone, brickstone or cement.
The mounting of stone strips on various foundations in a traditional method is already known.
The application for mounting stone strips on various building boards to realise a wooden or metal framing wall is already known.
Mounting stone strips on insulation panels and a mesh to reinforce it is also a known method.
It is known hereby for example that the wall is first provided with a layer of plaster in which the stone strips are pressed in a condition in which the layer of plaster is still wet. After curing of the layer of plaster the stone strips are secured on the wall and the joints between the stone strips can be pointed.
Such a method is known from US 8.966.845 and from FR 2.230.829 .
The traditional gluing of stone strips has several disadvantages, i.e. the stone strips may still sag in the wet layer of plaster under their own weight, such that the joints between the stone strips located above each other are not straight, leaving a messy impression.
Furthermore, said method is relatively labour-intensive for levelling the stone strips in horizontal rows and requires an execution by experienced professionals.
Another already known technique to simplify the aforementioned works consists of applying pre-formed or milled insulation panels which are part of an ETICS (external thermal insulation composite system) insulation system. Said insulation panels are attached with one side against the wall and on the opposite side are provided with parallel ribs which are milled or pressed into the insulating material of the insulation panels, whereby said ribs are intended for aligning the stone strips glued between them.
A disadvantage of said known method for cladding the wall with stone strips is that the insulation panels are relatively expensive because they must be provided with extra ribs and the fact that, in the case of ribs milled from the insulating material, a lot of material is lost.
Another disadvantage of said insulation panels with ribs, is that the ribs are relatively vulnerable when applying the stone strips and that said ribs furthermore make it impossible to mount a reinforcement mesh to prevent tears in the wall.
It is known from WO2017/069802 to fix a pre-manufactured board to a wall, the board comprising an insulating layer and a plaster with ribs. Stone strips are then fixed with mortar between the ribs and the joints are grouted.
It is known from KR 102.035.221 to use impression jigs to provide decorative effects on the plaster surface.
It is known from FR 2.230.829 to press a set of tiles into wet mortar.
The purpose of the present invention is to provide a solution to the aforementioned and other disadvantages.
To this end the present invention, which is defined by the appended claims, relates to a method for cladding a wall with stone strips, whereby the method contains the following steps:

applying a reinforcement mesh against the wall;
applying a layer of plaster over the reinforcement mesh;
providing an impression mould with parallel grooves at a relative distance from each other which is slightly greater than the width of the base of the stone strips to be applied, said base being intended to be applied against the wall;
pressing the impression mould into the still wet plaster, such that the wet plaster penetrates into the grooves of the impression mould to form parallel ribs;
removing the impression mould after full or partial curing of the plaster, such that a plaster structure with parallel ribs remains against the wall;
applying an adhesive mortar between the ribs;
pressing the stone strips in the still wet adhesive mortar between the ribs, whereby the superfluous adhesive mortar can escape through the gap between the adhesive strip and the ribs;
optional pointing of the gaps between the stone strips with jointing mortar.

