GB2536036A

GB2536036A - Improvements in and relating to pre-fabricated stone panels, a method of constructing a wall from pre-fabricated stone panels and a construction kit

Info

Publication number: GB2536036A
Application number: GB1503724.5A
Authority: GB
Inventors: Wilson Tom; Conway Declan; Blair Eamonn; Lyons John
Original assignee: WESTPORT STONE WORKS Ltd
Current assignee: WESTPORT STONE WORKS Ltd
Priority date: 2015-03-05
Filing date: 2015-03-05
Publication date: 2016-09-07
Also published as: GB201503724D0

Abstract

A prefabricated panel comprising a carrier support board 3, a plurality of stone pieces 1, and an adhesive for bonding the stone pieces to the carrier support board. The adhesive may be moisture curing and preferably diphenylmethane-4-4-diisocyante based. When mist sprayed with 100 g of cold water per 1000 g of adhesive, the film thickness of the adhesive will increase from 2 mm to 10 mm and rise around the sides of the stone pieces to anchor them. The support board may comprise magnesium silicate or calcium silicate. The panel may further comprise a layer of insulation 5 adhered to the support board by a solvent free vinyl chloride/ hydroxypropyl acrylate/ vinyl laurate terpolymer, preferably combined with a co-solvent such as monopropylene glycol which slows the drying. Multiple panels may be attached to an existing wall structure by metal fixings wherein the finished appearance resembles a traditional stone wall.

Description

TITLE

Improvements in and relating to pre-fabricated stone panels, a method of constructing a wall from pre-fabricated stone panels and a construction kit comprising pre-fabricated stone panels

FIELD OF INVENTION

The present invention relates to pre-fabricated stone panels and to an adhesive system for use in said pre-fabricated stone panels.

More specifically, the invention relates to pre-fabricated stone panels; and to an adhesive system included in the pre-fabricated stone panels. In another aspect, the present invention relates to a method of constructing a wall using the pre-fabricated stone panels where the finished contstructed wall has the appearance of being made entirely of stone.

BACKGROUND OF THE INVENTION

In summary, current state of the art for constructing stone walls requires labour intensive cutting of stone and transporting of stone as well as time consuming task of then selecting particular stones that are suitable shaped so that they can be located closely together and the stones are typically adhered to each other using mortar which is placed between the individual stones. To preserve a dry-laid stone appearance, the stones can be set in a mortar that is pigmented a dark gray. The stones are selected and set in a particular pattern to give the traditional stone wall appearance that is achieved by a skilled stone mason.

This traditional stone wall appearance is achieved only after going through the time consuming and labour intensive process referred to above and tends to be very expensive for these 30 reasons.

The present invention seeks to alleviate the disadvantages of the known methods of constructing stone walls.

SUMMARY OF THE INVENTION

Accordingly, a first embodiment of the present invention provides a pre-fabricated stone panel as set out in claim 1 of the appended Claims. Advantageous features of embodiments of the invention are set out in the dependent claims.

Accordingly, the present invention provides a pre-fabricated masonry element panel comprising: a carrier support board; a plurality of masonry element pieces arranged in a pre-determined pattern on the support panel; and an adhesive system for bonding the stone pieces to the carrier support board.

Preferably, the adhesive system comprises a moisture curing Diphenylmethane-4-4-Diisocyanate based adhesive for use in bonding the masonry element pieces to the carrier support board of the pre-fabricated panel.

The pre-fabricated stone panel of the present invention provides the significant advantage of enabling a wall to be constructed, having the appearance of a traditional stone wall but at a fraction of the time and cost involved by using the pre-fabricated stone panel of the invention.

The stone pieces provided on the pre-fabricated panel may comprise any suitable type of stone or masonry element for instance a masonry element selected as one or more elements from the following group: natural stone, faux stone, brick, pre-cast stone, ceramic files, slate, stone veneer, flexible stone veneer, re-constituted stone, and stone finish made using plaster.

Flexible stone veneer is a very thin strip of stone which is flexible and can bend around corners and columns.

