GB2453985A

GB2453985A - Brick slip or tile application guide

Info

Publication number: GB2453985A
Application number: GB0720909A
Authority: GB
Inventors: Gregory Curtis
Original assignee: Alumasc Group PLC
Current assignee: Alumasc Group PLC
Priority date: 2007-10-24
Filing date: 2007-10-24
Publication date: 2009-04-29
Anticipated expiration: 2027-10-24
Also published as: GB0720909D0; GB2453985B

Abstract

A brick slip or tile application guide system comprising of a lightweight mesh having a projection or ridge attached to the mesh so as to provide an alignment guide for a brick slip or tile to be adhered onto a substrate. The mesh can be non-metallic and flexible such as plastic or glass fibre and may provide heat insulation to the substrate. The ridges may be attached to the mesh to provide a template by a fastener which may be a releasable adhesive or Velcro (RTM). The ridge may be a bead, rod or bar and may be non-metallic such as plastic. At least one edge of the mesh may have a margin free of ridges or protrusions which can provide an overlapping surface to align an additional application guide. In use, the brick slip or tile application guide is easy to use and transport.

Description

Brick or Tile Application Guide

Field of Invention

The present invention relates to the cladding of walls using brick slips, tiles or the like.

It is known in the building industry to use a mesh with parallel ridges or protrusions in order to facilitate the attachment and support of brick slips onto a wall so as to give the external appearance of a solid brick wall. The ridges or protrusions are sufficiently spaced apart to accommodate the brick slips in between in aligned rows or courses. The mesh is generally attached to the wall by any suitable fixing means depending on the material of the wall, i.e. concrete, wood, steel etc. For example mechanical fixing means such as screws, tie-rods, staples or similar have traditionally been used. The ridges or protrusions are normally arranged horizontally so that the brick slips can be fixed to the wall in straight lines by unskilled labour. The brick slips are attached onto the wall underlying the mesh by either coating the mesh with a suitable adhesive such as mortar or back buttering each brick slip with the adhesive and subsequently pressing them into place on the mesh with their bottom edges resting against an adjacent ridge formed in the mesh. This is repeated until the whole area of the wall under the reinforcing mesh is covered. Finally, the gaps or valleys between the brick slips formed by the ridges and adjacent the brick slips are filled in or pointed with grout to give the wall a brick like effect.

Typically the mesh is constructed from metal such as chicken wire with a number of parallel spaced ridges bent outwardly from the wire (see US 4920716 Coffey). The mesh used to date tends to be of relatively heavy gauge, the adhesive keying into and being reinforced by the mesh. The mechanical fastenings in turn secure the thus formed composite sheet structure to the wall, although the adhesive may also assist in this function. Although metallic meshes provides the necessary support for the brick slips during construction, the meshes tend to be bulky, awkward to handle, heavy to transport and occupy a lot of space. Even if the meshes are rolled up to conserve space, they are difficult to unroll again and secure in a generally flat condition or shaped to accommodate corners, protrusions and other non-planar features in the wall. In extreme cases rolling may cause unwanted bends in the metallic wires particularly around the ridges making them unable to secure the brick slips correctly. In US 4920716 Coffey, it is necessary that the wire mesh is attached onto the wall by suitable fixing means otherwise the weight of the mesh and the attached brick slips would make it more susceptible to break away from the wall.

The spacing between the ridges or protrusions is normally set to accommodate a standardised brick size. The ridges/protrusions are formed in the mesh by bending which makes it difficult and expensive. There is no option to adjust the spacing to Suit a particular or unusual brick size.

Moreover, the manufacturer of the mesh in metal is time consuming since the individual metallic wires have to be woven or otherwise secured together and the ridges bent from the mesh. This transposes into high costs of manufacture let alone the transport costs.

A mesh is thus required that is simple to manufacture including for a variety of brick slip or tile sizes, that is lightweight, that does not occupy much space, that is easily transportable, and that is easy to attach onto and shape to fit an underlying wall.