The ribs formed in this way by curing of the layer of plaster, are sufficiently firm to offer sufficient support when mounting the stone strips to prevent the stone strips from sagging during mounting.
Because the ribs are located at fixed distances from each other and in each other's extension, continuous compartments are delimited between the ribs between which the stone strips are automatically aligned to each other, such that the method is easy to apply compared to the known method and such that the number of necessary working hours to realise the wall is reduced and the need for skilled professional decreases.
This also provides the advantage that the layer of plaster can be applied on a flat smooth foundation, in other words without ribs, which offers the advantage that a reinforcement mesh is simple to apply to prevent tears in the wall, whereby the reinforcement mesh is made from woven glass fibre.
The ribs function as support point for the stone strips and preferably have a height that is less than the thickness of the stone strips. Impression moulds are used for this, the depth of the grooves of which is less than the thickness of the stone strips.
This prevents that the ribs protrude from the wall. Hence the ribs are hidden in the joints between adjacent stone strips. Furthermore, this allows the joints to be filled over a sufficient depth, although pointing is not necessary.
Preferably the ribs are located at a distance from each other which is slightly greater than the width of the base of the stone strips to be applied, all this such that a gap remains between the stone strips and the ribs which when pressing the stone strips into the adhesive mortar between the ribs allows the superfluous adhesive mortar to be pushed out through said gap. In this way the stone strips can be pressed to a desired depth between the stone strips, for example to obtain one plane or to achieve a certain desired relief.
The invention is applicable both for walls with and without a joint or with a minimal joint between the stone strips.
In the case of a wall with joint it is ensured that between adjacent stone strips sufficient distance is left for pointing, whereby the width of the joint is determined by the distance between the ribs, the width of the stone strips and of the ribs.
In the case of a wall without or with a minimal joint, stone strips can be used which at their base are provided with one or more recesses with which the stone strips fit over the ribs breadthways, in such a way that the stone strips connect closely to each other.
According to a practical embodiment this can be realised for example by stone strips which in their base surface, in other words the surface with which they are pressed into the adhesive mortar, are provided with such recess along two opposite edges.
The invention also relates to a kit for use in the method, whereby the kit contains at least one stone strip and contains an impression mould for forming parallel ribs in a layer of plaster intended for attaching the stone strips against, said impression mould being provided with parallel grooves at least on one side at a distance from each other which is slightly greater than the width of the base of the stone strips to be applied.
It is understood that said kit offers at least the same advantages as the method for cladding a wall with stone strips.
The impression mould is preferably rectangular and in a preferred embodiment is made of a light material such as foam, for example but not exclusively of polyethylene, foam-rubber or plastic foam. However, the impression moulds can also be made from other materials to which the dried layer of plaster does not stick.
With the intention of better showing the characteristics of the invention, a few preferred applications of the method for cladding a wall with stone strips according to the invention and a stone strip and impression mould applied thereby are described hereinafter by way of an example, without any limiting nature, with reference to the accompanying drawings, wherein:

figure 1 shows a schematic perspective view of an impression mould according to the invention;
figures 2 to 8 show consecutive steps for the method of the invention, whereby particularly figure 4 is a cross-section according to line IV-IV in figure 3 and figure 6 is a cross-section according to line VI-VI in figure 5;
figure 9 shows a variant of figure 5;
figure 10 shows a variant of a method according to the invention.