The carrier support board in a preferred embodiment, comprises a board manufactured of Magnesium Silicate, Calcium Silicate or blends thereof. Any reference to Magnesium Silicate or Magnesium Silicate board herein is to be understood to also refer to a board constructed from Calcium Silicate or from a blend of Magnesium Silicate and/or Calcium Silicate. In alternative embodiments, the carrier support board may be formed of any fibre cement board suitable for use in construction. Thus alternatively, the carrier support board may be formed of weatherproof plywood type board; or oriented strand boards (OSB) or similar, or extruded plastics based fluted boards; or honeycomb boards constructed of various materials. In an additional aspect the present invention also provides: A) A first adhesive system for bonding the stone pieces to the carrier support board eg. A Magnesium Silicate board; and B) A second adhesive system for bonding the Magnesium Silicate board to the layer of insulation eg PI R layer.

In construction and general building work, the technique of inserting mortar in joints between stones, bricks, blocks or other masonry elements is referred to as "pointing". For instance, when aging mortar joints crack and disintegrate, the defective mortar is removed by hand or power tool and replaced with fresh mortar, preferably of the same composition as the original. Often an entire wall, or even a whole structure, is "pointed" with fresh mortar because defective points cannot easily be detected, and adjacent joints may also be in need of repair. The mortar is packed tightly in a thin layer and then any excess mortar that oozes out between the masonry element is cleared away and the remaining mortar at the joint is smoothed using a tool to achive a smooth finished surface.

In one embodiment of the present invention, the pre-fabricated panel may include comprise mortar between the stones as one of the manufacturing steps so that, when in use to construct a wall, a pointing material need only be applied to the void in the mortar finish that appears over the metal fixings that are inserted to securely afix the pre-fabricated panel to a pre-existing wall structure e.g the brick wall of a house where an external traditional stone wall outer finish is desired.

However, in the preferred embodiment, the application of mortar i.e. the pointing, carried out when the plurality of pre-fabricated panels are in use and have been assembled together to construct a wall and the mortar is then applied to the spaces between the stones in the prefabricated panels; and also between the individual pre-fabricated panels having the various respective profiles; This pointing is carried out so as to achieve the finished appearance of a traditional stone wall and also to achieve waterproofing.

The pre-fabricated panel may preferably, also comprises a layer of insulation for use in applications where insulation is required, eg as the outer wall of a dwelling place. The layer of insulation comprises a layer comprising of any one or more selected from the following group: Polyisocyanurate (PIR) insulation, Polyurethane (PU), Polystyrene or aerogels.

When the pre-fabricated panel is being used for fixing to a perimeter wall around a garden for instance, clearly no insulation layer is required for that application.

In the embodiment where the pre-fabricated stone panel includes a layer of insulation, then the panel also comprises a layer of adhesive comprising an adhesive system configured for bonding the carrier support board to the layer of insulation.

In a preferred embodiment, the carrier support board comprises a fibre cement board such as a board manufactured of Magnesium Silicate.

Ideally, the panel includes a sealing means comprising a primer or sealer for sealing around the edges of the carrier support board. The sealing means may comprise an acrylic-based sealant material but of course, it is to be understood that any suitable sealant material may be used for this purpose. An advantageous feature of the present invention is that the adhesive system used to adhere the plurality of stone pieces to the carrier support board incorporates a sealing functionality such that it is not necessary to use a separate sealant to seal the major faces of the carrier support board, eg Magnesium Silicate board. It is quite surprising that it is not essential to have the apply a sealant to the major faces of an alkaline board such as a Magnesium Silicate board since it is well known that it is extremely difficult to achieve good adhesion to an alkaline board. Nevertheless, this has been achieved by the present invention and the adhesive system used in the present invention also has the capability of providing such excellent adhesion, without use of a sealant pre-applied to the carrier board, and still able to adhere the heavy weight stone pieces to the board. It is noteworthy that the load created by the stone pieces can be up to about 20kg and the adhesive system of the present invention securely adheres the plurality of stone pieces directly to the carrier board, without use of an intermediary material such as a mesh or a web to provide structural integrity; and furthermore without having to apply a sealant material to the face(s) of the carrier board.

Accordingly, the pre-fabricated panel of the present invention involves bonding the decorative stone pieces to a carrier support board. The carrier support board is preferably constructed of magnesium silicate or and calcium silicate boards which are typically used in the construction industry and are relatively inexpensive. A characteristic property of such boards is that, unlike plasterboard, silicate boards are structural and can be weight bearing. Silicate boards are also fireproof. Hence, a silicate board provides an ideal carrier support board for the pre-fabricated panel of the present invention.

