IL320323A - Kits, systems and methods for cladding walls and structures manufactured in this way - Google Patents

Kits, systems and methods for cladding walls and structures manufactured in this way

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Publication number
IL320323A
IL320323A IL320323A IL32032325A IL320323A IL 320323 A IL320323 A IL 320323A IL 320323 A IL320323 A IL 320323A IL 32032325 A IL32032325 A IL 32032325A IL 320323 A IL320323 A IL 320323A
Authority
IL
Israel
Prior art keywords
cladding
elements
cementitious material
undercut
formwork
Prior art date
Application number
IL320323A
Other languages
Hebrew (he)
Inventor
LAMDAN Moshe
Pokotinsky Ariel
Original Assignee
Tidhar Eco Wall Ltd
LAMDAN Moshe
Pokotinsky Ariel
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from IL288212A external-priority patent/IL288212A/en
Application filed by Tidhar Eco Wall Ltd, LAMDAN Moshe, Pokotinsky Ariel filed Critical Tidhar Eco Wall Ltd
Publication of IL320323A publication Critical patent/IL320323A/en

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Classifications

    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00Coverings or linings, e.g. for walls or ceilings
    • E04F13/07Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Finishing Walls (AREA)

Description

WALL CLADDING KITS, SYSTEMS, METHODS AND STRUCTURESFORMED THEREWITH FIELD AND BACKGROUND OF THE INVENTIONThe present invention, in some embodiments thereof, relates to wall cladding kits, 5systems, methods and structures cladded therewith and, more particularly, but not exclusively, towet wall cladding kits, systems, methods and structures cladded therewith.Wall cladding is often used in place of plastering to provide an aesthetic and durablefinish to both interior and exterior walls. The finish may be decorative as well as functional.There are different wall cladding systems and methods. Gluing is the simplest and cheapest 10method, and is often used for internal walls. In this method an end cladding element or material(as these terms are used alternatively throughout), e.g., a ceramic tile, is directly glued onto anexisting (i.e., pre-existing, backup, all three terms are used herein interchangeable) wall.Building standards typically limit the use of gluing for external wall cladding at least to maximalheight and/or weight or tile size, as gluing durability relies on the skill of the workman, material 15selection and aging and is therefore difficult to ensure.Dry wall cladding is a system used primarily on external walls. In dry wall cladding, theend cladding material is mechanically fixed directly or indirectly to a (pre-existing) wall withsteel attachments, e.g., screws, that restrain its vertical and horizontal movement. The steelattachments may be fixed directly into the wall, or may be fixed onto galvanized or stainless 20metal beams positioned along and connected to the pre-existing wall. Various types ofattachments are available. In one known method, an attachment in the form of an undercutanchor which is secured to the back surface (i.e., underside) of the end cladding material is used.This method is based on drilling an undercut hole into the back surface of the end claddingmaterial and fixing the undercut anchor onto the end cladding material with a simple screw 25aimed at flaring the undercut anchor. Typically, the end cladding material is fixed to the wallwith an air gap formed by the beams. The air gap may provide ventilation as assisting in thermalinsulation of the cladded structure. Although dry wall cladding is known to be highly durable, itis also costly and requires skilled labor as compared to the gluing method and/or wet claddingmethods as is further delineated herein below. Because of the large potential number of locations 30in the back surface of the end cladding element, in dry cladding there is no size limitationimposed by the method per se to the size of the end cladding element. This allows forarchitectural and functional variations as required and/or desired. Hence, dry cladding allows thearchitectural selection of numerous end cladding materials, such as, but not limited to, ceramics, stone, artificial stone, architectural concrete, HPL and various forms of aluminum in any size,shape, color, texture, shin or finish.Wet cladding is another method for external wall cladding that is often used in Israel, aswell as other regions in the middle-east to clad external walls with natural stone and/or artificialstone made of concrete (for the latter, see section 1872 Part 1 of the Israeli building standard). 5About 80 % of the residential buildings in Israel are cladded using wet cladding methodologies.Wet cladding involves embedding mechanical fixing elements into an end cladding element atone end and to a wet cementitious material at the other end. Typically, but not necessarily, wetcladding combines gluing, i.e., chemical bonding, as well as mechanical fixing as is furtherdiscussed herein under. 10For both regulatory and practical reasons, all three wet cladding methods practiced inIsrael are limited to stone.One method of wet cladding which is limited to stone having 2-3 cm thickness, is detailedin section 2378 Part 2 of the Israeli building standard and is typically used when cladding withJerusalem stone. Section 2378 Part 2 requires fixing a reinforcement metal mesh to a backup 15wall, gluing a row of stones over the reinforcement metal mesh with mortar while mechanicallyfixing the stones to the reinforcement metal mesh and the mortar (once hardened) with metal pinshaving a predefined structure. Each such metal pin has a proximal section, a middle section and adistal section. The proximal section of the pin is designed to be inserted into a pre-drilled holeextending along the thickness, i.e., the edge surface, the upper, left and right side, of the stone, 20which is why the stone has to be at least 2 cm thick. This is true for all wet cladding methodspracticed. The distal section is designed to protrude from the edge surface of the stone towardsthe net and backup wall. Section 2378 Part 2 further requires forming a slot extending from thehole to the back surface of the end cladding material, so as to embrace the middle section of thepin, in order to ensure the pin will not fall off the stone during construction. The metal pins 25provide for mechanical fixing to secure the stones to the backup wall in addition to gluing, i.e.,chemically bonding, with the mortar, resulting in higher durability and safety of the claddedstructure. As discussed, in Section 2378 Part 2, the end cladding material is required to be stonehaving a thickness of at least 2 cm. The metal pins are required to have a diameter of 3.5 mm.The 2 cm thickness supports drilling holes and slots through a thickness (i.e., side) of the stone 30and accommodates inserting the metal pins with a diameter of 3.5 mm therein. This particularcladding method requires assembling a scaffold for constructing a backup wall, disassembling thescaffold and allowing the backup wall to harden, re-assembling the scaffold for cladding and re-disassembling the scaffold after cladding. Thus, scaffolds are assembled and disassembled twice.
This process is labor intensive, far from being "industrial", not at all economical and/orregulatory viable and not at all practical for buildings higher than 9 stories.The Baranovich method (named after Eng. Mr. Baranovich, who invented the method) isyet another known wet cladding method that has been commonly used in Israel since the 1980’s.The Baranovich method is designed to solve the limitations described above for wet cladding, 5rendering wet cladding more industrial, less labor-intensive, cheaper, faster to construct andpractical for buildings of any height. In fact, nearly all residential building higher than 9 storiesin Israel are built using the Baranovich method. The Baranovich method is solely practiced inIsrael. Standardization of this method was established in 2015 in the Israeli Building standard2378 Part 5. In the Baranovich method, the external wall of a structure is formed and 10concurrently cladded with a stone exterior. Being more industrialized, this method conservesconstruction time, is less prone to construction mistakes and increases the durability andhomogeneity of the cladding. In the Baranovich method, rows of stones are laid against an outerformwork sheet and similar to the manual wet cladding method described above, metal pins arefitted through pre-drilled holes and slots. A reinforcement metal mesh is placed behind the 15stones with the pins extending in the direction of the reinforcement metal mesh, without arequired physical engagement there between. The stones are held in place by tying thereinforcement metal mesh and the outer formwork sheet with a barbed wire which is inserted viaholes formed in the outer formwork sheet, thereby securing the stones between the outer sheetand the reinforcement metal mesh. Rows of stones are spaced from one another via spacers 20formed on the back surface of the outer formwork sheet. The gaps between the stones are sealedwith a cementitious material commonly referred to in the art as "chochla" and the back surface iscovered with a sealant, e.g., a primer, to prevent soaking of cement into the volume of stone,thereby preventing irreversible staining of the front surface of the stone. At this stage, a pluralityof the described assemblies are hoisted (i.e., lifted) with a crane to a floor under construction, the 25inner formwork sheets are put in place (with or without heat insulating building blocks placedbetween the inner formwork sheet and the reinforcement metal mesh) and tied to the respectiveouter formwork sheets via a plurality of securing bolts passing between the two sheets throughdedicated holes, generating a continuous formwork circumferencing the floor under construction.Concrete is poured in the gap between the inner formwork sheets (or the heat insulating building 30blocks when used) and the end cladding stone rows, in which gap the reinforcement metal meshis pre-positioned. Once the concrete hardens the ties, the securing bolts and both formwork sheetsare removed. The reinforcement metal mesh together with the concrete forms the external wallof the structure and cladding can then be carried out in a single step, without the need for scaffolds altogether. Building standard 2378 Part 5 also requires stone having a thickness of atleast 2 cm and pins having a diameter of 3.5 mm. In practice, this standard also applies to pre-castcladded walls, the difference being that the walls are typically formed in a factory and thereafterbrought to a construction site and hoisted to floors under construction. Pre-cast stone claddedwalls can be formed horizontally as well, whereby stone with pins as herein described are placed 5horizontally with the pins extending upwardly. A reinforcement metal mesh is placed thereon andconcrete is poured to form the cladded pre-cast wall. Similarly, pre-cast stone cladded walls canbe formed horizontally by forming a fortified wall structure (having a reinforcement metal meshburied therein) and prior to hardening of the concrete, placing thereon end cladding stones withpins as herein described, the pins extending downwardly into the concrete and are physically 10engaged thereby when the concrete hardens.For traditional wet cladding method and the Baranovich method, the mechanical fixingrequires inserting pins through pre-drilled holes formed in the thickness (sides) of the stones.The stone for this purpose is required to have a certain thickness to support the drill hole and thepins. 15The Baranovich method has its specific limitations as well. One major limitation is thefact that liquid cement pours through the gaps formed between the stones in the regions of thepins and in locations where the "chochla" seal is compromised, as well as through the holesformed in the outer formwork sheet for insertion of the barbed wire, and more so through thebolt-dedicated holes, resulting in cementitious material accumulating between the front surface of 20the stones and the back surface of the front sheet, staining the façade of the cladded wall. Suchstains have to be removed after the entire construction is completed using sanding disk and/orpressurized water (see, for example, Figure 15). This cleaning process costs ca. 40 % of the totalcost of typical cladding.Another limitation associated with the Baranovich method is the misplacement of the 25pins, which are loosely engaged by the drilled holes, resulting in weakening the mechanicalfixing of the stone to the concrete wall. Due to potential misplacement of the pins, whileconstructing using the Baranovich methods, the use of concrete pumps and ultrasonic vibratorsare forbidden, hampering the construction quality as a whole. The cladding regulations and methods described herein are limited to stone, which is 30thick for reasons described above and is therefore heavy, requiring heavier fortification for theentire structure.Also, stone has inherent limitations, as detailed below: It has a very high water absorption, requiring the addition of heat insulation layers to theinner side of the external walls of the structure and resulting in high water ingress and acceleratedageing of the construction as a whole.It ages non-homogenously, its aging behavior is variable and unpredictable, resulting incladding failure. 5It readily stains, e.g., by graffiti, as it soaks the stains.It is costly for numerous reasons. First natural stone is inherently costly. Second, naturalstone is heavy, resulting is high shipping costs.The architectural variety of cladding material is very limited to the extent that all thefacades of constructions built therewith in Israel look very similar. The color consistency of 10natural stone is very poor.The regulation requires that the pins are to be spaced no more than 30 cm apart from oneanother, resulting in that all the buildings wet cladded with stone are made of 30 cm high stonestripes because, as described above, the mechanical fixing pins are engaging the stone throughthe thickness (side) thereof. 15The chemical bonding between the back surface of the stone and the cementitiousmaterial is weak, due to the use of sealant or primer.Last, but not least, the use of natural stone harms the environment, considered not "green"and therefore quarries are being discontinued worldwide.Table 1 below summarizes some of the differences between stone and non-stone (e.g., 20porcelain) end cladding elements.