The impression mould 1 shown in figure 1 is made from a block of foam with two opposite parallel edges 2 and 3 which are connected to each other by two opposite sides, respectively one side 4 which is flat and the other side 5 which is provided with grooves 6 that run parallel with the aforementioned edges 2 and 3.
The grooves 6 are located at a fixed distance A from each other, whereby in the case the outer grooves are located at a distance B', respectively B", from the adjoining edge, respectively 2 and 3, the sum of said distances B' and B" is equal to said fixed distance A, such that when two impression moulds 1 are positioned with their edges 2, 3 against each other, the outer grooves of said adjacent impression moulds 1 are located at a distance A from each other.
Figure 2 shows a cross-section of a wall 7 which is intended to be cladded with stone strips 8, whereby the wall 7 is already provided with an insulation panel 9 which in this case is attached against the wall 7 by means of anchors 10 and/or adhesive cement.
The side 11 of the insulation panel 9 to be cladded is flat, such that against said flat side 11 a reinforcement mesh 12 can be applied as shown in figure 2, whereby for the execution of the method according to the invention a layer of plaster 13 in wet condition is applied over the reinforcement mesh 12.
For attaching the reinforcement mesh 12, a first layer of plaster can, for example, be applied against the wall into which the reinforcement mesh 12 can be pressed, after which possibly a second layer of plaster 13 can be applied over the reinforcement mesh 12.
However, it is not excluded that the reinforcement mesh 12 is glued.
In a next step of the method, as shown in figures 3 and 4, the layer of plaster 13 is covered with impression moulds 1 which with their grooved side 5 are pressed into the wet layer of plaster 13, in this case with the grooves 6 oriented horizontally and such that the plaster penetrates in the grooves 6.
The impression moulds 1 are applied in horizontal rows 14 with their edges 15 and 16 laterally against each other, such that the grooves 6 extend in each other's extension.
In this way the impression moulds 1 are stacked row by row with their edges 2 and 3 against each other, whereby preferably the rows 14 are staggered in the direction parallel with the grooves 6 relative to each other over a length that is less than the length C of the impression moulds 1, such that the rows, when mounted, are staggered relative to each other as illustrated in figure 3.
In a next step of the method according to the invention, the impression moulds 1 are removed after the layer of plaster 13 has cured sufficiently, for example after one to two days, depending on the curing time of the plaster used.
As shown in figures 5 and 6, a cured layer of plaster 13 remains after removal of the impression moulds 1, which is provided with ribs 17.
In a next step as shown in figure 6, a layer of adhesive mortar 18 is applied against the layer of plaster 13, at least between the ribs 17, after which, as shown in figure 7, stone strips 8, which may or may not be provided with a layer of adhesive mortar 18 at the base 19 for a better adhesion of the stone strip 8, are pressed into the wet adhesive mortar 18.
In the example shown in figure 7, bar-shaped stone strips 8 with a rectangular base 19 are used with which they are pressed into the adhesive mortar 18.
The impression moulds 1 are chosen such that the distance D between two parallel adjoining ribs 17 is greater than the width E of the wall-facing base 19 of the stone strip 21 to be applied, such that when the stone strips 8 are pressed into the adhesive mortar 18 between the ribs 17, the superfluous adhesive mortar 18 can be pushed out through the gap 20 between the ribs 17 and the stone strips 8 into the joint 21 between adjacent stone strips 8.
After the adhesive mortar 18 has cured, the joints 21 can be pointed with grout 22 as shown in figure 8 to finish the wall 7 with stone strips 8.
Figure 9 shows a possible variant 1 of an impression mould 1 according to the invention which differs from the impression mould 1 of figure 1 in that said variant is provided along two opposite edges 15, 16 with a tongue 23 and groove 24 with which adjoining impression moulds 1 in a same row 14 fit in each other's extension.
This simplifies the alignment when mounting the impression moulds 1 in the still wet layer of plaster 13.
Figure 10 shows an example of an application of the method according to the invention, but for a finished wall 7 with stone strips 8 without or with minimal joints 21.
In this case no strips 8 are used of which the width E of the base 19 of the stone strip 8 is still less than the distance D between two ribs, such that a surplus of adhesive mortar can be pushed out of the space between the ribs.
In this case, the base 19 is provided along two opposite edges with a recess 25 with which the stone strips 8 fit over the ribs 17 as shown in figure 10, and whereby, in other words, the stone strips 8 are executed 26 wider on the visible side with a width F which is chosen such that when the stone strips 8 are supported with their base 19 against or on a rib 17, only a small joint 21 is present between consecutive rows of stone strips 8 which does not necessarily have to be pointed.
Instead of two recesses 25, the stone strips 8 can also be provided with one recess in the form of a groove on one single edge or in the form of a groove between two opposite edges of the base (19) which fits over a rib 17 and extends parallel to said edges.
It is understood that the edges 2, 3, 15 and 16 of the impression moulds 1 are provided with protrusions and recesses with which the impression moulds 1 fit against each other with their edges 2, 3, 15 and 16.
The described method for cladding a wall 7 with stone strips 8 can be executed on both hard foundations such as for example brick work, concrete surfaces or hard composite plates as well as on soft foundations, including insulating material.
Furthermore, it is also possible to use alternative strips next to brick strips such as natural stone strips, epoxy stone strips, concrete and cement stone strips to clad a wall according to the method in this invention.
The present invention also relates to a kit for use in the method.
Such kit contains at least one stone strip 8 and an impression mould 1 for forming parallel ribs in the layer of plaster 13 which is intended for attaching stone strips 8 against.
Said impression mould 1 is provided at least on one side 5 with parallel grooves 6 which are located at a distance A from each other.
The distance A between the parallel grooves 6 is slightly greater than the width E of the base 19 of the stone strips 8 to be applied.
In addition, the aforementioned distance A between the parallel grooves 6 is less than the side of the stone strips 8 to be applied that faces away from the layer of plaster 13.
In a preferred embodiment, the stone strips 8 are provided with two recesses 25in their base 19, respectively one on each of two opposite edges of the base 19.
In an alternative embodiment, the stone strips 8 are provided with one groove 6 in their base 19 located between, and parallel with, two opposite edges. Preferably, the impression mould 1 of the kit is made of a light material, preferably foam, for example polyethylene, foam-rubber or plastic foam.
The present invention is by no means limited to the embodiments described as an example and shown in the figures, however, such method and an impression mould and a stone strip applied thereby can be realised according to different variants, without departing from the scope of the invention defined by the appended claims.