Summary of the Invention

The present applicant has mitigated the above problem by providing a brick slip or tile application guide system comprising of a lightweight mesh having a projection or ridge attached to the mesh so as to provide an alignment guide for a brick slip or tile to be adhered onto a substrate. Flexible, non-metallic mesh materials are preferred. This allows the mesh to be easily rolled up or folded for ease of transport, storage or packaging without damaging or introducing creases in the structure of the mesh. The non-metallic material gives the mesh resiliency so that it can be easily opened out. The brick slip or tile adheres primarily directly to the substrate through the mesh, so that neither the mesh nor any mechanical fixings used to secure the mesh to the substrate needs to be mechanically strong. Indeed, any additional mechanical fixings between the mesh and the wall can be eliminated. Suitable materials for the mesh include plastics, glass fibre or cloths (cotton, polyester) or other plastics. The use of non-metallic materials particularly glass fibre, additionally provides heat insulation to the substrate, e.g. wall. The mesh can be integrally manufactured such as by moulding, extrusion or any other suitable means. In addition, the mesh can easily be shaped without any effort by simply cutting using scissors, a knife or the like, and bending as necessary to suit different sizes and shapes of wall. As the material of the mesh is non-metallic various markings can be printed on the surface of the mesh such as a trade mark, or instructions, alignment/cutting/measuring indicia using conventional printing means known in the art.

The size of the mesh is sufficiently large for the adhesive or render to impregnate the mesh and provide reinforcement to the render as well as allowing the render/adhesive to be pressed through the mesh, e.g. to contact the wall or to secure the mesh in position on the wall.

Moreover, the ridges or protrusions can be in the form of beads or rods or bars and can equally be formed of any lightweight material such as plastic, wood, aluminium and can be attached to the mesh using an adhesive or any other suitable means, e.g. staples, or solvent or ultrasonic welding. Using adhesive allows the ridges to be supplied separately to the mesh and subsequently attached to the mesh depending on the size of the brick slip.

For example, markings can be printed on the mesh that indicates various brick slip sizes.

Moreover, the adhesive can be releasable to allow the user to easily re-position the ridges on the mesh depending on the size of the brick slip. Alternatively the ridges can be integrally formed with the mesh such as by moulding.

Optionally, at least one edge of the mesh has a margin that is free of the ridges or protrusions. The margin provides an overlapping surface with the margin of a neighbouring brick or tile application guide system so as to provide continuity of the ridge or protrusion. Where coverage of a large wall is required, a number of the brick slip or tile application guide systems can be joined together at the margins and the ends of the ridges or protrusions subsequently aligned to provide continuity of the ridge or protrusion.

A method of cladding a wall with brick slips comprises the step of attaching a brick slip or tile application guide system to the wall with a suitable adhesive or render such as mortar, attaching a brick slip or tile adjacent the ridge or protrusion and pointing or filling the gaps formed between the brick slips or tiles. The brick slip or tile application guide system can be attached to the wall by pressing the mesh into the wet render. The brick slips or tiles can then be attached to the wall by pressing them into the wet render, guided and positioned by the ridges or protrusion of the brick slip application guide system. The gaps formed between the brick slips are filled or pointed with grout or mortar.

Alternatively, the brick slips can be attached by back buttering each brick slip with mortar or other suitable adhesive and simply pressing it into position on the wall over which the mesh is positioned, either with or without a render coat first being applied to the wall. The mesh may be tacked to the wall by spaced blobs of adhesive, or by spaced buttered brick slips, or by mechanical fixings. Alternatively, the mesh may be pressed into a wet render coat as described above. The use of light weight materials allows the brick slip application guide system of the present invention to be easily adhered onto the wall using any suitable adhesive or render without the need for any separate fastening means such as staples or tie-rods. However, such fastening means can be used in order to provide further support to the brick slip support system on the wall.

The use of lightweight materials such as plastic or glass fibre mean that the brick slip application guide system can be manufactured cheaply since relatively cheap materials can be used in comparison to the metallic brick slip support systems known in the prior art.

Detailed Description

Further preferred features and aspects of the present invention will be apparent from the claims and the following description of illustrative embodiments made with reference to the accompanying drawings in which:-Fig I is a perspective view of the brick slip application guide system according to an embodiment of the present invention; Fig 2 is a perspective view of the brick slip application guide system with a brick slip placed adjacent a guide support ridge or protrusion.

The brick slip application system 10 according to an embodiment of the present invention comprises of a mesh sheet 12 and a plurality of ridges or protrusions 14 attached to the mesh 12. The mesh 12 is non-metallic, lightweight and flexible so that is can be easily rolled or folded for ease of transport, storage or packing without damaging or introducing creases in the structure of the mesh 12. The non-metallic material gives the mesh 12 resiliency so that it can be easily opened out. Suitable materials for the mesh 12 include plastics, glass fibre or cloths (cotton or polyester) or other suitable plastics. The use of non-metallic materials such as glass fibre additionally provides heat insulation to the wall.