Table 1 25Item 10 mm thickPorcelain Tilemm thickNatural StoneThermal Conductivitytimes moreinsulating-Water Sealed Façade + -Bending Strength (MPa) 38 17Breaking Strength At least 2500 1600Scratch Resistance + -Chemical Resistance + -Doesn’t Contain salable salts andMinerals+ -Consistent strength and resistance + -Low Expansion with temp change + - Uniform Size and color + -Wide architectural variety + -Doesn’t Requires Expensive cleaning + -Does not Absorb water and concrete + - Patent number IL243159 describes a cladding method designed to assist in thermalinsulation by forming an air gap and ventilation path for hot air through the gap. The gap isformed by spacing a thermal insulation layer from the end cladding elements via spacers andpouring concrete between the back side of the layer and a back sheet of a formwork. Heat 5insulation layers are formed from soft, air trapping, materials, otherwise they are dysfunctional asheat insulating elements.The drawbacks of the cladding method described in IL243159 are numerous.First, during pouring of concrete at 600 Kg per square meter (as is the case usingconventional Baranovich formwork), the heat insulation layer, especially at the lower end of the 10formwork, albeit the spacers, is likely to collapse over the back surface of the cladding elements,thereby eliminating or constricting the air gap, resulting in compromised or no air ventilation.Second, the holes formed in the heat insulation layer to allow pins to protrude from theback surface of the layer into the concrete will allow the wet concrete to spill into the gap, furthereliminating or constricting the air gap, resulting in compromised or no ventilation. 15Third, there is no chemical bonding between the back surface of the end claddingelements and the concrete, as is specifically required by section 2378 Part 2 of the Israeli buildingstandard.Fourth, in order for the air gap to function as a ventilation gap, air gaps should also bemaintained between the end cladding elements, resulting is a structure that may age faster over 20time due to water ingress through the gaps between the end cladding elements.Fifth, although heat insulation layers are typically supplemented with fire retardants,nearly no fire retardation technology can prevent the ignition and burning of the insulation layerwhen fed by more and more heated oxygen containing air rushing ever faster through the gapsventing out from the top of the cladded structure, which may result in complete burnout and 25destruction of the entire cladded structure.Sixth, there is no existing heat insulation layer that can withstand exposure to theelements over time as in this case. Indeed, ventilated building facades do exist, but are never usedalongside with heat insulation layers exposed to the elements.Seventh, although structurally and practically advantageous, the Baranovich method does 30not allow the use of concrete pumps nor the use of sonication probes, as using same may displace the pins. The method described in IL243159, also does not allow the use of concrete pumps, northe use of sonication probes, because the weight of the wet concrete and aggregates therein,especially when accelerated by the concrete pump or sonication probe is not dissipated by anymeans which may result in the disengagement of the pins from the pre-formed holes in the backside of the end cladding elements, especially if ceramic porcelain tiles are used, whereby the 5depth of the pre-formed undercut hole cannot extend beyond ca. 5 mm into the end claddingelement.Last, but not least, the cladding method described in IL243159 fails to comply with Israelibuilding standard 1555, section 4, that pertains to structures having external air ventilatedfacades. In fact, there is no standard or combination of standards that would allow constructing 10an external cladded wall using the method described in IL243159.Additional background art includes JP2003328532; DE102007060956; and US5,083,407; as well as the Israeli standards for building coverings, including, e.g., standard 314 -Ceramic tiles definitions and specifications; standard 1555 Part 1 – flooring and cladding inporcelain and mosaic outdoor cladding; standard 1555 part 2 – flooring and cladding in porcelain 15and mosaic indoor and closed; standard 1555 part 4 – flooring and cladding in porcelain andmosaic dry cladding; standard 1872 part 1 – Cladding in artificial stone – definitions; standard1872 part 2 – Cladding in artificial stone – wet cladding; standard 1872 Part 4 – Cladding inartificial stone – Gluing with mechanical fixing; standard 1872 part 5.1 – Cladding in artificialstone – Precast and mechanical fixing; standard 1872 part 5.2. – Cladding in artificial stone – 20Toothed units; standard 2378 part 1 – Cladding in stone – general demands; standard 2378 part 2– cladding in stone – wet cladding; standard 2378 part 3 – cladding in stone – dry cladding;standard 2378 part 4 – cladding in stone – gluing with mechanical fixing; standard 2378 part 5 –cladding in stone – precast and on site pre casting; standard 2378 part 6 – cladding in stone –double wall system; standard 6560 – cladding with external thermal barrier; standard 1414part 1 25– external plastering; standard 1414 part 3 – External thermal plastering; and standard 1568 –Ventilated facades.All of these references are incorporated herein by reference in their entirety.There is thus, a great need for, and it would be highly advantageous to have, a wetcladding method that will allow the advantages inherent to the method itself, allowing the use of 30industrialized cladding materials such as ceramic tiles, while avoiding the limitations associatedwith the use of stone and/or the method described in IL243159 and which complies with Israelibuilding standards.
SUMMARY OF THE INVENTIONAccording to an aspect of the present invention there is provided a wet cladding kit forfixing an end cladding element to cementitious material of, or on, a backup wall, the kitcomprising:an undercut anchor configured for being inserted into a hole formed on a back surface of 5the end cladding element;a flaring element configured for flaring said undercut anchor in said hole, said flaringelement comprises a first portion of a connecting structure; anda cementitious material engaging element which comprises at its proximal end a secondportion of said connecting structure, said second portion of said connecting structure directly or 10indirectly connectable to said first portion of said connecting structure, said cementitious materialengaging element further comprises a distal end extending from the second portion of theconnecting structure for being embedded in the cementitious material;wherein the first portion of the connecting structure and the second portion of theconnecting structure are designed to be directly or indirectly potentially looseably connectable to 15form the connecting structure, so as to reduce a tendency of the undercut anchor from damagingwalls defining the hole when a torque is applied onto the engaging element;whereby the undercut anchor, the flaring element and the connecting structure are selectedto provide a load bearing attachment between the cementitious material engaging element and theend cladding element, so as to provide mechanical fixing of the end cladding element to the 20cementitious material when the cementitious material is hardened.According to embodiments of the invention, the first end of the connecting structure isdirectly connectable to the second end of the connecting structure.According to embodiments of the invention, the first end of the connecting structure isindirectly connectable to the second end of the connecting structure. 25According to embodiments of the invention, the cementitious material engaging elementhas a normal vector component in the distal end which, during service, is positioned parallel tothe backup wall and the end cladding element.According to embodiments of the invention, the normal vector component is formed, atleast in part, by selecting the distal end of the cementitious material engaging element with a 30bend.According to embodiments of the invention, the cementitious material engaging elementis threaded at the distal end and wherein the normal vector component is formed at least in partby a threaded surface of the distal end.
According to embodiments of the invention, the kit further comprises a load dispersionelement connectable to, or integrally formed with, the flaring element or the undercut anchor,wherein the load dispersion element is configured to disperse load over a surface area of the loaddispersion element, the surface area being at least twice the surface area of the hole, so as toreduce load imposed by the undercut anchor on walls defining the hole. 5According to embodiments of the invention, the second portion of the connectingstructure is a connecting element selected from the group consisting of a washer shaped element,a closed ring, an open ring, a loop and a helix.According to embodiments of the invention, the first portion of the connecting structure isa head structure of the flaring element. 10According to embodiments of the invention, the flaring element is a threaded elementconfigured to be received through the second portion of the connecting structure and into theundercut anchor to fix the cementitious material engaging element onto the back surface of theend cladding element.According to embodiments of the invention, the kit further comprises end cladding 15elements.According to embodiments of the invention, the kit further comprises a securing plate anda removable end cladding element securing agent for temporarily securing the end claddingelement to a formwork.According to embodiments of the invention, the kit further comprises water sealing strips 20attachable onto the back surface of adjacent the end cladding element, configured to seal gapsbetween the adjacent end cladding element, so as to prevent leakage of the cementitious materialbetween a front surface of the end cladding elements and an outer sheet of a formwork and towater seal the wall once the cementitious material is hardened.According to an aspect of the invention, there is provided a wet cladding system for fixing 25an end cladding element to cementitious material of or on a backup wall comprising:at least one kit described herein; andat least one end cladding element.According to embodiments of the invention, the hole is an undercut hole.According to embodiments of the invention, the hole is a blind hole which traverses a 30thickness of an end-cladding element, the blind hole having an opening on a back surface of theend-cladding element, the blind hole being defined by internal walls having a length and asubstantially identical diameter along the length.
According to embodiments of the invention, the material has a plasticity and issufficiently non-brittle, so as to allow flaring of the undercut anchor into the material withoutbreaking the end-cladding element, the material having a retention force that allows rigidattachment of the undercut anchor to the end-cladding element.According to embodiments of the invention, the end cladding element is fabricated from a 5synthetic material.According to embodiments of the invention, the end-cladding element is fabricated from apre-prefabricated cementitious material.According to embodiments of the invention, the end-cladding element is a pre-fabricatedcement board. 10According to embodiments of the invention, the pre-fabricated cement board is a cementbonded particle board or a cement fiber board.According to embodiments of the invention, the end cladding element is fabricated from amaterial selected from the group consisting of ceramic clay, porcelain, a high pressure laminate(HPL), concrete, Corian®, Caesarstone®, glass, slate and stone. 15According to embodiments of the invention, the front surface of the end cladding elementis lined with a removable protective cover.
According to embodiments of the invention, the end cladding element includes the holepre-formed on the back surface. 20According to embodiments of the invention, the end cladding element includes theundercut anchor inserted into the hole.According to embodiments of the invention, the end cladding element includes the flaringelement installed in the undercut anchor.According to embodiments of the invention, the cementitious material engaging element 25is connected to the flaring element.According to embodiments of the invention, the system comprises at least eleven kits persquare meter of the end cladding element.According to embodiments of the invention, the system further comprises a corner bracketconfigured for engaging two end cladding elements at a predetermined angle. 30According to embodiments of the invention, the corner bracket is connectable to the endcladding element via undercut anchors and respective undercut holes.According to embodiments of the invention, the system comprises:at least two end cladding elements; and at least one corner bracket fixed to at least one of the at least two end cladding elements.According to embodiments of the invention, the water sealing strips seal gaps betweenadjacent end cladding elements.According to embodiments of the invention, the system further comprises securing platesand removable end cladding element securing agents for temporarily securing the end cladding 5elements to an outer sheet of the formwork.According to embodiments of the invention, the removable end cladding element securingagents are configured to be removable when the cementitious material is hardened.According to another aspect of the invention, there is provided a method of wet cladding abackup wall, the method comprising: 10(a) providing a plurality of kits described herein;(b) providing a plurality of end cladding elements having back surfaces whichcomprise a hole;(c) engaging a reinforcement metal mesh onto a backup wall to be cladded;(d) engaging the kits in the undercut holes; and 15(e) applying the cementitious material between the back surfaces of the plurality ofend cladding elements and the backup wall with the cementitious material engaging elementspenetrating into the cementitious material;(f) allowing the cementitious material to harden with the cementitious materialengaging elements penetrating therein, thereby providing mechanical fixing and chemical 20bonding of the plurality of end cladding elements to the cementitious material when thecementitious material is hardened, thereby wet cladding the backup wall.According to embodiments of the invention, the hole is an undercut hole.According to embodiments of the invention, the hole is a blind hole which traverses athickness of the end-cladding element, the blind hole having an opening on a back surface of the 25end-cladding element, the blind hole being defined by internal walls having a length and asubstantially identical diameter along the length.According to embodiments of the invention, the method further comprises spacing theplurality of end cladding elements with spacers.According to embodiments of the invention, the method further comprises removing 30cementitious material leakages from a front surface of the plurality of end cladding elements.According to embodiments of the invention, the cementitious material engaging elementspenetrate beyond and engages the reinforcement metal mesh.
According to still another aspect of the invention, there is provided a wet cladding methodof constructing a cladded wall, the method comprising:(a) providing a plurality of kits described herein;(b) providing a plurality of end cladding elements formed with holes in back surfacesof the plurality of end cladding elements; 5(c) providing a formwork having an outer sheet and an inner sheet;(d) arranging the plurality of end cladding elements with a front surface thereofagainst a back surface of the outer sheet of the formwork;(e) engaging the plurality of kits in the undercut holes;(f) securing the inner sheet and the outer sheet of the formwork to one another with 10formwork securing elements;(g) applying the cementitious material into the formwork; and(h) allowing the cementitious material to harden with the cementitious materialengaging elements penetrating therein, thereby providing the mechanical fixing and chemicalbonding of the end cladding elements to the cementitious material when the cementitious material 15is hardened, thereby constructing the cladded wall.According to embodiments of the invention, the applying is effected with a concretepump.According to embodiments of the invention, the method further comprises ultrasonicallyvibrating the cementitious material before the cementitious material is hardened. 20According to embodiments of the invention, the method further comprises spacing theplurality of end cladding elements with spacers spaced on the back surface the outer sheet of theformwork.According to embodiments of the invention, the spacers are integrally formed with orpermanently attached to the outer sheet of the formwork. 25According to embodiments of the invention, the method further comprises placing areinforcement metal mesh between the plurality of end cladding elements and the inner sheet ofthe formwork.According to embodiments of the invention, the method further comprises placinginsulating building blocks against an inner surface of the inner formwork sheet. 30According to embodiments of the invention, the method further comprises applying aplurality of water sealing strips onto the back surfaces of the plurality of end cladding elements,the water sealing strips configured to seal gaps between adjacent the plurality of end claddingelements, so as to prevent leakage of the cementitious material between the front surface of the plurality of end cladding elements and the outer sheet of the formwork and to water seal the wallonce the cementitious material is hardened.According to embodiments of the invention, the method further comprises:(i) arranging an additional set of end-cladding elements with a front surface thereofagainst a back surface of an inner sheet of the formwork; and 5(j) connecting cementitious material engaging elements with the end-claddingelements of the additional set, wherein steps (i) and (j) are carried out prior to step (f).According to embodiments of the invention, the additional set of end-cladding elementsare fabricated from a cementitious material.According to embodiments of the invention, the additional set of end-cladding elements 10comprise pre-fabricated cement boards.According to embodiments of the invention, the pre-fabricated cement boards are cementbonded particle boards or cement fiber boards.According to embodiments of the invention, the connecting is via holes that are formed inback surfaces of the first set of end-cladding elements into which undercut anchors have been 15inserted.According to embodiments of the invention, the holes are undercut holes.According to embodiments of the invention, the holes are defined by internal walls havinga length and a substantially identical diameter along the length.According to embodiments of the invention, the connecting is via holes that are formed in 20sides of the additional set of end-cladding elements.According to embodiments of the invention, the method further comprises un-securing theinner sheet and the outer sheet of the formwork from one another by removing the formworksecuring elements and removing the formwork.According to embodiments of the invention, the method further comprises removing 25cementitious material leakages from a front surface of the plurality of end cladding elements.According to an aspect of the invention, there is provided a wet cladding method forconstructing a cladded wall, the method comprising:(a) providing a plurality of kits described herein;(b) providing a plurality of end cladding elements formed with undercut holes on back 30surfaces of the plurality of end cladding elements;(c) placing the plurality of end cladding elements inside an area defined by ahorizontal framework;(d) engaging the plurality of kits in the undercut holes; (e) applying the cementitious material onto the back surfaces;(f) allowing the cementitious material to harden with the cementitious materialengaging elements of the kits penetrating therein, thereby providing mechanical fixing andchemical bonding of the plurality of end cladding elements to the cementitious material oncehardened, thereby constructing the cladded wall. 5According to embodiments of the invention, the method further comprises applying aplurality of water sealing strips onto back surfaces of the plurality of end cladding elements, thewater sealing strips configured to seal gaps between adjacent the plurality of end claddingelements.According to an aspect of the invention, there