The stone is bonded to one side of the silicate board; and, if insulation is included in the prefabricated panel of the invention, then the insulation is bonded to the other side of the silicate board. As is common with all silicate boards, such as calcium and magnesium silicate boards, applying and adhering any coating, to the silicate board, be it a paint or an adhesive is problematic. This is because the surface of silicate boards is quite porous which leads to both coatings (paint or adhesive) being absorbed rapidly into the board, thus leading to surface skinning of the coating and defective film formation. The silicate boards are also highly alkaline which due to alkaline hydrolysis, will result in saponification of vinyl acetate which is contained in most building materials.

In accordance with the present invention, an adhesive system is provided for bonding the decorative stone to the magnesium silicate; this stone-carrier board adhesive preferably, comprises a moisture curing Diphenylmethane-4-4-Diisocyanate based adhesive. (This adhesive system is indicated by reference name, DP462 adhesive).

Again it will be noted that, given the properties of the board and the porosity of the decorative stone, a water-based adhesive cannot be used. This moisture curing Diphenylmethane-4-4-Diisocyanate based adhesive is advantageous for use in the pre-fabricated panel of the present invention as it is solvent free adhesive and given the fact that it is moisture curing, experiments showed that it had excellent adhesion to both the moisture containing silicate board and the decorative stone.

The adhesive system is applied to a first side of the carrier board using a roller or more preferably, using a toothed blade ( 2.0 mm X 2.0 mm), optimally at a wet film thickness of 250g/M2. The adhesive is moisture curing and when mist sprayed with 100g of cold water per 1,000g of adhesive, the film thickness will increase from approximately 2.0 mm to 10.0 mm plus.

This increase in film thickness is beneficial in that the adhesive rises around the four sides of the decorative stone, thus anchoring the decorative stone to the magnesium silicate board.

Turning now to the other side of the silicate board, for bonding the aluminium foil faced PU/PIR board to the silicate board, a second adhesive system, the insulation-carrier support board, is used. This insulation -carrier support board adhesive comprises a solvent free vinyl chloride/hydroxypropyl acrylate/vinyl laurate terpolymer. This second adhesive system is referred to by the reference name, DP457 adhesive This adhesive does not contain vinyl acetate and therefore is very stable when applied to the silicate board. The adhesive also contains a glycol co-solvent (specifically monopropylene glycol), which slows down the drying properties of the adhesive, thus retarding adhesive absorption into the silicate board. The particle size of the adhesive is approximately 3p. Large for a building adhesive but anything below 2p, will not give optimum film properties on the silicate board. The adhesive has excellent wetting characteristics & adhesion to the aluminium foil surface. The adhesive is typically applied by roller, optimally at a wet film of 300g/M2.

In order to meet the required insulation values for houses, insulation is of a typical thickness of 75mm + is used. The negative of using such a thick material, is in the fact that it has a bigger footprint. In addition, larger external works, such as allowing for windows, down-pipes etc, will be required. One suggestion would be to replace the PU/PIR insulating board with an aerogel material.These aerogels are flexible and offer the same insulation value as PU/PIR, but up-to 70% less thickness (75 mm V 23 mm).

The pre-fabricated panel in accordance with the present invention comprises fixing means for fixing the panel to an existing wall structure. The fixing means comprises any one or more selected from the following group: preferably, a metal fixing, most preferably, a sleeve anchor; though masonry screws or screws with rawlplugs are also suitable. Of course, alternative fixing means such as various designs of metal brackets or aluminium extrusions.

A washer may be included on the fixing means or alternatively, fixing means may be used which has washer integrated heads.

This construction system of pre-fabricated stone panels gives the benefits of a quick installation as well as providing a high insulation factor when using pre-fabricated stone panels which include a layer of insulation.

In another aspect, the present invention provides a construction system of pre-fabricated stone panels comprising a plurality of pre-fabricated panels having a variety of profiles which when fitted in a particular sequence give the appearance of a random built stonework facing. This system comprises an elongate panel, a panel having an elongate portion with two arms protroding therefrom. This system also comprises at least one corner panel and preferably, two corner panels.