Moreover, the material is sufficiently strong to provide reinforcement to the render to which it is impregnated.

The mesh can be integrally manufactured such as by moulding, extrusion or any suitable means. In addition the mesh can easily be shaped without any effort by simply cutting using scissors or knives etc to suit different sizes and shapes of wall. As the material of the mesh is non-metallic various markings can be printed on the surface of the mesh such as a trade mark, measuring, cutting indicia or instructions using conventional printing means known in the art (see Fig. 1).

The ridges or protrusions 14 are generally in the form of longitudinal beads, rods or bars and can be formed of any suitable light-weight material so as to provide support and alignment for the brick slips. Suitable materials for the ridge include various moulded plastics, polymers such as PVC, wood, aluminium etc, which can easily be cut to size without any degree of effort. Damp, rot and corrosion resistant materials are preferred.

The ridges are arranged in parallel on the mesh and sufficiently spaced apart to accommodate a brick slip 16 as shown in Fig 2. They can either be pre-attached onto the mesh prior to use or attached onto the mesh in-situ. This enables the ridges to be supplied separately and subsequently attached onto the mesh when in use. In either case, the mesh can be easily rolled into a compact package, thus further contributing to the ease by which the brick application guide system of the present invention can be stored or transported or packaged. The ridges or protrusions can be attached onto the mesh by any suitable means such as by means of an adhesive or self adhesive reinforced fabric. The adhesive can be releasable allowing the user to re-position the ridges on the mesh. For example, double sided sticky tape can be applied along the length of one side of the ridge. The exposed adhesive side used for attaching onto the mesh can be protected by a releasable strip. In use, the operator simply peels the releasable strip and presses the ridge or protrusion into the desired position on the mesh.

A plurality of ridges can be placed spaced apart on a flat surface with the adhesive side exposed and the mesh simply rolled out onto the ridges so that the adhesive subsequently attaches the ridges to the mesh at the desired spacing.

The ridges can be securely attached on the mesh by any other suitable fastening means known in the art such as by means of staples, clips, Velcro�, moulding, solvent or ultrasonic welding etc. Alternatively the ridges can be formed integrally with the mesh.

By virtue of the light-weight materials used in the brick slip application guide system of the present invention, it can be easily tacked onto the wall using suitable adhesive material such as render without the need of any fastening means such as tie-rods or staples. However, fastening means can be used if further support is needed.

In a preferred procedure for cladding a wall with brick slips, the wall is first rendered with mortar and the mesh is simply pressed into the mortar. Due to the light weight materials used for the brick slip application guide system, the tackiness of the mortar is sufficient to hold the mesh in place. The brick slips are then back-buttered with mortar and pressed into place with the bottom edge of the brick slip resting against the ridge line below it (see Fig. 2). This is repeated until the entire wall under the mesh is covered with brick slips.

Alternatively the mesh can be first tacked to the wall with "dabs" of adhesive and the slips then individually buttered with further adhesive which is pressed onto the wall through the mesh. A combination of back buttering the slips before applying them between the support system ridges, and rendering the wall before applying the support system mesh, is also possible.

Finally, the gaps between the brick slips formed by the ridges and adjacent brick slips are filled in or pointed with grout material to give the appearance of a solid brick wall.

At least one edge of the brick slip or tile application guide system is formed with a margin, l2a or 12b, which is free of ridges or protrusions 14 (see Fig. 3). This provides an overlapping surface with a margin from a neighbouring brick slip or tile application guide system so as to provide continuity of the ridge or protrusion. Where the margin is at the top or bottom of the mesh l2b, i.e. running along the length of the ridges or protrusions, the width of the margin corresponds to the spacing between the ridges or protrusions so that when the margins overlap the spacing between the ridges or protrusions remains uniform. Where coverage of a large wall is required, a number of such brick slip or tile application guide systems are joined together at the margins and the ends of the ridges or protrusions are aligned to provide continuity of the ridge or protrusions. The brick slip or tile application guide systems can be joined together prior to attaching to the wall or joined together when attached onto the wall. The lightness of the brick slip or tile application guide systems means that it can be easily manoeuvred and positioned on the wall.