is provided a wet cladding method for 10constructing a cladded wall, the method comprising:(a) providing a plurality of kits described herein;(b) providing a plurality of end cladding elements formed with undercut holes onback surfaces of the plurality of end cladding elements;(c) applying cementitious material into a horizontal framework; 15(d) engaging the plurality of kits in the undercut holes;(e) placing the plurality of end cladding elements with a back surface thereof ontothe cementitious material;(f) allowing the cementitious material to harden with the cementitious materialengaging elements of the kits penetrating therein, thereby providing mechanical fixing and 20chemical bonding of the plurality of end cladding elements to the cementitious material oncehardened, thereby constructing the cladded wall.According to embodiments of the invention, the applying is effected with a concretepump.According to embodiments of the invention, the method further comprises placing a 25reinforcement metal mesh inside the cementitious material.According to another aspect of the invention there is provided a wet cladding method, themethod comprising:(a) providing a plurality of the kits described herein;(b) providing a plurality of end cladding elements formed with holes in back surfaces 30of the plurality of end cladding elements;(c) providing a plurality of formworks, each the formwork having an outer sheet andan inner sheet; (d) placing the plurality of end cladding elements with a front surface thereof againsta back surface of the outer sheet of each the formwork;(e) engaging the plurality of kits in the holes;(f) securing the plurality of end cladding elements to the outer sheet of each theformwork so as to form a plurality of assemblages; 5(g) hoisting the plurality of assemblages to a floor under construction and placing theplurality of assemblages adjacent to one another;(h) placing a plurality of reinforcing elements against the back surface of the pluralityof end cladding elements;(i) optionally placing heat insulating building blocks against the plurality of 10reinforcing elements;j) securing each the inner sheet and each respective the outer sheet of the plurality offormworks to one another with formwork securing elements, so as to form a continuousformwork unit;(k) applying the cementitious material into the continuous formwork unit; 15(l) allowing the cementitious material to harden with the cementitious materialengaging element penetrating therein, thereby providing the mechanical fixing and chemicalbonding of the end cladding elements to the cementitious material once hardened.According to embodiments of the invention, the method further comprises securing theplurality of end cladding elements with securing plates and removable end cladding element 20securing agent to the outer sheet of the formwork.According to embodiments of the invention, the method further comprises removing theremovable end cladding element securing agent once the cementitious material is hardened.According to embodiments of the invention, the method further comprises applying aplurality of water sealing strips onto the back surfaces of the plurality of end cladding elements, 25the water sealing strips configured to seal gaps between adjacent the plurality of end claddingelements, so as to prevent leakage of the cementitious material between the a front surface of theplurality of end cladding elements and the outer sheet of the formwork and to water seal thestructure once the cementitious material is hardened.According to embodiments of the invention, the method further comprises removing the 30formwork.According to embodiments of the invention, the method further comprises:(m) arranging an additional set of end-cladding elements with a front surface thereofagainst a back surface of an inner sheet of the formwork; and (n) connecting cementitious material engaging elements with the end-claddingelements of the additional set, wherein steps (m) and (n) are carried out prior to step (j).According to embodiments of the invention, the additional set of end-cladding elementsare fabricated from a cementitious material.According to embodiments of the invention, the additional set of end-cladding elements 5comprise pre-fabricated cement boards.According to embodiments of the invention, the pre-fabricated cement boards are cementbonded particle boards or cement fiber boards.According to embodiments of the invention, the connecting is via holes that are formed inback surfaces of the first set of end-cladding elements into which undercut anchors have been 10inserted.According to embodiments of the invention, the holes are undercut holes.According to embodiments of the invention, the holes are defined by internal walls havinga length and a substantially identical diameter along the length.According to embodiments of the invention, the connecting is via holes that are formed in 15sides of said additional set of end-cladding elements.According to still another aspect of the invention there is provided a structure constructedusing the methods described herein.According to embodiments of the invention, the plurality of end cladding elements aretiles of a synthetic material. 20According to embodiments of the invention, the structure further comprises a plurality ofwater sealing strips attached on the back surface of the plurality of end cladding elements,configured to seal gaps between adjacent the plurality of end cladding elements, so as to preventleakage of the cementitious material between a front surface of the plurality of end claddingelements and the outer sheet of the formwork and to water seal the structure once the 25cementitious material is hardened.According to embodiments of the invention, the sealing strip is a gasket.According to embodiments of the invention, the structure comprises a plurality ofsecuring plates arranged over edges of the back surface of contiguous pairs of the plurality of endcladding elements, the securing plates embedded in the cementitious material. 30According to yet another aspect, there is provided a wet cladding method, the methodcomprising:(a) attaching a plurality of cementitious material engaging elements to back surfacesof a plurality of cladding elements; (b) arranging the plurality of cladding elements in a formwork; and(c) adding cementitious material to the formwork, thereby providing mechanicalfixing and chemical bonding of the end cladding elements to the cementitious material oncehardened.According to yet another aspect, there is provided a wet cladding method, the method 5comprising:(a) attaching a plurality of cementitious material engaging elements to back surfacesof a plurality of cladding elements;(b) adding cementitious material so as to provide mechanical fixing and chemicalbonding of the end cladding elements to the cementitious material once hardened. 10According to yet another aspect, there is provided a wet cladding method, the methodcomprising:(a) attaching a plurality of cementitious material engaging elements to back surfacesof a plurality of cladding elements;(b) arranging the plurality of cladding elements in a formwork; 15(c) securing the plurality of end cladding elements with securing plates and removableend cladding element securing screw to the formwork; and(d) adding cementitious material to the formwork, thereby providing mechanicalfixing and chemical bonding of the end cladding elements to the cementitious material oncehardened. 20According to yet another aspect, there is provided a wet cladding method, wet claddingmethod, the method comprising:(a) attaching a plurality of cementitious material engaging elements to back surfacesof a plurality of cladding elements;(b) arranging the plurality of cladding elements in a formwork; 25(c) sealing gaps between adjacent end cladding elements by applying a water sealingstrips to the back surfaces so as to seal the gaps; and(d) adding cementitious material to the formwork, thereby providing mechanicalfixing and chemical bonding of the end cladding elements to the cementitious material oncehardened. 30According to yet another aspect, there is provided a cladded structure comprising:(a) a plurality of cementitious material engaging elements engaged to back surfaces ofa plurality of cladding elements; and(b) hardened cementitious material; wherein the plurality of cementitious material engaging elements are engaged in the hardenedcementitious material, thereby providing mechanical fixing of the end cladding elements to thehardened cementitious material, whereas the plurality of cladding elements are chemicallybonded to the hardened cementitious material.According to embodiments of the invention, the cladded structure further comprises water 5sealing strips attached on the back surface of adjacent the end cladding elements, configured toseal gaps between the adjacent end cladding elements, so as to prevent leakage of thecementitious material between a front surface of the adjacent end cladding elements and an outersheet of a formwork and to water seal the structure once the cementitious material is hardened.According to embodiments of the invention, the cladded structure further comprises 10securing plates for securing the plurality of end cladding elements with removable end claddingelement securing agent to a formwork while casting the structure.According to embodiments of the invention, the structure selected from the groupconsisting of a precast wall, a wall and a building.According to embodiments of the invention, the structure further comprises a corner 15bracket connecting a pair of the plurality of end cladding element to one another at an angle.According to embodiments of the invention, at least one of the plurality of claddingelements is a quadrangle having X and Y dimensions, whereby both X and Y are eachindependently greater than 35 cm.According to embodiments of the invention, the chemical bonding pull strength exceeds 1 20MegaPascal (MPs) per mm.According to embodiments of the invention, at least eleven kits are provided per 35 kg ofend cladding element.According to embodiments of the invention, a pulling strength of the cladding element isat least 100 Kg/m. 25According to embodiments of the invention, the second portion of the connectingstructure is formed by forging.According to yet another aspect there is provided a kit for connecting to one another afirst end cladding element to a second end cladding element at a predetermined angle, the firstend cladding element formed with a first undercut hole in a back surface thereof, the second end 30cladding element formed with a second undercut hole in a back surface thereof, the kitcomprising: (a) a corner bracket having a first arm having a first hole formed there through and asecond arm having a second hole formed there through, the first arm and the second armconnected to one another directly or indirectly at the predetermined angle;(b) a first undercut anchor and a second undercut anchor; and(c) a first flaring element and a second flaring element; 5wherein the first flaring element designed insertable through the first hole for flaring thefirst undercut anchor within the first undercut hole;whereas the second flaring element designed insertable through the second hole forflaring the second undercut anchor within the second undercut hole;thereby connecting the first end cladding element to the second end cladding element at 10the predetermined angle to one another.According to yet another aspect there is provided a structure comprising a cladded cornersupported by the kit of claim 96.According to yet another aspect there is provided a method of securing an undercutanchor in a blind hole which traverses a thickness of an end-cladding element, the blind hole 15having an opening on a back surface of the end-cladding element, the blind hole being defined byinternal walls having a length and a substantially identical diameter along the length, the methodcomprising:inserting the undercut anchor into the blind hole;screwing a flaring element into the undercut anchor, so as to allow the undercut anchor to 20flare inside the hole and beyond the internal walls of the hole, while compressing material of theend-cladding element surrounding the hole.According to embodiments of the invention, the end-cladding element is fabricated from amaterial having a plasticity and being sufficiently non-brittle, so as to allow flaring of theundercut anchor beyond the walls of the hole without breaking the end-cladding element, the 25material having a retention force that allows rigid attachment of the undercut anchor to the end-cladding element.According to embodiments of the invention, the flaring element is integrally formed with,or attachable to, an undercut anchor (UA) attaching end of a cementitious material engagingelement. 30According to embodiments of the invention, the end-cladding element is fabricated from apre-prefabricated cementitious material.According to embodiments of the invention, the end-cladding element is a pre-fabricatedcement board.
According to embodiments of the invention, the pre-fabricated cement board is a cementbonded particle board or a cement fiber board.According to yet another aspect there is provided an end-cladding element having a backsurface which comprises a blind hole into which an undercut anchor has been flared and secured,the end-cladding element being fabricated from a material, wherein the material of the end- 5cladding element surrounding the undercut anchor, after the undercut anchor has been flared andsecured, is more compressed than the material of the end-cladding element not surrounding theundercut anchor.According to embodiments of the invention, the material has a plasticity and issufficiently non-brittle, so as to allow flaring of the undercut anchor into the material without 10breaking the end-cladding element, the material having a retention force that allows rigidattachment of the undercut anchor to the end-cladding element.According to embodiments of the invention, the material is a cementitious material.According to embodiments of the invention, the end-cladding element is a pre-fabricatedcement board. 15According to embodiments of the invention, the pre-fabricated cement board is a cementbonded particle board or a cement fiber board.Unless otherwise defined, all technical and/or scientific terms used herein have the samemeaning as commonly understood by one of ordinary skill in the art to which the inventionpertains. Although methods and materials similar or equivalent to those described herein can be 20used in the practice or testing of embodiments of the invention, exemplary methods and/ormaterials are described below. In case of conflict, the patent specification, including definitions,will control. In addition, the materials, methods, and examples are illustrative only and are notintended to be necessarily limiting.BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)Some embodiments of the invention are herein described, by way of example only, withreference to the accompanying drawings. With specific reference now to the drawings in detail, itis stressed that the particulars shown are by way of example and for purposes of illustrativediscussion of embodiments of the invention. In this regard, the description taken with the 30drawings makes apparent to those skilled in the art how embodiments of the invention may bepracticed.In the drawings: FIGS. 1A and 1B and 1C are respectively an example profile of a wet cladded wall and anexample perspective view of a corner connection, both as depicted in Israel building standard2378 Part 2;FIGS. 2A, 2B and 2C are respectively a stone facade fixed to a metal formwork prior tocasting of the wall according to the Baranovich method and an example profile of a wet cladded 5wall according the Baranovich method, as depicted in Israel building standard 2378 part 5;FIGS. 3A and 3B are two examples of assembled systems, both in accordance with someexemplary embodiments of the invention;FIGS. 4A and 4B is a back and sectional view of the example assembled system shown inFIG. 3A, in accordance with some exemplary embodiments, where FIG. 4B, presents for the first 10time, an assembled kit of the present invention engaging an undercut hole formed on the backsurface of the end cladding element.FIG. 5A is an example kit in accordance with some exemplary embodiments of theinvention;FIG. 5B is an example of an undercut hole on the back surface of an end cladding 15element;FIGS. 6A, 6B, 6C and 6D are examples of cementitious material engaging elements, eachincluding at a proximal end an example washer type portion of a connecting structure and at adistal end, a bend for being embedded in the cementitious material, all in accordance with someexemplary embodiments of the invention; 20FIG. 6E is an image of an example engaging element including a bend in accordance withsome exemplary embodiments of the invention;FIG. 7 is a simplified drawing of an example engaging element with screw threads in adistal end in accordance with some exemplary embodiments of the invention;FIGS. 8A, 8B, 8C and 8D are sectional views of four example kits assembled on an end 25cladding element, all in accordance with some exemplary embodiments of the invention;FIGS. 9A, 9B and 9C are different views of an example load dispersion element inaccordance of some exemplary embodiments of the invention;FIG. 10A is an example assembled corner system in accordance with some exemplaryembodiments; 30FIG. 10B is a blow out of the corner bracket used in the exemplary corner systemillustrated in Figure 10A; FIGS. 11A and 11B are different views of a securing plate assembly securing endcladding elements to an outer sheet of a formwork over gaps covered with a sealing strip inaccordance with some exemplary embodiments of the invention;FIG. 12A and 12B are front and back views of four end cladding elements with sealingstrips sealing gaps between the four end cladding elements in accordance with some exemplary 5embodiments of the invention;FIG. 13 is an example securing plate assembly in accordance with some exemplaryembodiments of the invention;FIGS. 14A and 14B are a scheme and a photograph depicting an example outer sheet of aformwork including end cladding elements according with some exemplary embodiments of the 10invention while being hoisted to a floor under construction;FIG. 15 is a photograph depicting removal of cement stains on the surface of a stone endcladding elements when the cladded wall has been cast according to the Baranovich method;FIGS. 16A-C are photographs depicting the damage to a stone cladded wall due to ageing;FIG.17 is a photograph depicting the securing of end cladding elements to an outer sheet 15of a formwork and the inner shit of the formwork in accordance with some exemplaryembodiments of the invention;FIG. 18 is a simplified flow chart of an example method for wet cladding in accordancewith some exemplary embodiments of the invention;FIG. 19 is a simplified flow chart of an example method for wet cladding with formwork 20system in accordance with some exemplary embodiments of the invention;FIG. 20 is a simplified flow chart of an example method for wet cladding in accordancewith some exemplary embodiments of the invention;FIG. 21 is a simplified flow chart of an example method for wet cladding in accordancewith some exemplary embodiments of the invention; 25FIGs. 22A-B is a simplified flow chart of an example method for wet cladding inaccordance with some exemplary embodiments of the invention;FIGs. 23A and 23B and 23C are illustrations of three stages in preparation of end-cladding element assemblies with uniform (non-undercut) holes, according to embodiments ofthe invention; 30FIGs. 24A and 24B and 24C are illustrations of three stages in preparation of end-cladding element assemblies with undercut holes, according to embodiments of the invention;and FIG. 25 is an illustration of a wall which is cladded on both the internal-facing surfaceand the external-facing surface, according to embodiments of the invention.FIG. 26A, 26B, 26C and 26D are respectively an alternate example system including anexample kit with an example U-shaped element, two perspective views of the example kit and asectional view of the example kit installed on an edge of an end cladding element, all in 5accordance with some example embodiments;FIGS. 27A, 27B and 27C are two perspective views of another example kit with a U-shaped element and a sectional view of the example kit installed on an edge of an end claddingelement, all in accordance with some example embodiments; andFIGS. 28A and 28B are respectively a perspective view and a side view of yet another 10example kit including a U-shaped piece in accordance with some example embodiments.