In a further aspect, the present invention provides a method of constructing a wall having the appearance of a traditional stone wall or fireplace of stone or chimney breast, wherein the method comprises using a plurality of pre-fabricated stone panels. In this aspect, the present invention provides a method of constructing a stone wall assembled from the pre-fabricated stone panels of the present invention, comprising the following steps: (a) Selecting an existing wall to which the traditional stone wall appearance is to be applied by securing the pre-fabricated stone panels as claimed in Claim 1, thereto, in a pattern that enables the pre-fabricated stone panels to abut each other and in the assembled arrangement, gives the appearance of a traditional stone wall structure; (b) Applying a protective layer at the base of the existing wall, the protective layer thereby providing a reference level for the setting down of the first course of pre-fabricated stone panels; (c) Applying a layer of pointing material to the horizontal surface of the protective layer; (d) Applying a first pre-fabricated stone panels of the invention onto the protective layer and securing the pre-fabricated stone panel to the existing wall before proceeding to apply the next pre-fabricated stone panel; (e) Continuing to apply pre-fabricated stone panel to the protective layer and securing the pre-fabricated stone panels to the existing wall until a first row of stone wall has been constructed using the pre-fabricated stone panels; Repeating steps (d) to (e) to build the stone wall using the pre-fabricated panels by mating together each of the profiles of pre-fabricated panels and applying pointing material as appropriate. Preferably, the mortar is applied to the spaces between the stones in the pre-fabricated panels; and also between the individual pre-fabricated panels having the various respective profiles A, F, Cl and C2 as they occur in the assembled wall construction.

In accordance with step (f) of the method, pointing material is applied at the final step so as to provide a smooth, finished appearance having the appearance and waterproofing of a traditional stone wall finishing.

Further details of the assembly and construction of a stone wall using the pre-fabricated stone panels being in the form of a plurality of profile shapes, namely profiles, A, F, Cl and C2, will be provided hereinbelow.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be more clearly understood from the following description of two embodiments thereof, provided by way of example only, with reference to the Examples and with reference to the accompanying drawings, in which: Figure 1 is a perspective view of a first embodiment of the pre-fabricated panel of the present invention, including an insulation sheet element, shown in an assembly view; Figure 2 is a perspective view of the embodiment of Figure 1 shown with the elements assembled; Figure 2a is a perspective view On assembly) of pre-fabricated panel, constructed from a panel assembled by including insulation as shown in Figures 1 to 2; the panel having a first profile outline (referred to as "Panel A") Figure 2b is a perspective view (shown assembled) of the first profile (referred to as "Panel A") of pre-fabricated panel shown in Figure 2a; including insulation as shown in Figures 1 to 2; Figure 3 is a cross sectional view of the pre-fabricated panel of Figures 2b; Figure 4 is a front view of one embodiment of the pre-fabricated panel of the present invention; Typical front view of stone panel with three metal fixings and washers; the panel does not include any mortar between the stones on the face of the panel i.e. no pointing has been carried out on the panel as shown; Figure 5 is a front view of the embodiment of the pre-fabricated panel of Figure 4 with mortar having been applied between the stones on the front of the pre-fabricated panel so as to give the resulting finished appearance of a traditional stone wall; Thus Figure 5 shows a typical front view of stone panel after pointing has been carried out; Figure 6 is a perspective view of a second embodiment of a pre-fabricated panel of the present invention, without an insulation sheet element, shown in exploded view; Typical view of stone panel without the FIR insulation board; this embodiment of the pre-fabricated panel would be used in situations where the insulation factor is not an important consideration, e.g. an outer boundary wall at the end of a garden; or a stone fireplace or internal feature wall.

Figure 7a is a perspective view (shown in assembly, with the stone pieces indicated separately from the carrier support board,) of the pre-fabricated panel of Figure 6" the panel having a first profile outline (referred to as "Panel A" profile) constructed without using insulation and as shown in Figure 6; Figure 7b is a perspective view (shown assembled) of the pre-fabricated panel shown in Figure 7a having the profile referred to as "Panel A" profile; Figure 8 is a front view of a first profile (referred to as "Panel A") of pre-fabricated panel, constructed from the panel assembled by including insulation as shown in Figures 1 to 3; or constructed from a panel of Figs 6, 7a and 7b, assembled without insulation; Figure 9 is a front view of a second profile (i.e. the profile referred to as "Panel F") of pre-fabricated panel, constructed from the panel assembled by including insulation as shown in Figures 1 to 3; or constructed from the panel assembled without insulation as shown in Figure 6, Figure 7a and 7b; Figures 10(a) and 10(b) are respective front views of third and fourth profiles ( referred to as "Panel Cl and Panel C2") of pre-fabricated panels for use at comers, constructed from a panel assembled by including insulation as shown in Figures 1 to 3; or constructed from a panel assembled without insulation as shown in Figure 6; Figure 11 is a front view of each of the first, second, third and fourth profiles of pre-fabricated panels shown adjacent to each other; Figure 12 shows the sequence of assembling the plurality of pre-fabricated panels having the first, second, third and fourth profiles so as to build a wall for instance on the front of a building including at corners of the building; Figure 13 shows the final appearance of the wall constructed from the set of profiles of prefabricated panels; the panels being constructed from a panel assembled by including insulation as shown in Figures 1 to 3; or constructed from a panel assembled without insulation as shown in Figure 6; Figures 14 and 15 are perspective views of the set of profiles of pre-fabricated panels including panel profiles A, F, Cl and C2; it is to be understood that these panel profiles A, F, C1 and C2 can be in the form of pre-fabricated panel 100 with insulation or pre-fabricated panel 200 without insulation; and Figure 16 is a perspective view of a completed stone wall constructed from the pre-fabricated panels having the profiles A, F, C1 and C2 with the set of plurality of the panel profiles shown in their respective locations along the constructed wall.