By virtue of the lightness and flexibility of the brick slip or tile application guide system of the present invention it can easily be rolled up compactly and packaged. This allows it to be transported and assembled onto the wall without any degree of effort. Moreover, the lightweight material used means that it can be easily shaped or cut for installation. The brick slips or tiles are attached to their supporting substrate primarily by the adhesive and/or render layer between them and the substrate, into which the mesh of the brick slip or tile application guide system is incorporated. The mesh need not be secured to the substrate by any separate mechanical fixings and therefore need not serve directly to support the brick slips or tiles. The mesh may however serve to reinforce the adhesive or render layer and so help to maintain the integrity of the cladding, e.g. where there is localised degradation of the bond between the adhesive or render and the substrate.

Claims

Claims 1. A brick slip or tile application guide system comprising of a lightweight mesh having a projection or ridge attached to the mesh so as to provide an alignment guide for a brick slip or tile to be adhered onto a substrate.
2. A brick slip or tile application guide system as claimed in 1 wherein the mesh is non-metallic.
3. A brick slip or tile application guide system as claimed in Claim 2, wherein the mesh provides heat insulation to the substrate.
4. A brick slip or tile application guide system as claimed in any of Claims 1 to 3, wherein the mesh is flexible.
5. A brick slip or tile application guide system as claimed in any of Claims 2 to 4, wherein the mesh is plastic.
6. A brick slip or tile application guide system as claimed in any Claims 2 to 4, wherein the mesh is glass fibre.
7. A brick slip or tile application guide system as claimed in anyone of the preceding claims wherein the mesh size is substantially O.34m2
8. A brick slip or tile application guide system as claimed in anyone of the preceding claims wherein the ridges are attached onto the mesh by fastening means.
9. A brick slip or tile application guide system as claimed in Claim 8 wherein the fastening means is an adhesive.
10. A brick slip or tile application guide system as claimed in Claim 9 wherein the adhesive is releasable.
11. A brick slip or tile application guide system as claimed in Claim 8, wherein the fastening means is by the use of Velcro�.
12. A brick slip or tile application guide system as claimed in any of the preceding claims wherein the ridge is a bead or rod or bar.
13. A brick slip or tile application guide system as claimed in any of the preceding claims wherein the ridge is non-metallic.
14. A brick slip or tile application guide system as claimed in Claim 13 wherein the ridge is plastic.
15. A brick slip or tile application guide system as claimed in any of the preceding claims, wherein at least one edge of the mesh has a margin that is free of the ridges or protrusions.
16. A brick slip or tile application guide system as claimed in Claim 14, wherein the margin provides an overlapping surface with the margin of a neighbouring brick slip or tile application guide system so as to provide continuity of the ridge or protrusion.
17. A method of manufacture of a brick slip or tile application guide system comprising the steps of attaching a ridge or protrusion to a lightweight mesh so as to provide an alignment guide for a brick slip or tile.
18. A method as claimed in Claim 17 wherein the ridge or protrusion is attached to the mesh by an adhesive.
19. A method as claimed in Claim 18 wherein the adhesive is provided by a double sided sticky tape having one side attached to the ridge and the other side attachable to the mesh.
20. A method as claimed in Claim 17, wherein the ridge or protrusion is attached to the mesh by Velcro�.
21. A method of applying a cladding onto a wall comprising of the steps of: a. attaching a brick slip or tile application guide system as defined in any one of Claims 1 to 16 to the wall; b. attaching a brick slip or tile adjacent the ridge or protrusion; c. pointing or filling the gaps formed between the brick slips or tiles.
22. A method of applying a cladding onto a wall as claimed in Claim 21, wherein the brick slip or tile application guide system is attached onto the wall by a render.
23. A method of applying a cladding onto a wall as claimed in Claim 21 or 22 wherein the brick slip or tile application guide system is attached onto the wall by mechanical fastening means.
24. A veneered wall comprising a plurality of brick slips and a brick slip or tile application guide system as defined in any claims 1 to 16 disposed between the wall and the brick slips.
25. A veneered wall as claimed in Claim 24 wherein the brick slip or tile application guide system is embedded within the render.
26. A veneered wall as claimed in Claim 24 or 25, wherein the brick slip or tile application guide system is embedded with adhesive applied to the back of a brick slip or tile.
27. A brick slip or tile application guide and substantially described herein with reference to the accompanying drawings.
28. A veneered wall as claimed in any Claims 22 to 24 and substantially described herein with reference to the accompanying drawings. * .* ** * * *S * S.. * I II). * II S. * * SS S.. S... * S*

S S. S * S S I 50

28. A method of manufacturing a brick support system as claimed in any of Claims 17 to 20 and substantially described herein with reference to the accompanying drawings.