DESCRIPTION OF SPECIFIC EMBODIMENTS OF THE INVENTIONThe present invention, in some embodiments thereof, relates to wall cladding kits,systems, methods and structures cladded therewith, more particularly, but not exclusively, to wetwall cladding kits, systems, methods and structures cladded therewith. 15Before explaining at least one embodiment of the invention in detail, it is to be understoodthat the invention is not necessarily limited in its application to the details of construction and thearrangement of the components and/or methods set forth in the following description and/orillustrated in the drawings and/or the Examples. The invention is capable of other embodimentsor of being practiced or carried out in various ways. 20According to some exemplary embodiments a wet cladding fixing kit for fixing an endcladding element to cementitious material of, or on, a backup wall, is provided.The kit comprises an undercut anchor, configured for insertion into a hole (e.g. anundercut hole) formed on a back surface of the end cladding element. The kit further comprises aflaring element (typically, but not necessarily, a screw) which is configured for flaring the 25undercut anchor in the hole. The flaring element comprises a first portion of a connectingstructure (typically, but not necessarily, a screw head).The kit further comprises a cementitious material engaging element, typically a pin likeelement, having an elongated structure. The engaging element comprises at its proximal end asecond portion of the connecting structure (typically, but not necessarily, a washer shaped 30element, an open ring, a closed ring, a helix or a loop). The second portion of the connectingstructure is connectable, directly or indirectly, to the first portion of the connecting structure. Thecementitious material engaging element further comprises a distal end extending from the second portion of the connecting structure for being embedded in the cementitious material. The secondportion of the connecting structure is optionally formed by forging.The term "proximal end" refers to the end, which after engagement (i.e. after constructionof the cladded wall) is closest to the end cladding element. The proximal end of the cementitiousmaterial engaging element may be referred to as the undercut anchor attaching end. The tern 5"distal end" refers to the end, which after engagement is furthest from the end cladding element.The distal end of the cementitious material engaging element may be referred to as the cementembedding (CE) end.The first portion of the connecting structure and the second portion of the connectingstructure are designed to be directly or indirectly potentially looseably connectable to form the 10connecting structure, so as to reduce the tendency of the undercut anchor from damaging wallsdefining the hole (e.g., undercut hole) when a torque is applied onto the engaging element. Inother words, the tightness of the connection between the first portion of the connecting structureand the second portion of the connecting structure is adjustable, so as to be able to control thetendency of the undercut anchor from damaging walls defining the hole (e.g., undercut hole) 15when a torque is applied onto the engaging element. The undercut anchor, the flaring elementand the connecting structure are selected to provide a load bearing attachment between thecementitious material engaging element and the end cladding element, so as to providemechanical fixing of the end cladding element to the cementitious material when the cementitiousmaterial is hardened. 20The tightness or looseness of the connection between the first and second portions or theconnecting structure (when the kit is in service), is physically determined by the relative sizes ofthe inner portion of the undercut anchor, the length of the flaring element, the size of the firstportion, the size of the second portion and the decision of the assembler of the kit, to whattightness or looseness to engage the parts together. 25The tightness or looseness of the connection between the first and second portions or theconnecting structure (when the kit is in service), is one of several crucial features of thisexemplary embodiment of the invention, as is allows the use of the kit with a wide variety ofcladding materials (ones that are softer than stone, harder than stone and/or more brittle thanstone), with lesser risk of damaging the walls defining the hole (e.g. undercut hole) while 30maximizing the load bearing attachment between the cementitious material engaging element andthe end cladding element. In an exemplary embodiment, in order to ascertain optimization, therelative physical sizes of the described parts of the kit are so selected such that when engaged atthe tightest engagement possible, the walls defining the hole (e.g. undercut hole) remain intact when a torque is applied onto the engaging element. Such a torque is applied to the engagingelement, for example, by the assembler of the kit. Other examples which are inherent to someuses of the kit will be described in more details below.In any event, the pull strength of a single kit of the invention out of its respective holes(e.g. undercut holes) is several orders of magnitude higher as compared to existing wet cladding 5methods where the pins are inserted into holes formed on the side surface of the stone withoutany undercut associated pull resistance. So, when using for example the Baranovich method forwet cladding, many of the pins are misplaced and find themselves spread at the bottom of thewall, reducing the mechanical fixing of the facade to the backup wall as a whole. This can hardlyhappen with the kits of the present invention because of the undercut system which far better 10stabilizes the pins in their respective locations.In any event, once the cementitious material hardens around the connecting structure, theattachment between the engaging element and the end cladding element becomes load bearingwith little or no correlation to its initial looseness or tightness.According to some exemplary embodiments of the invention, the loose attachment 15provided by the connecting structure may both simplify the casting process, when casting into aformwork as in wet cladding using the Baranovich method and may also improve the mechanicalfixation strength of the end cladding elements to the backup wall. When constructing andcladding using the Baranovich method, it is known that whilst pouring concrete from a heightand/or with pressure, aggregates within the concrete may repeatedly strike the metal pins fitted 20through pre-drilled holes extending within the stone end cladding element. Since in theBaranovich method, the metal pins are only loosely inserted into the stone end cladding elementwithout being integrally connected to the stone end cladding element, striking of the aggregatescan lead to the pins falling off the stone and accumulating at the bottom of the casted wall.Without all the metal pins engaging both the stone end cladding element and the backup wall, the 25mechanical fixing is compromised and the stones may fall over time due to ageing of thechemical bonding. In an attempt to prevent the metal pins from falling during casting, an oldfashion concrete funnel is used in place of modern concrete pumps for pouring the concrete intothe formwork. The funnel-poured concrete flows with much lower pressure as compared to flowwith a concrete pump. With the reduced flow rate, the number of metal pins that are likely to fall 30off may be reduced. For the very same reason, concrete sonication is also not used in conjunctionwith the Baranovich method, as the sonication probe itself and/or the sonic energy may misplacethe pins.
The invention overcomes this limitation by affording an undercut engagement forattachment of the cementitious material engaging element (e.g., pin) which creates a far strongermechanical connection between the engaging element and the end cladding element, allowing theuse of concrete pumps and sonicators.As said, according to some exemplary embodiments of the invention, the connecting 5structure is configured to loosely connect the proximal portion of the engaging element to the endcladding element, so as to provide some give or freedom of movement while not allowing theproximal portion to disengage from the end cladding element. According to some exemplaryembodiments, the loose attachment helps to reduce a torque that may otherwise be imposed onthe undercut anchor and thereby reduce a tendency of said undercut anchor from damaging walls 10defining the hole (e.g. undercut hole), e.g., from breaking the end cladding element at the regionssurrounding the undercut anchor.As said, according to another example embodiment, the connecting structure is configuredto tightly connect the proximal portion of the engaging element to the end cladding element, sothat no give or freedom of movement is allowed. This embodiment is advantageous when the 15end cladding element is not brittle and forces applied to the walls defining the hole (e.g., undercuthole) therein are not likely to crack these walls, resulting in disengagement of the kit from theend cladding element.Thus, unlike known wet cladding method, the present invention enables the use ofconcrete pumps which increases the rate and reduces the cost of construction and the use of 20concrete sonication probes which improve the strength and durability of the construction.According to some exemplary embodiments, in order to engage the cementitious material,the cementitious material engaging element has a normal vector component in the distal endwhich, during service, is positioned parallel to the backup wall and the end cladding element, soas to increase the pull resistance of the engaging element from the cementitious material once 25hardened. This can be achieved, in any one of several ways, non-limiting examples includeselecting the distal end (i.e., distal portion) with a bend and/or design at least a part thereofthreaded, whereby the normal vector component is formed at least in part by the threaded surface.According to some exemplary embodiments, the kit provides components for forming a loadbearing connection with end cladding elements having a wide range of thicknesses including 30thicknesses that are less than 3 cm, e.g., 1 cm - 3 cm, less than 2 cm, e.g., 1.9 cm or less, or even9-12 mm. According to some exemplary embodiments, the kit is suitable for cladding withporcelain ceramic tiles as well as with other tiles. The kit may be suitable for wet cladding otherman-made (i.e., synthetic) materials, with naturally occurring stone or with slate. According to some exemplary embodiments of the invention, the end cladding element may have a waterabsorption of less than 0.5 %. The end cladding elements may be of any shape (e.g., a polygon,such as rectangular or square; or combination of polygons having, for example, 5 and 6 gons toclad curved surfaces; or a non-polygon) and of any size – e.g., between 20 cm – 5 meters inlength and between 20 cm to 5 meters in height. According to some exemplary embodiments at 5least one of said plurality of cladding elements is a quadrangle having X and Y dimensions,whereby both X and Y are each independently greater than 35 cm. The back surface of the endcladding element may be smooth or rough. According to some exemplary embodiments of theinvention, the back surface is artificially roughened to include a texture (e.g., grooves, holes,protrusions, scratches), so as to increase its surface area, thereby increasing the chemical bonding 10between the end cladding element and the cementitious material once hardened. In exemplaryembodiments the chemical bonging exceeds 1 MegaPascal/mm (MPa/mm), see alternativevalues in Table 2 below. In exemplary embodiments at least 11 kits are provided per about 35 kgof end cladding element. In exemplary embodiments at least 11 kits are provided per about 1 m of end cladding element. 15According to exemplary embodiments, each corner of the end cladding element (e.g., tile)is connected to at least one kit on its back surface, e.g., at least four kits per tile. Depending onthe size of the end-cladding elements, additional kits may be required or desired.According to some exemplary embodiments, the end cladding elements may be pre-formed with the hole (e.g. undercut hole or uniform hole), e.g., during manufacturing. The 20uniform hole is a blind hole being defined by internal walls having a length and a substantiallyidentical diameter along the length. In an exemplary embodiment, the hole is about 5-7 mm indiameter and about 4-7 mm in depth. According to exemplary embodiments, the end claddingelement is formed with a plurality of holes (e.g. undercut holes), e.g., 4-8, 4-12 or 4-50 holes (e.g.undercut holes). According to exemplary embodiments a kit is engaged on each of the plurality 25of holes (e.g. undercut holes) formed on the back surface end cladding element.According to some exemplary embodiments, the distal end of the engaging element isconfigured to provide the mechanical engagement with the cementitious material of the backupwall (or cementitious material on the backup wall) for wet cladding. The distal end (e.g., pin)may be the same or similar to the metal pins described in section 2378 Part 2 of the Israeli 30building standard, may be the same or similar to the metal pins described in section 2378 Part 5of the Israeli building standard. In some exemplary embodiments of the invention the engagingelement may be formed from a stainless steel rod that has a diameter of at least 3 mm - 4 mm,e.g., 3.5 mm. According to some exemplary embodiments, larger diameter engaging elements may be used. The length of the part of the cementitious material engaging element that actuallyengages the cement or concrete may be between 50-100 mm for example, between 60-80 mm.In some exemplary embodiments, the second portion of the connecting structure at theproximal end of the cementitious material engaging element is a washer type element, a closedring, an open ring, a loop or a helix. According to some exemplary embodiments, the second 5portion of the connecting structure is cast together with the engaging element or forged togetherwith the engaging element, or welded together as a single entity; namely an integral part. Theengaging element may be formed from the same material defined in Israeli building standardsection 2378 Part 2 or Part 5.According to some exemplary embodiments the distal end of the engaging element 10includes one or more bend characterized by a normal vector component which when in service ispositioned parallel to the wall and the end cladding element and serves to increase the retentionof the engaging element in the cement According to some exemplary embodiments, the distalend of the engaging element has a threaded surface. According to some exemplary embodiments,the bend or surface with normal vector component parallel to the end cladding element provides 15the mechanical fixing with the cementitious material once the cementitious material is dried andhardened. According to an exemplary embodiment of the invention the pulling strength of the kitfrom an end cladding material is selected over 10 Kg pull strength, optionally over 20 Kg pullstrength, optionally over 40 Kg pull strength optionally about 10 Kg pull strength. According toan exemplary embodiment of the invention the pulling strength of an end cladding element from 20a cladded wall is at least 100 Kg/m, optionally at least 500 Kg/m, optionally at least 