IES20030436A2 - Sheet moulds for insitu brick facade - Google Patents

Abstract

Sheet moulds for in situ brick relates to a method of forming box shaped mould walls elevated on a base sheet of plastic or other similar materials. The mould walls are off a patterned shape to represent the outline of a concrete brick façade that can be attached to an old or new building. A multiple number of mould units a assembled together form panels which are fixed to the main building structure of concrete, timber or blocks to form a damp proof cladding. The brick shaped plastic units are then filled in with a concrete plaster mix to the level of the outer edge of the box moulds, resulting in a brick like façade finish. <Figure 1>

Description

This invention relates to sheet moulds for insitu brick and to a method of forming brick facing on walls of concrete timber or block construction.

The use of the standard single layer brick facing to concrete timber or block wall construction is the common method in use at present.

However the use of this conventional method of creating a brick fagade has many drawbacks in practice. Firstly standard bricks are very expensive to purchase compare to any other external wall surface finishes. The people who lay bricks have to be very skilled because of the uniformity of the exact joint lines both vertically and horizontally. The building of brick walls is extremely slow and labour intensive because of the extreme care that must be taken to avoid any of the mortar used for jointing getting on to the face of the bricks.

The conventional brick wall requires extensive ground preparation to cope with the combined load weight of the brick and the mortar bed. The preparation and building of the standard brick faced walling adds significantly to the overall cost of building construction whither the main structure is off concrete, timber or block.

It is an object of this invention to provide a brick facing to walls of concrete, timber or block construction, which is extremely economical with many advantages. A major advantage of the system is the damp proofing capability of the plastic sheet mould system and the simplicity of fixing the mould to the main structure whither of concrete, timber or block construction. h 7 0Ώ. iN/oS.

OPEN TO PUBLIC INSPECTION UNDER SECTON 28 ANL RULE 23 JNL No_, IE 0 5 04 J· According to the present invention there is provided a brick shaped multi mould unit comprising of a combination of open front plastic mould frames having a series of elevated walls for moulding the edges of the brick faced cladding. The open front-boxed shaped moulds are attached to the main building in horizontal rows laid in a continuous upward direction to the required height of the area to be covered.

When the moulds are jointed together they become one sheet of multi brick shaped box units with the base sheet of the moulds forming a single complete damp prove membrane, as each mould unit is attached to the pervious mould unit horizontally and vertically a continuous formation of brick pattern with perfect joint lines will emerge. The moulds can then be plastered in simultaneously with concrete plaster mix 24mm in depth and of a require colour and texture to resemble a bricked faced wall. Different shapes of the same colour can be used in different wall boxes giving a mixture of brick colour in the overall pattern.

The recessed plastic mould walls can be easily wiped clean before being allowed to dry and then dusted off.

The mould walls, which become joints of the filled in bricks, can be of a required colour to contrast with the insitu brick facing.

The filling or plastering in off the boxed shaped brick moulds is so simple that no training is required as the face of the mould walls are equal to the face of the Finished brick. A composite mould assembly maybe made up by connecting a number of mould units together. This may then be used to cast a plurality of brick units side by side simply by introducing moulding material such as concrete, plaster into the mould assembly with a standard plastering trowel and levelling to the surface of the mould boxes. ΙΕ Π 3 04 56 The box shaped mould walls are broad splayed to the front, which means that the concrete brick infill is dove tailed in on all four sides. This method of dove tailing prohibits the concrete infill from falling out when the wet concrete material dries out and hardens.

A 50mm wide thin plastic apron extends from the top and one side of the base of each mould sheet. The connecting mould sheet will over lap on to the apron of the pervious fixed mould sheet. The purpose of this over lapping is to prohibit any external moisture or damp penetrating into the internal structure on which the cladding is fixed. The over lap method while stopping external dampness from penetrating inwards allows the internal structure to breath and still remain dry. The ability of the internal structure to breath is vital to prevent the build up of condensation and stop the development of fungus. This is one of the problems with some of the timber-framed structures at present, where a continuous vapour barrier is in standard use. A continuous vapour barrier system keeps the damp and moisture out but it also stops the internal structure from breathing and the internal condensation is trapped on the inside of the vapour barrier.

The plastic insitu mould sheets come in various sizes upwards from 1200mm in length and 600mm in width.

The sheets can be assembled together to make up whatever surface area is required. The plastic insitu mould sheets are connected at the outer corner of the building by means of a plastic bead. The outer corner bead is of a square dimension, which is equal to the thickness of the two, adjoining insitu mould sheets. The inner corner ofthe corner bead has attached two 50mm aprons, which extend under the two adjoining plastic mould sheets. The aprons ofthe external corner bead IE03 0436 whither the bead is used in a vertical or horizontal position ensures that the external moisture is conveyed in a downward and outward direction.