29. A method of applying a cladding onto a wall as claimed in any of Claims 21 to 23 and substantially described herein with reference to the accompanying drawings.

30. A veneered wall as claimed in any Claims 24 to 26 and substantially described herein withy reference to the accompanying drawings.

AMENDMENTS TO THE CLAIMS HAVE BEEN FILED AS FOLLOWS

I. A brick slip or wall tile application guide system comprising of a non-metallic mesh having a protrusion or ridge in the form of a bead or rod or bar attached to the mesh so as to provide an alignment guide for a brick slip or wall tile to be adhered onto a substrate.

2. A brick slip or wall tile application guide system as claimed in Claim 1, wherein the mesh provides heat insulation to the substrate.

3. A brick slip or wall tile application guide system as claimed in any of Claims I or 2, wherein the mesh is flexible.

4. A brick slip or wall tile application guide system as claimed in any of Claims 1 to 3, wherein the mesh is plastic.

5. A brick slip or wall tile application guide system as claimed in any Claims I to 3, wherein the mesh is glass fibre.

6. A brick slip or wall tile application guide system as claimed in anyone of the preceding claims wherein the mesh size is substantially O.34m2. S... * .

7. A brick slip or wall tile application guide system as claimed in anyone of the preceding claims wherein the protrusion or ridge are attached onto the mesh by * fastening means. *.. * . .

8. A brick slip or wall tile application guide system as claimed in Claim 7 wherein the fastening means is an adhesive.

9. A brick slip or wall tile application guide system as claimed in Claim 8 wherein the adhesive is releasable. lL

10. A brick slip or wall tile application guide system as claimed in Claim 7, wherein the fastening means is by the use of a hook and loop fabric.

11. A brick slip or wall tile application guide system as claimed in any of the preceding claims wherein the protrusion or ridge is non-metallic.

12 A brick slip or wall tile application guide system as claimed in Claim 11 wherein the protrusion or ridge is plastic.

13. A brick slip or wall tile application guide system as claimed in any of the preceding claims, wherein at least one edge of the mesh has a margin that is free of the ridges or protrusions.

14. A brick slip or wall tile application guide system as claimed in Claim 13, wherein the margin provides an overlapping surface with the margin of a neighbouring brick slip or wall tile application guide system so as to provide continuity of the ridge or protrusion.

15. A method of manufacture of a brick slip or wall tile application guide system comprising the steps of attaching a ridge or protrusion to a non-metallic mesh so as to provide an alignment guide for a brick slip or wall tile.

16. A method as claimed in Claim 15 wherein the ridge or protrusion is attached to the mesh by an adhesive. * **. * * *

17. A method as claimed in Claim 16 wherein the adhesive is provided by a double sided sticky tape having one side attached to the protrusion or ridge and the other side attachable to the mesh.

IS

18. A method as claimed in Claim 15, wherein the ridge or protrusion is attached to the mesh by a hoop and loop fabric.

19. A method of applying a cladding onto a wall comprising of the steps of: a. attaching a brick slip or wall tile application guide system as defined in any one of Claims 1 to 14 to the wall; b. attaching a brick slip or wall tile adjacent the ridge or protrusion; c. pointing or filling the gaps formed between the brick slips or tiles.

to 20. A method of applying a cladding onto a wall as claimed in Claim 19, wherein the brick slip or wall tile application guide system is attached onto the wall by a render.

21. A method of applying a cladding onto a wall as claimed in Claim 19 or 20 wherein the brick slip or wall tile application guide system is attached onto the wall by Is mechanical fastening means.

22. A veneered wall comprising a plurality of brick slips and a brick slip or wall tile application guide system as defined in any claims I to 14 disposed between the wall and the brick slips.

23. A veneered wall as claimed in Claim 22 wherein the brick slip or wall tile *: : :* application guide system is embedded within the render. * S I...

24. A veneered wall as claimed in Claim 22 or 23, wherein the brick slip or wall tile application guide system is embedded with adhesive applied to the back of a brick 0.

slip or wall tile. * . . *5 S

*.. : 25. A brick slip or wall tile application guide and substantially described herein with reference to the accompanying drawings.

26. A method of manufacturing a brick support system as claimed in any of Claims 16 to 18 and substantially described herein with reference to the accompanying drawings.

27. A method of applying a cladding onto a wall as claimed in any of Claims 19 to 21 and substantially described herein with reference to the accompanying drawings.