1000Kg/m, optionally at least 1500 Kg/m, optionally at least 2000 Kg/m, optionally at least 2300Kg/m.According to an exemplary embodiment of the invention, the kit further comprises a loaddispersion element. The load dispersion element is connectable to, or integrally formed with, the 25flaring element or the undercut anchor. The load dispersion element is configured to disperse loadover a surface area of the load dispersion element, so as to reduce load imposed by the undercutanchor on walls defining the hole (e.g. undercut hole).In some exemplary embodiments of the invention the actual use and the size and shape ofthe load dispersion element is one of several crucial features, as it allows the use of the kit with 30softer and/or more brittle end cladding materials, with lesser risk of damaging the walls definingthe hole (e.g. undercut hole) when a torque is applied to the cementitious material engagingelement, while maximizing the load bearing attachment between the cementitious materialengaging element and the end cladding element. Such torque is applied to the engaging element, for example, by the assembler of the kit. Other examples which are inherent to some uses of thekit will be described in more details below. Thus, the load dispersion element is placed tightlyagainst the back surface of the end cladding element to relieve lateral forces and blows byspreading the force over a larger surface area. The load dispersion element may be a plate and/ora washer that is according to exemplary embodiments made of metal, e.g., steel. According to 5some exemplary embodiments of the invention, the load dispersion element is about 40 mm indiameter. According to some exemplary embodiments, the load dispersion element issandwiched between the first portion of the connecting structure and the back surface of the endcladding element surrounding the hole (e.g. undercut hole). According to some exemplaryembodiments of the invention, the load dispersion element is integrally formed with the first 10portion of the connecting structure and is pressed against the back surface of the end claddingelement surrounding the hole (e.g. undercut hole).According to some exemplary embodiments of the invention, the load dispersion elementis integrally formed with the undercut anchor and is pressed against the back surface of the endcladding element surrounding the hole (e.g. undercut hole). 15As will be further delineated below, when the kit is used for generating precast claddedwalls or wall cladding with the Baranovich method, the kit may according to some exemplaryembodiments further comprise water sealing strips attachable onto the back surface of the endcladding element, configured to seal gaps between adjacent end cladding elements, so as toprevent leakage of the cementitious material between a front surface of the end cladding 20elements and an outer sheet of a formwork and/or to water seal the backup wall or precast wallonce the cementitious material is hardened, thereby minimizing the amount of cleaning necessaryonce the cladded wall is constructed and minimizing water (e.g., rainfall) ingress behind the endcladding elements, which reduces the ageing of the cladding and the wall or structure as a whole.According to exemplary embodiments, the sealing strips are mounted over edges of pairs of 25adjacent end cladding elements on their back surfaces to cover the gaps formed there between.According to some exemplary embodiments, the sealing strip is a gasket. According to someexemplary embodiments, the sealing strip is an ethylene propylene diene monomer sheet or otherrubber or silicone sheet. According to some exemplary embodiments, the sealing strip may havea thickness of 0.5 mm - 1 cm, e.g., about 1 mm. Different colored sealing strips may be applied 30for aesthetic purposes.As will be further delineated below, when the kit is used for generating precast claddedwalls or wall cladding with the Baranovich method, the kit may according to some exemplary embodiments further comprise a securing plate and an end cladding element securing agent, fortemporarily securing the end cladding element to the formwork.A system according to exemplary embodiments of the present invention is meant toinclude at least one kit as described herein and at least one end cladding element at anyassembling state, from being all disassembled to being all assembled onto a cladded wall or 5structure. The end cladding elements are preferable pre-formed with holes (e.g. undercut holes)on the back surface, although such holes can also be formed on site of construction.The end cladding element can be of made of any material. In an exemplary embodiment,it is fabricated from a synthetic material. In an exemplary embodiment, it is fabricated from anatural material. In an exemplary embodiment the end cladding element is fabricated from a 10material such as, but not limited to, ceramic clay, porcelain, a high pressure laminate (HPL),concrete, Corian®, Caesarstone®, glass, and stone. It will be appreciated that when a non-undercuthole is drilled into the back surface of the end cladding element, the end cladding element isfabricated from a material having a plasticity and being sufficiently non-brittle, so as to allowflaring of the undercut anchor beyond the walls of the hole without breaking the end-cladding 15element, the material having a retention force that allows rigid attachment of the undercut anchorto said end-cladding element. Examples of such materials include pre-fabricated cementitiousmaterials including pre-fabricated cement boards.In an exemplary embodiment, the front surface of the end cladding elements are linedwith a protective cover. According to some exemplary embodiments the protective cover is 20configured to protect the front surface of the end cladding element from being soiled withcementitious material during casting. The protective cover may be fabricated from any material(e.g., nylon) that is removable once the cladding or cladded wall construction is completed.In an exemplary embodiment, at least eleven kits are used per square meter of the endcladding element. 25A major design challenge of the Baranovich cladding system is sealing the cladding layercladded onto the underlying backup wall. As is described in the background section above, theBaranovich cladding system is not water sealed for three reasons. Liquids can leak through gapsformed between the end cladding elements in regions of the pins and in locations where the"chochla" seal is compromised, as well as through the holes formed in the outer formwork sheet 30which serve for insertion of the barbed wire, and more so through the bolts dedicated holes.That and more. For reasons delineated in the Background section above, currently, wetcladding methods are limited to the use of stone. Stone, as well as "chochla" as well as cement aswell as concrete are all water absorbing materials and therefore water sealing a cladded wall cladded by any existing wet cladding method is an impossibility. Stone is so inherently watersoaking that, when wet cladding using the Baranovich method, the back surfaces of the endcladding elements are sprayed with a sealing primer, so as to prevent cement stains of the claddedfaçade caused by the stones soaking cement through the back surfaces and the entire thicknessthereof. However, this is problematic as the sealing primer has the adverse effect of reducing the 5chemical bonding between the backup wall and the end cladding elements.Water damage to stone cladding is evident for example in the photographs of Figures16A, 16B and 16C. Use of water sealed synthetic end cladding elements such as, for example,ceramic porcelain could have eliminated this limitation, however, it is not afforded by currentlyavailable wet cladding methods, because the thickness of ceramic porcelain, for example, is ca. 9- 10mm, not allowing forming holes on the sides thereof and/or engaging sufficiently thick pinstherein.Irrespective of the type of material used for end cladding exterior-facing surfaces of walls,sealing gaps formed between adjacent end cladding elements of the cladding layer has at leastthree functions. During construction, it limits the amount of liquid cement that can spill through 15gaps formed between adjacent end cladding elements and soil the front surface thereof. Figureis a photograph showing workers cleaning a cladded wall constructed using the classicalBaranovich method, this is both time consuming and expensive. During service, it limits theamount of water (e.g., rainfall) that can leak through gaps formed between adjacent end claddingelements and be absorbed the underlying backup wall, damaging the mechanical fixing and 20chemical bonding of the end cladding elements to the underlying backup wall and damaging theunderlying wall itself. If not water sealed, a backup wall can absorb a substantial amount ofwater, reducing its inherent thermal insulation. By water sealing the gaps between adjacent endcladding elements, the underlying wall does not wet and its inherent thermal insulationmaintained uncompromised. 25Irrespective of the wet cladding method used, sealing gaps formed between adjacent endcladding elements is not practical because of the pins extending from the sides (thickness) of theend cladding elements.The present invention overcomes this particular problem by engaging the end claddingelements from and the back surfaces thereof and not their sides (thickness). This, in turn, allows 30sealing the gaps between adjacent end cladding elements, resulting in water sealing the entirecladded façade.When wet cladding using the Baranovich method, liquids can leak not only through gapsformed between the end cladding elements in regions of the pins and in locations where the "chochla" seal is compromised, but also through the holes formed in the outer formwork sheetwhich serve for insertion of the barbed wire, and more so through the bolts dedicated holes.As described in the Background section above, the barbed wire is used to tie the outerformwork sheet to the fortification metal mesh, caging the end cladding elements there between,so as to avoid misplacement of the end cladding elements upon hoisting this assemblage to a 5floor under construction.The presently described methods and systems overcome this problem as the engagingelements extend from a back surface of the end cladding element and thereby do not penetrate thegaps between the end cladding elements. Based on this design, a gasket or other sealing stripmay be positioned along gaps between adjacent end cladding elements for superior insulation. In 10some exemplary embodiments, when ceramic porcelain end cladding elements are used,porcelain itself is water resistant, e.g., it does not absorb water. Thus, the front surface of aporcelain tile is water resistant, whereas the back surface is able to absorb water increasing theability to chemically glue the tile with cement onto the backup wall. In these embodiments,thermal and water insulation may be provided using the sealing strips. Another advantage of the 15sealing strips is that they prevent leakage of the cementitious material through the gaps duringcasting. Leakage is known to occur in the Baranovich system. When cladding with stone that isporous and water-absorbing as in the Baranovich system, the cleaning process is bothcomplicated and expensive. Rather, sealing as described herein may avoid leakages and preventsubsequent cleaning steps. 20In some exemplary embodiments, the system additionally includes securing plates tosecure the end cladding elements against a formwork (i.e., a temporary mold into/onto whichliquid concrete may be poured). In some exemplary embodiments, securing plates are mountedover edges of pairs of adjacent end cladding elements on their back surfaces. According to someexemplary embodiments, the securing plates are mounted over the sealing strip. The securing 25plate may be metal or other material, e.g., an acetal homopolymer such as Derlin ® manufacturedby DuPont in Delaware USA. According to some exemplary embodiments, the securing plate isinstead of ties that are known to be used in for example the Baranovich system. In someexemplary embodiments, each of the securing plates is fixed to the formwork with a securingelement that extends from a securing plate to the formwork through the spacing between the end 30cladding elements. According to some exemplary embodiments, if a spacer is used to space theend cladding elements, (i.e., to space one adjacent end cladding element from another and/or tospace a first row of end cladding elements from a second row of end cladding elements) thesecuring element penetrates the spacer. According to exemplary embodiments, the securing element is configured to be removed after the casted wall has hardened and dried. In someexemplary embodiments, the securing element is a threaded element, e.g., a bolt that is secured tothe formwork with a threaded nut. In some exemplary embodiments, the threaded engagement ofsecuring element prevents leakage of the cementitious material during casting. In the Baranovichsystem, holes through which the ties are introduced are known to be openings that allow cement 5to leak through during casting. By using the system and method as described herein, this leakagemay be prevented.According to an aspect of some exemplary embodiments, elements of the system arepackaged and delivered to the construction site. According to some exemplary embodiments, theend cladding elements are formed with holes (e.g. undercut holes) prior to delivery of the system. 10According to some exemplary embodiments, the system is delivered in an assembled state orpartially assembled state. According to some exemplary embodiments, the system is fully orpartially assembled at the construction site.According to an aspect of some exemplary embodiments, the wet cladding methodincludes providing a plurality of wet cladding systems, forming hole(s) (e.g. undercut hole(s)) if 15not already formed on the end cladding elements of the system, assembling the systems if notalready assembled and wet cladding the backup wall with the assembled system. According toexemplary embodiments, a reinforcement metal mesh is engaged on the backup wall prior to wetcladding.According to an aspect of some exemplary embodiments, the wet cladding method 20includes providing a plurality of kits, providing plurality of cladding elements formed with holes(e.g. undercut holes), and providing a formwork. In some exemplary embodiments, the claddingelements are positioned with a front surface against an outer sheet of the formwork and theplurality of kits are engaged in the holes (e.g. undercut holes). According to some exemplaryembodiments, the kits may be installed on the end cladding elements prior to arranging the end 25cladding elements on the formwork. In some exemplary embodiments, an inner sheet of theformwork (which may or may not include a thermal or sound insulating layer) is then secured tothe outer sheet with spacing therebetween in which the engaging elements are extended and thecementitious material is added within the spacing. The thermal insulating layer may befabricated from materials including, but not limited to fiberglass, mineral wool, cellulose, 30polystyrene, polyurethane and cementitious foam.Reinforcing elements, e.g., reinforcing bars, such as a metal grid, may be positionedwithin the spacing between the front and inner sheet of the formwork. According to someexemplary embodiments, the end cladding elements are spaced with dedicated spacers.