DETAILED DESCRIPTION OF THE INVENTION

Referring initially to Figures 1 to 3, inclusive, the construction of a panel in accordance with the present invention will be described in more detail.

The pre-fabricated panel in the first embodiment, as shown in Figs 1 to 3, is indicated generally by reference numeral 100 and comprises a plurality of natural stone planar pieces 1, a carrier support such as a support board for instance, a magnesium silicate board 3; and a layer of insulation such as a sheet of insulation comprised of, for example, PIR sheet 5.

The pre-fabricated stone panel 100 also comprises a first adhesive system [2] for adhering the stone planar pieces to the carrier support; and a second adhesive system [4] for adhering the carrier support to the layer of insulation. Further details of the respective adhesive systems are provided hereinbelow in the Examples.

The pre-fabricated stone panel 100 also comprises fixing means 6 for instance a metal fixing typically, the metal fixing 6 may be in the form of a sleeve anchor.

A washer 7 is also included which is preferably, manufactured of a a non-rust/corrosion resistant material, most preferably, metal such as stainless steel.

The pre-fabricated stone panel 100 also comprises the following: 1. Acrylic based sealing material [8] is also provided as a sealant for the edges of the Magnesium Silicate board; 2 Cement-based pointing material [9] is preferred. In alternative embodiments, an acrylic-based pointing material, polymer-based, silicone-based or silicate based pointing material may be used.

Additional information: A sealant material, preferably, an acrylic sealer [8] is applied by brushing to the edges of the Magnesium Silicate board.

This is a precautionary extra measure to further waterproof the edges of the Magnesium Silicate board. As already explained above, it is a significant additional advantage of the adhesive system adapted for use in the pre-fabricated panel of the present invention, that a sealant is not required to be applied to the face of the carrier support board.

An alternative embodiment of the pre-fabricated stone panel,indicated by reference numeral 200 is shown in Figures 6, 7a() and 7(b). The pre-fabricated panel 200 does not comprise insulation but all other features are the same as for the pre-fabricated panel 100. Therefore, the same reference numerals as used in relation to pre-fabricated panel 100 are used in relation to prefabricated panel 200.

With reference to Figures 8 to 16 which show a plurality of panel profiles indicated by the reference letters, A, F, Cl and C2. It is to be understood that these panel profiles A, F, Cl and C2 can be in the form of pre-fabricated panel 100 with insulation or pre-fabricated panel 200 without insulation.

The stone panels 100, 200 can be provided with pointing material already located between the stone pieces 1 on the panel 100, 200. However, in the preferred embodiment, the pointing process is carried out at the construction stage when a wall is being constructed such that an operator on site will carry out the entire pointing process by applying mortar between the stone pieces 1 on the panel 100,200. Since pointing mortar material must also be applied at the joints between the stone panels, then the entire pointing process can be carried out on site, with the same pointing material being used so there is consistency of appearance at all points on the finished, assembled stone wall constructed from the pre-fabricated stone panels.

The pointing material is waterproof and has anti fungal chemicals added.

Particular care with pointing must be taken at the joints between the stone panels to ensure that no water/ dampness can penetrate.

A plurality of hole drilling location templates ( not shown) are provided for use during the construction process; each template corresponding to the profile shape of each of the profiles of pre-fabricated stone panels A, F, Cl and C2. Thus, there is a template corresponding to panel profiles A, F, Cl and C2.