The same method that applies to the external corners can also apply to the internal application. The internal corner bead is also 25mm by 25mm of a squared dimension.

The adjoining plaster insitu mould sheets over lap on to the apron of the internal corner bead allowing only the bear edge of the internal comer bead to be invisible when the adjoining brick moulds are filled with concrete plaster.

A very important innovation in this insitu mould system is that it comprises of a very small number units in the make up of the total system. The total system comprises of three units, the plastic mould multi unit sheet, the internal corner bead and the external corner bead. The plastic mould multi unit sheet starts with a sheet size of 1200mm by 600mm with a box depth of 24mm but can be increased if required. ΐ The external and internal corner beads can be in lengths of one, two or three metres with a square dimension of 24mm. The sheet moulds are attached to the main construction be it concrete, timber frame or block by screws or masonry'nails with a large head. The screw or masonry nail would go through a centre core of an oblong galvanized expanded metal washer. The fixing points could be at centres of every other brick mould with a penetration into the main structure of not less than 40mm.

Special mould formations for window and door heads with vertical brick design who be available on requested.

These special moulds could be in a variation of arch designs but of similar construction as the plastic multi unit sheet mould.

IE Ο 3 04 3 6 CLAIMS

Claims (11)

1. This system is designed as an easy, inexpensive method of putting a brick face on an old plain wall, a new concrete wall or a timber framed building. The system has just three parts an inside corner unit that the adjoining panels butt into, an outside corner unit with a similar purpose and the main panel (1125mm x 440mm in size). The panels can be nailed or screwed onto the main structure and sit on a concrete plinth as a base support. The panels are then simple filled with a concrete plaster mix and when dried out you have a new brick face at a very low cost.

1. A concrete brick mould unit comprising an opened topped frame having side walls, attached to a base sheet for moulding a concrete brick fagade formed by means of connecting with other assembled mould units of the same form so as to permit a plurality of concrete brick mould units to be filled in simultaneously in position s immediately adjacent to one another. §eeF,gure1 A mould according to claim one where in the side walls are provided by attaching a series of plastic strips circa 3mm in thickness by 24mm in width to a base sheet of similar thickness. See Figure 5

2. 3. A mould according to claim 2, where in the mould units as described in claim 1, are assembled together to form a plurality of units in the shape of a panel. The base of each panel having attached to it’s top IE Ο 3 04 3 6 and one side an extended apron of thin formation to an extended distance of 40mm. SeeF '9 ure4

3. 4. A mould according to claims 1,2 and 3 where in the adjoining panel of mould units over lap both vertically and horizontally on to an apron of the pervious panel in order to form a continuous damp proof membrane between the structure and the external brick fagade cladding. SeeFi9ures1&4

4. 5. A mould according to claim 4 where in the mould walls are thicker at the outer face than at the base where they attach on to the base sheet. The in-word dove tailed shaped mould walls form a grip on the concrete in-fills of the plastic moulds and holds the in-fills in a positive lock in position. SeeF| 9 ureS

5. 6. A mould according to claim 5 where in the mould unit wall has an inverted circular shape to resemble brick pointing of the same hollow design and can be of a colour to contrast or embellish the colour of the adjoining brick pattern. The plastic brick jointing will clean easily and remain free from fungus growth. See Figure 5

6. 7. A mould according to any proceeding claim where in the method of attachment of the sheet plastic moulds to the main structure is by simple screw or nails which screwed or driven through a plastic or metal mesh washer. The mesh washer becomes imbedded in the in-fill plaster acting as a re-enforcing agent as it strengthens the holding bond of the nail or screw by means of holding the mould sheet to the main structure.

7. 8. A bead of square dimension according to any proceeding claims necessary for the joining of the previously described moulding at the internal and external corners of the building and the corners surrounding the windows and the door opes. The simplicity of this method of corner joining allows for easy fitting of the sheet moulds at the corners by simply butting the sheet panels to the side face of the corner bead. This method allows the panels to be cut where required and the subsequent filling of the cut units to be filled in and finished to the corner bead.

8. 9. The corner bead according to the proceeding claim where in a thin plastic apron extends from the two sides of the corner bead to form an under lap on to which the adjoining sheet moulds sit.

9. 10. A mould according to any of the proceeding claims where in the internal corner bead has attached two aprons of 40mm in width which runs the length of the corner bead and extend from the two opposite corners of the corner bead for the said purpose of under lapping the adjoining sheet moulds.

10.

11. An external corner bead similar to the pervious claim where in attached are two aprons of 40mm in width and running the length of the bead for the said purpose of under lapping the adjoining sheet moulds. IE Ο 3 04 3 6 030436 in LU t=l H cr · D υ 0 LX •ri1X1 CT