According to some exemplary embodiments, the gaps are covered with a water sealing strip.According to some exemplary embodiments, the end cladding elements are secured to theformwork with a plurality of securing plates. In some exemplary embodiments, the formworkincludes a plurality of sub-units that are fitted together.According to an aspect of some exemplary embodiments, there is provided a structure that 5is cladded with the kit, system and methods described herein. The structure may comprise a wallwhich is cladded on its exterior facing surface, on its interior facing surface and optionally onboth its exterior and interior facing surface.For purposes of better understanding some embodiments of the present invention, asillustrated in FIGS. 3B-22A-B of the drawings, reference is first made to the construction and 10operation of known wet cladding system as illustrated in FIGS. 1A-2B.Reference is now made to FIGS. 1A and 1B showing respectively an example profile of awet cladded wall and an example perspective view of a corner connection, both as depicted inIsrael building standard 2378 Part 2. In FIG. 1A a backup wall 30 is cladded with a plurality ofend cladding elements 10 . Cladding relies on both chemical bonding (i.e., gluing) end cladding 15element 10 to backup wall 30 with cementitious material 20 and mechanical fixing of endcladding element 10 to backup wall 30 with a plurality of engaging elements (e.g., pins) 50 . Toprovide the mechanical fixing with the engaging element 50 , a drill hole 12 is first formedthrough an edge surface 11 of end cladding element 10 and a reinforcement metal mesh 40 issupported on backup wall 30 with fixing element 45 . Cementitious material 20 is applied on 20backup wall 30 over reinforcement metal mesh 40 and on a back surface of end cladding element 10 . Engaging element 50 is then inserted into drill hole 12 at its proximal end 51 and physicallyengaged with reinforcement metal mesh 40 at its opposite distal end 57 . Proximal end 51 isloosely received by drill hole 12 and therefore positioning of proximal end 51 into drill hole 12 does not provide a load bearing connection. Engaging element 50 is typically formed with a first 25bend 52 and a second bend 53 . First bend 52 provides receiving proximal end 51 into drill hole 12 and second bend 53 provides folding or hooking a distal end of engaging element 50 ontoreinforcement metal mesh 40 . Engaging element 50 is fixed onto reinforcement metal mesh 40 while cementitious material 20 is wet and is an integral part of cementitious material 20 whencementitious material 20 hardens. Proximal end 51 of engaging elements 50 may be received 30through upper, side and lower edges surfaces of end cladding element 10 . Mortar 14 is typicallyused to fill gaps between end cladding elements 10 . Based on building standard 2378 part 2, endcladding element 10 is required to have a thickness of 20-30 mm to accommodate forming drillhole 12 and receiving engaging element 50 . Reinforcement metal mesh 40 is made of carbon steel and engaging element 50 is made from stainless steel. End cladding element 10 is requiredto be natural stone, although artificial stone can also be used.Referring now to FIGs. 1B-C, a corner connection is made based on arranging a pair ofend cladding elements 10 at right angles and inserting a corner engaging element 56 through anedge surface 11 of each end cladding element 10 . End cladding element 10 is required to have a 5thickness of 20-30 mm to accommodate forming drill hole 12 .Reference is now made to FIGS. 2A, 2B and 2C respectively showing a back side of stonefacade fixed to a metal formwork 37 prior to casting of the wall according to the Baranovichmethod, an example profile of a wet cladded wall and an example metal engaging element (i.e.,pin) according the Baranovich method. In the Baranovich method described in Israeli building 10standard 2378 part 5, end cladding elements 10 are arranged on a first (outer) metal formwork 37 prior to casting backup wall 30 . Metal engaging elements 55 are positioned in drill holes formedthrough edge surfaces of end cladding elements 10 as described in reference to engagingelements 50 (FIG. 1A). Each end cladding element 10 typically includes four engaging elements 55 . Engaging elements 55 typically include a first bend 52 and a second bend 54 . First bend 52 15in engaging elements 55 is similar to bend 52 in engaging element 50 . Proximal end 51 isinserted into a drill hole 12 of end cladding element 10 . Second bend 54 is a bend with an obtuseangle. Distal end 57 is not required to physically engage a reinforcement metal mesh 45 butrather provides for improved anchoring of engaging element 55 into cementitious material oncehardened and dried. Gaps between end cladding elements 10 are sealed with mortar (known as 20"chochla") 14 on first formwork 37 . Reinforcement metal mesh 45 is then positioned to face theback-surface of end cladding elements 10 leaving gaps through which the distal ends 57 ofengaging elements 55 penetrate. Ties 18 are typically used to temporarily tie formwork 37 toreinforcement metal mesh 45, thereby securing end cladding elements 10 to first formwork 37 . Asecond (inner) metal formwork 38, typically arranged with thermally insulating concrete blocks 25 31, is placed on an opposite side of reinforcement metal mesh 45 and cementitious material ispoured to fill the gap there between. Cementitious material forms the backup wall 30 and alsoserves as the chemical bonding (i.e., gluing) agent that maintains the entire structure includingend cladding elements 10 as single entity.Reference is now made to FIGS. 3A and 3B showing two example assembled systems, all 30in accordance with some exemplary embodiments. According to some exemplary embodiments,a system 250 includes an end cladding element 100 with one or more kits 200 installed on a backsurface 101 of end cladding element 100 , each kit 200 includes a cementitious material engagingelement 50 configured for wet cladding. According to exemplary embodiments, end cladding element 100 includes four kits 200 , one for each corner of end cladding element 100 . In someexemplary embodiments, system 250 includes a pair of upper engaging elements 50 fixed to twoupper corners of end cladding element 100 and a pair of lower engaging elements 50 fixed to twolower corners of end cladding element 100 .In some exemplary embodiments, system 250 include engaging elements 50 with a 5cement engaging element formed with a 90 degree bend, e.g., similar to bend 53 of engagingelements 50 used in Israeli building standard 2378 Part 2, as illustrated in FIG. 3A. In otherexemplary embodiments, illustrated in FIG. 3B, system 250 includes engaging elements 55 withdistal end 205 similar to the distal end 57 of engaging elements 55 used in the Baranovichmethod, which is illustrated in FIG. 2C. 10Reference is now made to FIGS. 4A and 4B which show a back and sectional view of theexample assembled system of FIG. 3A. FIG 4B is the first illustration demonstrating the type ofconnection between elements 50 and 100 , better viewed and described in FIGs. 5A and 5B.According to some exemplary embodiments, upper engaging elements 50 include a longer distalend 202 as compared to a relatively shorter distal end 204 of lower engaging elements 50 . 15Reference is now made to FIG. 5A which illustrates the components of a kit inaccordance with some exemplary embodiments and to FIG. 5B which illustrates undercut hole 105 formed in end cladding element 100 . According to some exemplary embodiments, kit 200 includes an undercut anchor 220 configured to be received in an undercut hole 105 formed onback surface 101 of end cladding element 100 , a flaring element 260 and a cementitious material 20engaging element, e.g., engaging element 50 or engaging element 55 . Flaring element 260 mayinclude a first portion 261 of a connecting structure for connecting with a second portion 230 of aconnecting structure. According to some exemplary embodiments, the connection is defined tobe loose so that engaging element 50 can wobble and/or move with respect to flaring element 260 . Flaring element 260 may be a screw, bolt, or stud that is configured to flare undercut anchor 25 220 with a screwing or bolting motion. According to some exemplary embodiments, first portion 261 of the connecting structure is a head of the screw, bolt or stud. The connecting structurecomprises first portion 261 of flaring element 260 directly or indirectly connected to secondportion 230 of cementitious material engaging element 50 or 55 . The tightness of the connectionbetween the two can be controlled as further described hereinabove and hereinunder. According 30to some exemplary embodiments, flaring element 260 may be a rod that is configured to flareundercut anchor 220 based on being pushed or hammered into undercut anchor 220 .According to some exemplary embodiments, the engaging element, e.g., engagingelement 50 or engaging element 55 , in kit 200 includes a proximal end with a connecting element (i.e., a second portion of a connecting structure) 230 and distal end with a cement engagingelement, e.g., distal end 204 (actually a pin structure) or 202 . According to some exemplaryembodiments, flaring element 260 may be received through connecting element 230 and may fixconnecting element 230 against back surface 101 as flaring element 260 penetrates into undercutanchor 220 . According to some exemplary embodiments, kit 200 provides a load bearing support 5to end cladding element 100 . It is noted that engaging element 50 with distal end 205 is shown asan example. In other examples, engaging elements 50 with connecting elements 230 may includedistal end 202 or engaging elements 55 with connecting element s 230 may include cementengaging element or distal end 205. FIGS. 6A, 6B, 6C and 6D are exemplary cementitious material engaging elements, each 10including at a proximal end an example washer type portion of a connecting structure and at adistal end, a bend for being embedded in the cementitious material, all in accordance with someexemplary embodiments. A variety of connecting elements 230 are shown for a cementitiousmaterial engaging element 50 with distal end 204 as an example. The same variety of connectingelements 230 may also be contemplated for each of engaging elements with distal ends (cement 15anchoring elements) 202 and 205 . In one example, connecting element 230 of a cementitiousmaterial engaging element 50 may be shaped as a flat ring or flat washer as shown in FIG. 6A. Inanother example connecting element 230 is helical as shown in FIG. 6B. The helical shapedconnecting element 230 may function as a spring washer. In yet another example, connectingelement 230 may be an open loop that is formed based on bending a proximal end of engaging 20element 50 (FIG. 6C). In yet another example, connecting element 230 may be a flat ring or flatwasher shaped element with a hexagonal bore (FIG. 6D) through which flaring element 260 isreceived. Connecting elements 230 are integral to the engaging element 50 . According to someexemplary embodiments, the engaging element 50 is cast together with connecting element 230 .Alternatively, connecting element 230 is welded or otherwise fixed onto a proximal end of the 25engaging element 50 .FIG. 6E is an image of an example engaging element 50 in accordance with someexemplary embodiments. In FIG. 6E engaging element includes a connecting element 230 at itsproximal end that is configured to be positioned flush against a back surface of an end claddingelement, a bend 232 configured to extend engaging element 55 in a direction normal to the back 30surface of the end cladding element, a distal end 205 at its distal end optionally in a form of abend.FIG. 7 is a simplified drawing of an example engaging element with screw threads in adistal end in accordance with some exemplary embodiments. In some exemplary embodiments, engaging element 50 does not include a bend in a distal end but rather includes a threading 60 . Insome exemplary embodiments, a normal vector 62 to a surface of threading 60 includes a vectorcomponent 65 that is perpendicular to the distal end 207 of engaging element 50 . In someexemplary embodiments, the normal vector 62 to a surface of threading 60 includes a vectorcomponent 65 that is also parallel to the distal end 207 of engaging element 50 . The distal end 5 207 is elongated, characterized by a longitudinal axis, and the threading 60 is at an angle,preferably an acute angle, to the longitudinal axis. In some exemplary embodiments, vectorcomponent 65 of thread 60 improves mechanical engagement of engaging element 50 with thecementitious material when penetrating the cementitious material and prevents engaging element 50 from being pulled out of the cementitious material when it dries. 10FIGS. 8A, 8B, 8C and 8D are sectional views of four example kits assembled on an endcladding element, all in accordance with some exemplary embodiments. According to someexemplary embodiments, an undercut hole 105 is formed through a back surface of end claddingelement 100 and kit 200 is configured to be assembled onto end cladding element 100 throughundercut hole 105 . Undercut anchor 220 may be inserted into undercut hole 105 and flaring 15element 260 may be positioned through connecting element 230 and into undercut anchor 220 .Insertion of flaring element 260 is configured to flare undercut anchor 220 and thereby fixconnecting element 230 against back surface of end cladding element 100 . A connectablestructure is formed with connecting element 230 being a first portion of the connecting structureand head 261 of flaring element 260 being a second portion of the connecting structure. FIG. 8A 20shows an example assembly with a flat ring or flat washer type connecting element 230 shown inFIG. 6A. FIG. 8B shows an example assembly with a spring washer type connecting element 230 shown in FIG. 6B. FIG. 8C shows an example assembly with an open loop shapedconnecting element 230 shown in FIG. 6C. FIG. 8D shows an example assembly with a flathelical type connecting element 230 shown in FIG. 6D. In some exemplary embodiments, flaring 25element 260 fixes connecting element 230 against a back surface of end cladding element 100 with a desired degree of give or freedom.FIGS. 9A, 9B and 9C are different views of an exemplary load dispersion element inaccordance with some exemplary embodiments. According to some exemplary embodiments,load dispersion element is positioned against back surface 101 of an end cladding element 100 30over an undercut anchor and under a first portion 230 of a connecting structure on engagingelement 50 . In some exemplary embodiments, lateral forces applied on engaging element 50 maybe partially spread over a surface area of load dispersion element 300 . According to someexemplary embodiments, load bearing element 300 is a pressure relieving washer including a central bore 303 . According to some exemplary embodiments, a nut element 262 is fitted in thecentral bore. In some exemplary embodiments, central bore 303 has a polygon shape, e.g.,pentagonal for receiving nut element 262 and resisting rotation between nut element 262 in bore 303 . Load dispersion element 300 is shown to have a pentagonal shape. Other shapes, e.g.,rectangular, round, and hexagonal are also contemplated. In some exemplary embodiments, 5flaring element 260 may penetrate nut element 262 with a threaded engagement. The threadedengagement reinforce the pressure of the load dispersion element 300 against back surface 101 of end cladding element 100 .According to some exemplary embodiments, load dispersion element 300 is metal. Insome exemplary embodiments, load dispersion element 300 has a width or diameter of 20 mm – 10mm, e.g., 40 mm and a bore with a diameter that is 5 mm – 20 mm, e.g., 10 mm.FIGs. 10A-B provide examples of assembled corner system in accordance with someexemplary embodiments. According to some exemplary embodiments, a system 550 for claddinga corner of a structure includes a pair of end cladding elements 100 attached to one another at apredetermined angle (e.g. right angles, closed angle or open angle) and secured from behind with 15one or more corner brackets 502 . The corner structure may be the corner of building or anothercorner on the surface of the building – e.g. under a window, balcony, shelf etc. The corner ofsystem 550 may be a Gerung type corner or a non-Gerung type corner. Preferably the cornerstructure comprises a sealant between the two end cladding elements. In some exemplaryembodiments, end cladding elements 100 are formed with dedicated undercut holes configured 20for receiving an undercut anchor 506 and a flaring element 504 to flare the undercut anchor forfixing corner brackets 502 against end cladding elements 100 . End cladding elements 100 maybe additionally assembled with kits 200 .Thus, a kit for connecting to one another a first end cladding element to a second endcladding element at a predetermined angle is provided. The first end cladding element formed 25with a first undercut hole in a back surface thereof, the second end cladding element formed witha second undercut hole in a back surface thereof. The kit comprises a corner bracket having afirst arm having a first hole formed there through and a second arm having a second hole formedthere through, the first arm and the second arm connected to one another directly or indirectly viaa connector element at the predetermined angle. The corner bracket may be at least in part (e.g. at 30the connector element region) spaced from the back surfaces of the cladding elements so as toallow cementitious material to fill the space formed between the corner bracket and the claddingelements, thereby further securing the end cladding elements of the corner system to the corner ofthe structure.