Claims

Method for cladding a wall (7) with stone strips (8), comprising the following steps:
- applying a reinforcement mesh (12) against the wall (7);

- applying a layer of plaster (13) over the reinforcement mesh (12);
characterised in that the method further comprises the following steps:
- providing an impression mould (1) with parallel grooves (6) at a relative distance (A) from each other which is slightly greater than the width of the base (E) of the stone strips (8) to be applied, said base (19) being intended to be applied against the wall (7);

- pressing the impression mould (1) into the still wet plaster (13), such that the wet plaster (13) penetrates into the grooves (6) of the impression mould (1) to form parallel ribs (17);

- removing the impression mould (1) after full or partial curing of the plaster (13), such that a plaster structure with parallel ribs (17) remains against the wall (7);

- applying an adhesive mortar (18) directly between the ribs (17) and/or to the base (19) of the stone strips (8);

- pressing the stone strips (8) into the still wet adhesive mortar (18) between the ribs (17), whereby the superfluous adhesive mortar (18) can escape through the gap (20) between the stone strip (8) and the ribs (7);

- optional pointing of the gaps (20) between the stone strips (8) with jointing mortar (22).
Method according to claim 1, wherein the depth of the grooves (6) in the impression mould (1) is less than the thickness of the stone strips (8), such that after applying the stone strips (8) between the ribs (17) an open joint (20) between the stone strips (8) still remains that can then be pointed.
Method according to claim 1 or 2, wherein several impression moulds (1) are provided which are adjoiningly applied against each other to cover the layer of plaster (13) and to form continuous horizontal ribs (17) on the wall (7) after removing the impression moulds (1).
Method according to claim 3, wherein the impression moulds (1) are staggered in the longitudinal direction of the grooves (6) relative to each other according to a staggered pattern in said direction.
Method according to claim 4, wherein the impression moulds (1) are rectangular impression moulds (1) .
Method according to claim 4, wherein the impression moulds possess (1) two opposite parallel edges (2, 3) which run parallel with the longitudinal direction of the grooves (6) and two transverse edges (15, 16) which are provided with a tongue (23) and groove (24) which fit into each other when the impression moulds (1) are applied on the layer of plaster (13) with their transverse edges (15, 16) against each other and in each other's extension.
Method according to any one of the previous claims, wherein the wall (7) on the side to be cladded is provided with an insulation layer (13) against which the reinforcement mesh (12) is applied and against which the layer of plaster (13) is applied into which the impression mould (1) or impression moulds (1) are pressed with their grooves (6).
Method according to claim 7, wherein the insulation layer (9) is flat on the side (11) to be cladded with stone strips (8).
Method according to any one of the previous claims, wherein the impression mould (1) or impression moulds (1) are pressed into the layer of plaster (13) with their grooves (6) oriented horizontally to form parallel continuous horizontal ribs (17).
Method according to any one of the previous claims, wherein when mounting the stone strips (8) between the ribs (17), the stone strips (8) are supported against or on one of the relevant ribs (17).
Method according to any one of the previous claims, wherein the stone strips (8) without joint (21) or with a minimal joint (21) are applied against the wall (7), whereby to this end the stone strips (8) are provided with one or more recesses (25) in the base (19) facing the wall (7) with which the stone strips (8) fit over the ribs (17).
Method according to claim 11, wherein they use stone strips (8) of which the base (19) facing the wall (7) is provided along two opposite edges with a recess (25) with which the stone strip (8) fits over said ribs (8) .
Method according to any one of the previous claims, wherein the stone strips (8) are made of brickstone.
Method, according to any one of the previous claims, wherein the reinforcement mesh (12) is made of woven glass fibre.
Kit for use in the method according to claim 1, characterised in that the kit contains at least one stone strip (8) and an impression mould (1) for forming parallel ribs in a layer of plaster (13) which is intended for attaching the stone strips (8) against, said impression mould (1) being provided at least on one side (5) with parallel grooves (6) at a distance (A) from each other which is slightly greater than the width (E) of the base (19) of the stone strips to be applied (8)said distance (A) being less than the side of stone strips (8) to be applied facing away from the layer of plaster (13).
Kit according to claim 15, wherein the stone strip (8) is provided with two recesses (25) in its base (19), respectively one on each of two opposite edges of the base (19)
Kit according to claim 15, wherein the stone strip (8) is provided in its base (19) with one groove (6) located between, and parallel with, two opposite edges.
Kit according to claim 15, wherein the impression mould (1) is made of a light material, preferably foam, for example polyethylene, foam-rubber or plastic foam.