Each template is made from a rigid structural board and has a 90 degree lip at the bottom. The holes in each template are protected by correctly sized steel washers to protect them from wearing.

In use, the template is positioned tightly against the preceding panels to enable when the holes are being drilled.

The accuracy of the dimensions of each of the pre-fabricated stone panels 100, 200 provided in the form of the panel profiles A, F, Cl and C2 is critical to ensure that the stone panels interlock tightly together. Also the straight edges of the panel profiles A, F, Cl and C2 enable them to abut together and achieve waterproof joints between respective abutting panel profiles A, F, Cl and C2..

The pre-fabricated stone panels 100, 200 provided in the form of profiles A, F, Cl and C2 are manufactured to an accuracy of + -0.5 mm.

The building sequence of the panels is critical to achieve the correct stonework look and to avoid long straight jointing/pointing lines in either the horizontal or vertical directions.

Referring now to Figure 16, in which a finished wall is shown constructed from the plurality of panel profiles A, F, Cl and C2; and referring also to Figs 8 to 15 in which the panel profiles A, F, Cl and C2 are shown, the method of construction will be described.

The method of constructing a stone wall assembled from the pre-fabricated stone panels of the present invention, preferably comprises the following steps: (a) Selecting an existing wall to which the traditional stone wall appearance is to be applied by securing the pre-fabricated stone panels of the present invention, thereto, in a pattern that enables the pre-fabricated stone panels to abut each other and in the assembled arrangement, gives the appearance of a traditional stone wall structure; (b) Applying a protective layer at the base of the existing wall, the protective layer thereby providing a reference level for the setting down of the first course of pre-fabricated stone panels; (c) Applying a layer of pointing material to the horizontal surface of the protective layer; (d) Applying a first pre-fabricated stone panels of the invention onto the protective layer and securing the pre-fabricated stone panel to the existing wall before proceeding to apply the next pre-fabricated stone panel; (e) Continuing to apply pre-fabricated stone panel to the protective layer and securing the pre-fabricated stone panels to the existing wall until a first row of stone wall has been constructed using the pre-fabricated stone panels; (f) Repeating steps (d) to (e) to build the stone wall using the pre-fabricated panels by mating together each of the profiles of pre-fabricated panels and applying pointing material as appropriate.

In accordance with step (t) of the method, pointing material is applied at the final step so as to provide a smooth, finished appearance having the appearance and waterproofing of a traditional stone wall finishing The protective layer may comprise any suitable damp proof coursing but in a preferred embodiment, the protective layer comprises an aluminium extrusion. Thus, the aluminium extrusion is preferably, used at the base of the stonework to seal off the bottom of stone panels from vermin or water ingress from the ground level. The aluminium extrusion may be of a generally [-shaped channel profile having 90 degree angled side wall.

The protective layer comprising the aluminium extrusion also has the function of providing the reference level for the first course of stone panels.

A layer of the pointing material is applied to the horizontal surface of this extrusion and the stone panels are then fitted on top of this layer.

In the preferred embodiment, the application of mortar i.e. the pointing, is carried out when the plurality of pre-fabricated panels are in use and have been assembled together to construct a wall and the mortar is then applied to the spaces between the stones in the panels and pointing is carried out so as to achieve the finished appearance and water proofing of a traditional stone wall.

Additional steps regarding fitting and sequence to construct a wall from the plurality of panels 1 The pre-fabricated stone panel profiles are fixed to the existing wall structure by working out from the comers, therefore, in the assembly process, the panel profiles Cl and C2 are used firstly in the construction process; 2 The lower reference level is taken using a spirit level and that level is marked; 3. The right angled Aluminium extrusion pieces are put in place so that they run horizontally along the reference levels; 4 Using the drill hole template for panel Cl, the first two holes are drilled; panel profile Cl is attached using sleeve anchors or other fixings; 6 Using drill hole template A, the next holes are drilled for attaching Panel profile A; 7 panel A is attached; 8 Using drill hole template F, the next holes are drilled for attaching panel profile F; 9 Panel F is attached; When the corner is reached, the panels A or F are trimmed to size in the width so as to be able to use panel Cl at the opposite corner 11 The above steps are repeated on the second row, beginning with panel C2 It is necessary to ensure that the drill templates are held tight against the previously fitted panels in the row below, before commencing drilling. This is to ensure that there is no gap between the joints of the panels.