The kit further comprises a first undercut anchor and a second undercut anchor. The kitfurther comprises a first flaring element and a second flaring element. The first flaring elementdesigned insertable through the first hole for flaring the first undercut anchor within the firstundercut hole. The second flaring element designed insertable through the second hole forflaring the second undercut anchor within the second undercut hole. The advantage of the kit 5depicted in FIG. 10A is that it allows for "Gerung" type corner which is not affordable by theprior art as is evident from FIG. 1C.Reference is now made to FIGS. 11A and 11B showing different views of a securingplate assembly securing end cladding elements to an outer sheet of a formwork over gaps coveredwith a sealing strip, FIG. 12A and 12B showing front and back views of four end cladding 10elements with sealing strips sealing gaps between the four end cladding elements and FIG. 13showing an example securing plate assembly, all in accordance with some exemplaryembodiments. According to some exemplary embodiments, sealing strips 320 are positionedover gaps between adjacent end cladding elements and are secured on back surfaces 101 of theend cladding elements. In some exemplary embodiments, sealing strips 320 , provide a water 15impermeable seal to resist water penetrations through the gaps into the backup wall and resistleakage of cementitious material out to a front surface of the end cladding element during casting.According to some exemplary embodiments, sealing strips 320 are positioned over spacers of aformwork defining the spacing between end cladding elements. Sealing strips 320 may forexample be a gasket. Since there are no pins penetrating the gaps between adjacent end cladding 20elements, it is possible to seal the gap with a solid material as opposed to a paste or liquid. Thesolid sealing may be more robust and may provide superior sealing. According to someexemplary embodiments, the sealing strip is a 1 mm Ethylene Propylene Diene Monomer(EPDM) sheet. EPDM sheets are known to be used to weather-seal roofs and are outdoor andUV rated for over 80 years of use. The sheet may be adhered to edges along back surface 101 . 25According to some exemplary embodiments, substantially the entire surface area of back surface 101 is left exposed so that it can engage the cementitious material for chemical bonding.According to some exemplary embodiments, securing plates 330 are configured tosupport back surfaces 101 of end cladding elements against formwork panel. Securing plates 330 supports the end cladding element over its edges so that back surfaces 101 can have substantially 30full contact with the cementitious material during casting. According to some exemplaryembodiments, securing plates are rectangular plates with a bore 335 through which a securingelement 340 is received. Securing element 340 may extend through an outer sheet of a formworkand may be fixed with a nut element 345 that engages securing element 340 with a threaded connection. According to some exemplary embodiments, the threaded connection resists leakageof cementitious material through bore 335 during casting and thereby provides a cleaner finish.In some exemplary embodiments, the securing plates 330 are used in place of the tying methodused in the Baranovich system.Securing plates 330 may be metal or may be another material that resists rust. According 5to some exemplary embodiments, securing plates 330 is formed with Delrin®. According tosome exemplary embodiments, securing plates 330 are square with a width and height of 30 mm– 90 mm, e.g., about 60 mm. According to some exemplary embodiments bore 335 is 5 mm 15mm, e,g, 7 mm, in diameter.After casting, securing element 340 is removed to release the outer sheet of formwork and 10expose the end cladding elements.FIGS. 14A and 14 B are a scheme and a photograph of an example outer sheet of aformwork including end cladding elements in according with some exemplary embodiments.According to some exemplary embodiments, an outer sheet 37 of a formwork is configured tosupport a plurality of end cladding elements 100 . In some exemplary embodiments, end 15cladding elements 100 are assembled with kits 200 . Gaps between end cladding elements 100 are sealed with sealing strip 320 . According to some exemplary embodiments, end claddingelements 100 are held against outer sheet 37 formwork with securing plates 330 pressing againstback surfaces of end cladding elements and bolted to outer sheet 37 through sealing strip 320 . Aphotograph of an exemplary inner sheet of a formwork with the end cladding elements on the 20outer sheet is provided in FIG 17.FIG. 18 is a simplified flow chart of an example method for wet cladding in accordancewith some exemplary embodiments. According to some exemplary embodiments, the methodincludes providing both a plurality of wet cladding kits (block 605 ) and end cladding elementswith hole (e.g. undercut holes) (block 610 ) at a construction site. According to some exemplary 25embodiments, one or more holes (e.g. undercut holes) may be formed in the end claddingelements as needed after receiving the system. In some exemplary embodiments, kits in thesystem may be fully or partially assembled on the end cladding if not already assembled whenreceived. The assembled system may then be used to wet clad a precast backup wall of astructure. Wet cladding with the assembled system may for example be based on Israeli building 30standard 2378 method or based on the Baranovich method. In some exemplary embodiments, areinforcement metal mesh is engaged to a backup wall (block 615 ). According to exemplaryembodiments, the kits may then be engaged in the holes (e.g. undercut holes (block 620 ). Theend cladding elements and the cementitious material are applied on the backup wall (block 625 ).
According to some exemplary embodiments, the end cladding elements are spaced with spacers.The cementitious material may then be applied on the reinforcement metal mesh, on the backupwall, and/or on the back surface of the end cladding elements. According to some exemplaryembodiments, the engaging elements penetrate holes of the reinforcement metal mesh andengage with the reinforcement metal mesh. The end cladding elements which are pressed 5against the cementitious material may then be allowed to dry (block 630 ). According to someexemplary embodiments, prior to allowing the cementitious material to dry, cementitiousmaterial leakages from a front surface of the end cladding elements is removed.FIG. 19 is a simplified flow chart of an example method for wet cladding with formworksystem in accordance with some exemplary embodiments. The method may be used to construct 10a cladded backup wall of a structure. According to some exemplary embodiments, the methodincludes providing both a plurality of wet cladding kits (block 635 ) and end cladding elementswith holes (e.g. undercut holes (block 640 ) at a construction site. According to some exemplaryembodiments, one or more holes (e.g. undercut holes) may be formed in the end claddingelements as needed after receiving the system. In some exemplary embodiments, kits in the 15system may be fully or partially assembled on the end cladding if not already assembled whenreceived. The assembled system may then be used to wet clad a backup wall of a structure. Wetcladding with the assembled system may for example be based on the Baranovich method. Themethod may further include providing a formwork (block 645 ). In some exemplaryembodiments, the formwork includes an outer sheet on which a front side of the end cladding 20elements is positioned and an inner sheet. The end cladding elements may be arranged on thefront surface of the outer sheet of the formwork (block 650 ). According to some exemplaryembodiments, the method includes spacing the end cladding elements with spacers positioned onsaid outer sheet of said formwork. According to some exemplary embodiments, the end claddingelements are secured against the outer sheet of said formwork with securing plates. According to 25some exemplary embodiments, the securing plates are secured to the outer sheet of saidformwork through the spacers. According to some exemplary embodiments each of the securingplates are arranged on the back surface of the end cladding elements (over the joining edge of twoadjacent end cladding elements with spacers therebetween). According to some exemplaryembodiments, the spacers are fixed to the outer sheet of the formwork with a screw thread 30connection. In some exemplary embodiments, water sealing strips are applied onto back surfacesof the end cladding elements to cover gaps between the end cladding elements (block 653 ). Thesealing strips may seal the gaps and prevent leakage of the cementitious material onto the front surface of the end cladding elements and the outer sheet of the formwork. According to someexemplary embodiments, the securing plates are positioned over the sealing strips.According to exemplary embodiments, the kits may then be engaged in the holes (e.g.,undercut holes) (block 655 ). According to some exemplary embodiments, one or more holes(e.g., undercut holes) may be formed in the end cladding elements as needed after receiving the 5system. In some exemplary embodiments, kits in the system may be fully or partially assembledon the end cladding if not already assembled when received. The assembled system may then beused to wet clad a backup wall of a structure. In some exemplary embodiments, a reinforcementmetal mesh is placed between the end cladding elements and the inner sheet of the formwork,(wherein the cementitious material engaging elements optionally but not necessarily penetrate 10holes of the reinforcement metal mesh and engage with the reinforcement metal mesh). The frontportion and the back portion of the formwork may then be secured to one another to define avolume in which the cementitious material may be received (block 660 ). Reinforcements may beadded to the defined volume, e.g., reinforcement bars (block 665 ). According to some exemplaryembodiments, a thermal insulating material may be added to the defined volume. According to 15some exemplary embodiments, the cementitious material is added to the defined volume (block 670 ) and allowed to dry (block 675 ). In some exemplary embodiments, the cementitious materialis added with a pump pumping the cementitious material. In some exemplary embodiments, thecementitious material is added through a funnel to reduce the flow rate of the cementitiousmaterial within the volume. According to some exemplary embodiments, the cementitious 20material is added directly on the back surfaces of the end cladding material.As mentioned, the present invention further contemplates constructing walls which arecladded both on the exterior facing surface of the wall and the interior facing surface of the wall.In one embodiment, the exterior facing surface of the wall is clad using the kits describedherein (e.g. kit 200 ). In another embodiment, the interior facing surface of the wall is clad using 25the kits described herein (e.g. kit 200 ). In still another embodiment, both the interior and theexterior of the wall are clad using the kits described herein. Alternatively, either one of theinterior or the exterior facing surface is clad using other methods known in the art including forexample the Baranovich method (further described herein above and illustrated in FIG. 1) orusing U-shaped elements as further described herein below. 30 According to this embodiment, end cladding elements (with holes in either the backsurface thereof or on the side thereof) suitable for cladding an interior facing surface are arrangedon the front surface of an inner sheet of the formwork. According to some exemplaryembodiments, the end cladding elements are not spaced with spacers on the formwork.
According to some exemplary embodiments, the end cladding elements are secured against theinner sheet of the formwork with securing plates (as described herein above). According to someexemplary embodiments, the securing plates are fixed to the inner sheet of the formwork with ascrew thread connection. Kits may then be engaged in the holes (e.g., undercut holes or uniformholes), as further described herein above. 5After drying of the cementitious material, the inner sheet and outer sheet of the formworkmay be removed. According to some exemplary embodiments, the method includes removingcementitious material leakages from a front surface of said plurality of end cladding elements.FIG. 25 is a diagram of a wall 58 which is cladded on both its interior facing surface 64 and the exterior facing surface. End-cladding element 100 suitable for cladding an exterior facing 10surface of the wall 58 is attached to the wall using kit 200, whereas end-cladding element 120 suitable for cladding an interior facing surface of the wall 58 is attached to the wall using kit 200 .FIG. 20 is a simplified flow chart of an example method for wet cladding in accordancewith some exemplary embodiments and is essentially similar to the one described in FIG. 19except that the casting may be carried out on the ground (i.e. horizontally) without the need for 15both sides of a formwork. The method may be used to construct a cladded backup wall of astructure. According to some exemplary embodiments, the method includes providing both aplurality of wet cladding kits (block 680 ) and end cladding elements with holes (e.g., undercutholes) (block 685 ) at a construction site. According to some exemplary embodiments, one ormore holes (e.g., undercut holes)may be formed on the back surface of the end cladding elements 20as needed after receiving the system. In some exemplary embodiments, kits in the system may befully or partially assembled on the end cladding if not already assembled when received. Theassembled system may then be used to construct a wet-cladded backup wall of a structure. Themethod may further include providing a framework which defines an enclosed space (block 690 ).In one embodiment, the framework comprises an outer sheet of a formwork. The end cladding 25elements may be arranged inside the area defined by the framework (block 695 ), optionally on aplatform which comprises spacers, with the back surface of the end cladding element facingupwards. In some exemplary embodiments, water sealing strips are applied onto back surfaces ofthe end cladding elements to cover gaps between the end cladding elements (block 700 ). Thesealing strips may seal the gaps and prevent leakage of the cementitious material onto the front 30surface of the end cladding elements and the outer sheet of the formwork. According to someexemplary embodiments, the securing plates are positioned over the sealing strips.According to exemplary embodiments, the kits may then be engaged in the holes (e.g.,undercut holes) (block 705 ). According to some exemplary embodiments, one or more hole (e.g., undercut holes) may be formed in the end cladding elements as needed after receiving the system.In some exemplary embodiments, kits in the system may be fully or partially assembled on theend cladding if not already assembled when received. In some exemplary embodiments, areinforcement metal mesh is placed on top of the end cladding elements, (wherein thecementitious material engaging elements optionally but no obligatorily penetrate holes of the 5reinforcement metal mesh and engage with the reinforcement metal mesh). The assembledsystem may then be used to construct a cladded wall of a structure. According to someexemplary embodiments, the cementitious material is added to a volume defined by theframework (block 710 ) and allowed to dry (block 715 ). According to some exemplaryembodiments, the cementitious material is added directly on the back surfaces of the end cladding 10material.After drying of the cementitious material, the framework may be removed and theconstructed wall may be moved to its appropriate location. According to some exemplaryembodiments, the method includes removing cementitious material leakages from a front surfaceof said plurality of end cladding elements. 15FIG. 21 is a simplified flow chart of an example method for wet cladding without aformwork system in accordance with some exemplary embodiments and is essentially similar tothe one described in FIG. 20 except that the casting of the wall is carried out prior to placing ofthe end cladding elements. The method may be particularly suitable for constructing a claddedpre-cast wall. According to some exemplary embodiments, the method includes providing both a 20plurality of wet cladding kits (block 720 ) and end cladding elements with holes (e.g., undercutholes) (block 725 ) at a construction site. According to some exemplary embodiments, one ormore holes (e.g., undercut holes) may be formed in the end cladding elements as needed afterreceiving the system. In some exemplary embodiments, kits in the system may be fully orpartially assembled on the end cladding if not already assembled when received. The assembled 25system may then be used to construct a cladded wall. Cementitious material is spread on ahorizontal surface - e.g., a floor (block 730 ) whose area has been defined using a framework.According to exemplary embodiments, the kits may then be engaged in the holes (e.g., undercutholes) (block 735 ). According to some exemplary embodiments, one or more holes (e.g.,undercut holes) may be formed in the end cladding elements as needed after receiving the system. 30In some exemplary embodiments, kits in the system may be fully or partially assembled on theend cladding if not already assembled when received. The assembled system may then be used towet clad a surface (e.g., a floor or a precast wall). The end cladding elements may be arranged onthe surface to which the cementitious material has been applied (block 740 ). According to some exemplary embodiments, the method includes spacing the end cladding elements with spacerspositioned on the surface. According to some exemplary embodiments, the cementitious materialis added directly on the back surfaces of the end cladding material.After drying of the cementitious material, leakages from a front surface of said pluralityof end cladding elements may be removed. 5FIGs. 22A-B is a simplified flow chart of an example method for constructing a wetcladded structure with formwork system in accordance with some exemplary embodiments.According to some exemplary embodiments, the method includes providing both a plurality ofwet cladding kits (block 750 ) and end cladding elements with holes (e.g., undercut holes) (block 755 ) at a construction site. According to some exemplary embodiments, one or more holes (e.g., 10undercut holes) may be formed in the end cladding elements as needed after receiving thesystem. In some exemplary embodiments, kits in the system may be fully or partially assembledon the end cladding if not already assembled when received. Wet cladding with the assembledsystem may for example be based on the Baranovich method. The method may further includeproviding a plurality of formworks (block 760 ). In some exemplary embodiments, the formwork 15includes an outer sheet on which a front side of the end cladding elements is positioned and aninner sheet. The end cladding elements may be arranged and secured on the front surface ofeach of the formworks (block 765 ), as described herein above so as to form a plurality ofassemblages. According to some exemplary embodiments, the method includes spacing the endcladding elements with spacers positioned on said outer sheet of said formwork. According to 20some exemplary embodiments, the end cladding elements are secured against the outer sheet ofsaid formwork with securing plates. According to some exemplary embodiments, the securingplates are secured to the outer sheet of said formwork through the spacers. According to someexemplary embodiments each of the securing plates are arranged on the back surface of the endcladding elements (over the joining edge of two adjacent end cladding elements with spacers 25therebetween). According to some exemplary embodiments, the spacers are fixed to the outersheet of the formwork with a screw thread connection. In some exemplary embodiments, watersealing strips are applied onto back surfaces of the end cladding elements to cover gaps betweenthe end cladding elements. The sealing strips may seal the gaps and prevent leakage of thecementitious material onto the front surface of the end cladding elements and the outer sheet of 30the formwork. According to some exemplary embodiments, the securing plates are positionedover the sealing strips.