When assembing the panels, it is important to note that on the second row, the panel F has to be re-sized in the horizontal dimensions. Thus, in use, the F panel ( Filler panel) typically has to be cut vertically to give a different width of the panel; the height of panel profile F remains the same, only the width may need adjustment in use and this can be achieved by trimming the panel profile.

12. When all panels are fixed, then as a final stage, the pointing process is carried out.

EXAMPLES of the adhesive systems: 1. First adhesive system [2] for adhering the stone planar pieces to the carrier support board; and 2. a second adhesive system [4] for adhering the carrier support board to the layer of insulation; 3. Acrylic based sealing material [8] is also provided as a sealant for the edges of the Magnesium Silicate board; and 4.Cement-based pointing material.

Example 1:

Adhesive system [2] for adhering the stone planar pieces to the carrier support board; DP462 Adhesive Raw Material Function PBW (Range) PBW (Actual) Desmodur 44V20L lsocyanate Unknown 27.00 Desmodur CD lsocyanate Unknown 70.00 Activator Unknown 2.88 Catalyst Unknown 0.12

Example 2:

Adhesive system [4] for adhering the carrier support board to the layer of insulation: DP457 Adhesive Raw Material Function PBW (Range) PBW (Actual) Acronal S702 Binder 1.0 to 99.0 78.00 Monopropylene Glycol Humectant 5.0-10 7.00 Coadis 123K Surfactant 0.1-1.0 2.50 Crosslinking Unknown 1.00 Agent Collacral HP Thickener 0.5-1.0 0.60 Acticide MKX Preservative 0.25-1.50 0.90 Water 10.0 It will of course, be understood that the present invention is not limited to the details described herein which are provided by way of example only. The scope of the present invention is limited only by the appended Claims.

Claims

CLAIMS1. A pre-fabricated masonry element panel comprising: a carrier support board; a plurality of masonry element pieces arranged in a pre-determined pattern on the support panel; and an adhesive system for bonding the stone pieces to the carrier support board; optionally, wherein the adhesive system comprises a moisture curing Diphenylmethane-4-4-Diisocyanate based adhesive for use in the pre-fabricated panel.
2. The pre-fabricated masonry element panel as claimed in claim 1 wherein the adhesive system is applied to a first side of the carrier support board using a roller or more preferably, using a toothed blade ( 2.0 mm X 2.0 mm), optimally at a wet film thickness of 250g/M2;the adhesive is moisture curing and when mist sprayed with 100g of cold water per 1,000g of adhesive, the film thickness will increase from approximately 2.0 mm to in excess of 10.0 mm wherein the adhesive rises around the sides of the decorative stone, thus anchoring the decorative stone to the carrier support board.
3. The pre-fabricated panel as claimed in claim 1 or claim 2 wherein the carrier support board comprises a panel composed of a silicate material.
4. The pre-fabricated panel of claim 3 wherein the masonry element pieces comprises stone pieces and the stone pieces provided on the pre-fabricated panel comprise any one or more selected from the following group: natural stone, faux stone, brick, pre-cast stone, ceramic tiles, slate, stone veneer, flexible stone veneer, re-constituted stone, and stone finish made using plaster.
5.The pre-fabricated panel of any one of the preceding claims wherein the pre-fabricated panel also comprises a layer of insulation.
6. The pre-fabricated stone panel of claim 5 wherein pre-fabricated panel also comprises a layer of adhesive comprising a second adhesive system configured for bonding the carrier support board to the layer of insulation; the second adhesive system comprising a solvent free vinyl chloride/hydroxypropyl acrylate/vinyl laurate terpolymer.
7. A pre-fabricated panel as claimed in claim 6 wherein the second adhesive system for bonding the insulation to the carrier support board adhesive comprises a solvent free vinyl chloride/hydroxypropyl acrylate/vinyl laurate terpolymer.
8. A pre-fabricated panel as claimed in claim 7 wherein the adhesive also contains a glycol co-solvent, preferably, monopropylene glycol, which slows down the drying properties of the adhesive, thus retarding adhesive absorption into the silicate board.
9. A pre-fabricated panel as claimed in claim 6 or claim 7, or claim 8 wherein the particle size of the adhesive is approximately 3p.
10. A pre-fabricated panel as claimed in any one of claims 6, 7, 8 or 9 claim 6 or claim 7 wherein the adhesive is applied by roller, optimally at a wet film of 300g/M2.
11.The pre-fabricated panel of any preceding claim wherein the carrier support board comprises a fibre cement board such as a board manufactured of Magnesium Silicate and/or Calcium silicate and/or a blend thereof
12. The pre-fabricated panel as claimed in any one of the preceding claims wherein the panel includes a sealing means comprising a primer or sealer for sealing the edges of the carrier support board.
13. A pre-fabricated panel as claimed in claim 12 wherein the sealing means comprise an acrylic-based sealant material
14. The pre-fabricated panel of any one of claims 5 to 13 wherein the layer of insulation comprises a layer comprising of any one or more selected from the following group: Polylsocyanurate (PIR) insulation, PolyUrethane ( PU), Polystyrene or aerogels.
15.The pre-fabricated panel of any one of the preceding claims wherein the first adhesive system further comprises a moisture curing Diphenylmethane-4-4-Diisocyanate based adhesive
16. The pre-fabricated panel as claimed in any one of the preceding claims comprising fixing means for fixing the panel to an existing wall structure.
17. The pre-fabricated panel as claimed in claim 16 wherein the fixing means comprises any one or more selected from the following group: a metal fixing preferably, a sleeve anchor; masonry screws or screws with rawlplugs; metal brackets or aluminium extrusions.
18. A construction system of pre-fabricated stone panels comprising a plurality of pre-fabricated panel profiles having a variety of profiles which when fitted in a particular sequence give the appearance of a random built stonework facing wherein the construction system comprises a plurality of panels as claimed in claim 1.
19. The construction system of claim 18 wherein the system comprises a first panel having a profile with an elongate portion with two arms protruding therefrom; and a second panel having an elongate profile for use along a face of a wall.
20. The construction system of claim 18 or claim 19 wherein the system also comprises at least one corner panel profile and preferably, two corner panels adapted for use at a corner of a wall where a right angled corner is required to be built around an existing structural wall.
21. The construction system of claim 20 wherein the system also comprises at least a third panel having a profile adapted for use at corners such as in construction of a wall around a corner.
22. The construction system of claim 19 or 20 wherein the system comprises a third and fourth panel having a profile adapted for use at a corner.
23. A construction kit comprising a plurality of panel profiles comprising a pre-fabricated panel as claimed in claim 1 wherein the panel profiels are adapted to abut each other, with substantially straight edges so as to facilitate abutting of the panel profiles, such that when the plurality of panels have been abutted together in a pre-determined pattern, and secured to an existing wall; the finished appearance resembles that of a traditional stone wall appearance.
24. A construction kit as claimed in Claim 23 wherein the abutted plurality of panels are secured to the existing wall by fixing means; and optionally, wherein the fixing means comprises any one or more selected from the following group: a metal fixing preferably, a sleeve anchor; masonry screws or screws with rawlplugs; metal brackets or aluminium extrusions.
25. A construction kit as claimed in Claim 24 wherein pointing material can be applied to the plurality of pre-fabricated panels to give the waterproofing and appearance of a traditional stone wall in the assembled wall constructed from the plurality of pre-fabricated panels.
26. A method of constructing a wall having the appearance of a traditional stone wall, wherein the method comprises using a plurality of pre-fabricated stone panels as claimed in Claim 1.
27.A method of constructing a stone wall assembled from the pre-fabricated stone panels of the present invention, comprising the following steps: (a) Selecting an existing wall to which the traditional stone wall appearance is to be applied by securing the pre-fabricated stone panels as claimed in Claim 1, thereto, in a pattern that enables the pre-fabricated stone panels to abut each other and in the assembled arrangement, gives the appearance of a traditional stone wall structure; (b) Applying a protective layer at the base of the existing wall, the protective layer thereby providing a reference level for the setting down of the first course of pre-fabricated stone panels; (c) Applying a layer of pointing material to the horizontal surface of the protective layer; (d) Applying a first pre-fabricated stone panels of the invention onto the protective layer and securing the pre-fabricated stone panel to the existing wall before proceeding to apply the next pre-fabricated stone panel; (e) Continuing to apply pre-fabricated stone panel to the protective layer and securing the pre-fabricated stone panels to the existing wall until a first row of stone wall has been constructed using the pre-fabricated stone panels; and (0 Repeating steps (d) to (e) to build the stone wall using the pre-fabricated panels by mating together each of the profiles of pre-fabricated panels and applying pointing material as appropriate.