If not already at the site of construction, the assemblages are then hoisted to a floor underconstruction and placed adjacent to one another to form a continuous structure of assemblages(block 7 85 ).In some exemplary embodiments, a reinforcement metal mesh is placed between the endcladding elements and the inner sheet of the formwork - block 790 . 5According to some exemplary embodiments, a thermal insulating material may be addedto the defined volume.The front portion and the back portion of the formwork may then be secured to oneanother to define a volume in which the cementitious material may be received and form anassemblage (block 800 ). A continuous framework unit is thus constructed. Cementitious 10material is added into the continuous framework unit (block 805 ) and allowed to dry (block 810 ).In some exemplary embodiments, the cementitious material is added with a pump pumping thecementitious material. In some exemplary embodiments, the cementitious material is addedthrough a funnel to reduce the flow rate of the cementitious material within the volume.Table 2 below combines some optional engineering values, rendering the wet cladding 15kits, methods, systems and/or constructions of some exemplary embodiments superior over anyprior art wet cladding method. It is to be understood that any optional value or any combinationof any one or more optional alternative values can be used in conjunction of the wet claddingkits, methods, systems and/or constructions described herein, even if a given combination of anyone or more optional alternative values is not explicitly described. 20 Table 2 Item Specification Material e.g., Ceramic Porcelain, other SizeX: at least 35 cm;Y: at least 35 cm;Alternatively and optionally30x60 – 60x120 cm.
Inherent water absorption Less than 0.5 % w/w when soakedin water. E.g., less than 0.1 % w/w.Optionally, 0 % w/w.Substantially o water absorptionfrom the front surface of thecladding element.
Abrasion ResistanceClass, 1 or better, Class 2 or better,class 3 or better, Class 4 or better,According to Israeli BuildingStandard 314.Tile Thickness 9-12 mm, optionally about 10 mm.Tile Breaking Strength Over 1300 Newton, optionally over 1600 Newton, optionally over 2000NewtonTile Bending StrengthNewton/mm, optionally 35Newton/mm Tile Breaking strengthAt least 1300 Newton, optionally atleast 1550 Newton, optionally atleast 1,800 Newton Mechanical Fixing of the Kit to the end cladding element Kit pull strength Over 10 Kg pull strength,optionally over 20 Kg pull strength,optionally over 40 Kg pull strengthoptionally about 10 Kg pullstrength.Pin thickness (per kit)At least 3 mm, optionally at leastabout 4 mm.
Pin MaterialStainless steel (Nirosta), optionallystainless steel 316, optionallystainless steel 304 Load Dispersion Element (per kit) At least 20 mm in diameter,optionally at least 30 mm indiameter, optionally at least 40 mmin diameter, optionally at least 50mm in diameter. If not circular,diameter refers to the longestdiameter of an inclusion circle.Optionally 0.5-2 mm in thickness,optionally about 1 mm in thickness.Pin Length (per kit), protrusion intocement/concrete50-90 mm, optionally 50-80.Undercut Hole Diameter at surface 5-9 mm, optionally about 6 mm.Undercut Hole Depth 5-7 mm, optionally about 6 mm.
Chemical Bonding Pull StrengthAt least 1 MPs/mm, optionally atleast 1.5 MPs/mm, optionally atleast 2 MPs/mm. (average of atleast 10 measurements) Cladding element pulling strength At least 100 Kg/m, optionally atleast 500 Kg/m, optionally at least1000 Kg/m, optionally at least1500 Kg/m, optionally at least2000 Kg/m, optionally at least2300 Kg/m.Kits per square meter of claddingelementAt least 11, at least 12; at least 13-20.Kits per Kg of cladding elementAt least 11/35 Kg, at least 12/35Kg; at least 13-20/35K.
The present inventors have now devised a method for attaching an undercut anchor to theback surface of an end-cladding element without the need to drill an undercut hole, provided thematerial of the end-cladding element is sufficiently non-brittle and plastic.Figures 23A-C illustrate how an undercut anchor may be attached to an end-claddingelement without the need to drill undercut holes. 5Figure 23A depicts a round, blind hole 110 having an opening on a back surface 101 of anend-cladding element 100 . Blind hole 110 is defined by internal walls having a length and asubstantially identical diameter along the length. Blind hole 110 does not penetrate the frontsurface 102 of the end-cladding element 100 .Figure 23B depicts an unflared undercut anchor 220 partially inserted into a blind hole 10 110 .Figure 23C depicts a flared undercut anchor 220 which has now been fully inserted intoblind hole 110 , following the screwing of a flaring element 260 into undercut anchor 220 . Thescrewing allows undercut anchor 220 to flare inside hole 110 beyond the internal walls of thehole. As the anchor flares, it compresses material of the end-cladding element defining the hole. 15Thus, the material 270 of the end-cladding element surrounding undercut anchor 220 is morecompressed than the material of the end-cladding element not surrounding the undercut anchor.Without being bound to theory, it is believed that the compression of the material around theundercut anchor leads to the enhanced retention force exerted by the end-cladding element on theundercut anchor. 20For the sake of comparison, reference is now made to Figures 24A-24C which depictsvarious stages of securing an undercut anchor in an undercut hole which traverses a thickness ofan end-cladding element, according to currently known methods.Figure 24A depicts undercut hole 105 on a back surface 101 of end-cladding element 100 .Figure 24B depicts a non-flared undercut anchor 220 partially inserted into undercut hole 25 105 .Figure 24C depicts flared undercut anchor 220 which has now been fully inserted intoundercut hole 105 , following the screwing of flaring element 260 into undercut anchor 220 . Thescrewing allows the undercut anchor to flare inside the hole.The present method for securing an undercut anchor into an end-cladding element 30portrayed in Figures 23A-C may be summarized as follows:A method of securing an undercut anchor in a blind hole which traverses a thickness of anend-cladding element, the blind hole having an opening on a back surface of the end-claddingelement, the blind hole being defined by internal walls having a length and a substantially identical diameter along said length, the method comprises inserting the undercut anchor into theblind hole; and screwing a flaring element into the undercut anchor, so as to allow the undercutanchor to flare inside the hole and beyond the internal walls of the hole, while compressingmaterial of the end-cladding element surrounding the hole.According to some exemplary embodiments, the end-cladding elements may be pre- 5formed with the uniform holes, e.g., during manufacturing or may be drilled followingmanufacturing. In an exemplary embodiment, the hole is about 5-7 mm in diameter and about 4-mm in depth. According to exemplary embodiments, the end-cladding element is formed witha plurality of holes, e.g., 4-8, 4-12 or 4-50 holes.Typically, each end-cladding element comprises a plurality of holes - for example at least 10four, one in each corner, at least 6, at least 8, at least 12. Depending on the size of the end-cladding element more holes may be drilled.Thus, the present invention provides for an end-cladding element having a back surfacewhich comprises a blind hole into which an undercut anchor has been flared and secured, the end-cladding element being fabricated from a material, wherein the material of the end-cladding 15element surrounding the undercut anchor, after the undercut anchor has been flared and secured,is more compressed than the material of the end-cladding element not surrounding the undercutanchor.The end-cladding elements which can be used in the present invention have a wide rangeof thicknesses less than 3 cm, e.g., 1 cm - 3 cm, less than 2 cm, e.g., 1.9 cm, or 1.5 cm or less, or 20even 9-12 mm. The end-cladding elements may be of any shape (e.g., a polygon, such asrectangular or square; or combination of polygons having, for example, 5 and 6 gons to cladcurved surfaces; or a non-polygon) and of any size – e.g., between 20 cm – 5 meters in length andbetween 20 cm to 5 meters in height. According to some exemplary embodiments at least one ofthe plurality of cladding elements is a quadrangle having X and Y dimensions, whereby both X 25and Y are each independently greater than 35 cm. The back surface of the end-cladding elementmay be smooth or rough.The end-cladding element is fabricated from a material having a plasticity and beingsufficiently non-brittle, so as to allow flaring of the undercut anchor into the material withoutbreaking the end-cladding element, the material having a retention force that allows rigid 30attachment of the undercut anchor to the end-cladding element.According to a particular embodiment, the end-cladding element is fabricated from acementitious material, including but not limited to pre-fabricated cement boards (e.g., cementbonded particle board or a cement fiber board).
As mentioned herein above, the present invention also contemplates using U-shapedelements for connecting cementitious material engaging elements to end-cladding elements viaholes (e.g. slots) in the sides of the end-cladding elements. The end-cladding elements must besufficiently thick and non-brittle so as to allow drilling of side holes therein. This method will befurther described with the aid of FIGs. 26A-D, 27A-C and 28A-B. 5FIG. 26A, 26B, 26C and 26D are respectively an alternate example system including anexample kit with an example U-shaped element, two perspective views of the example kit and asectional view of the example kit installed on an edge of an end cladding element, all inaccordance with some example embodiments. According to some example embodiments, asystem 350 includes an end cladding element 100 and one or more end cladding kits 360 . 10According to some example embodiments, kit 360 includes a U-shaped element 362 and a pin 364 (i.e., a cementitious material engaging element) extending out from U-shaped element 362 .U-shaped element is formed with a first wall 366 , a second wall 368 spaced from first wall 366 and a base 370 extending from first wall 366 to second wall 368 . According to some exampleembodiments, pin 364 extends out from first wall 366 in a substantially normal direction. A 15distal end of pin 364 may include cement anchoring element 372 . According to some exampleembodiments, second wall 368 is configured to be received within a slot formed through an edgesurface of end cladding element 100 .FIGS. 27A, 27B and 27C are two perspective views of another example kit with a U-shaped piece and a sectional view of the example kit installed on an edge of an end cladding 20element, all in accordance with some example embodiments. In some example embodiments,second wall 368 of U-shaped element 362 may be shorter than first wall 366 and/or otherwiseshaped. Optionally, second wall 368 includes a curved shape to match a shape of a slot cutthrough an edge surface of end cladding element through which second wall 368 is to bereceived. 25FIGS. 28A and 28B are respectively a perspective view and a side view of yet anotherexample kit including a U-shaped piece in accordance with some example embodiments. Insome example embodiments, kit 360 includes a stud pin 374 with screw threads that extend tocement anchoring element 372 at a distal end. In other example embodiments, the screw threadsdo not extend into cement anchoring element 372 . Stud pin 374 may be fixed onto U-shaped 30element 362 based on welding or with a screw type connection.As used herein the term "about" refers to  10 %.The terms "comprises", "comprising", "includes", "including", "having" and theirconjugates mean "including but not limited to".
The term "consisting of" means "including and limited to".The term "consisting essentially of" means that the composition, method or structure mayinclude additional ingredients, steps and/or parts, but only if the additional ingredients, stepsand/or parts do not materially alter the basic and novel characteristics of the claimedcomposition, method or structure. 5As used herein, the singular form "a", "an" and "the" include plural references unless thecontext clearly dictates otherwise. For example, the term "a compound" or "at least onecompound" may include a plurality of compounds, including mixtures thereof.Throughout this application, various embodiments of this invention may be presented ina range format. It should be understood that the description in range format is merely for 10convenience and brevity and should not be construed as an inflexible limitation on the scope ofthe invention. Accordingly, the description of a range should be considered to have specificallydisclosed all the possible subranges as well as individual numerical values within that range. Forexample, description of a range such as from 1 to 6 should be considered to have specificallydisclosed subranges such as from 1 to 3, from 1 to 4, from 1 to 5, from 2 to 4, from 2 to 6, from 15to 6 etc., as well as individual numbers within that range, for example, 1, 2, 3, 4, 5, and 6. Thisapplies regardless of the breadth of the range.Whenever a numerical range is indicated herein, it is meant to include any cited numeral(fractional or integral) within the indicated range. The phrases "ranging/ranges between" a firstindicate number and a second indicate number and "ranging/ranges from" a first indicate 20number "to" a second indicate number are used herein interchangeably and are meant to includethe first and second indicated numbers and all the fractional and integral numerals therebetween.As used herein the term "method" refers to manners, means, techniques and proceduresfor accomplishing a given task including, but not limited to, those manners, means, techniquesand procedures either known to, or readily developed from known manners, means, techniques 25and procedures by practitioners of the chemical, and mechanical arts.It is appreciated that certain features of the invention, which are, for clarity, described inthe context of separate embodiments, may also be provided in combination in a singleembodiment. Conversely, various features of the invention, which are, for brevity, described inthe context of a single embodiment, may also be provided separately or in any suitable sub- 30combination or as suitable in any other described embodiment of the invention. Certain featuresdescribed in the context of various embodiments are not to be considered essential features ofthose embodiments, unless the embodiment is inoperative without those elements.
In addition, any priority document(s) of this application is/are hereby incorporated hereinby reference in its/their entirety.

Claims (32)

WHAT IS CLAIMED IS:
1. A wet cladding kit for fixing an end cladding element to cementitious material ofwall, the kit comprising:an undercut anchor configured for being inserted into an undercut hole formed on a backsurface of the end cladding element;a screwable flaring element configured for flaring said undercut anchor in said undercuthole, said element comprises a first portion of a connecting structure; anda cementitious material engaging element which comprises at its proximal end a secondportion of said connecting structure, said second portion of said connecting structure directlyconnectable to said first portion of said connecting structure, said cementitious material engagingelement further comprises a distal end extending from said second portion of said connectingstructure for being embedded in the cementitious material, said distal end having a bend;wherein said first portion of said connecting structure and said second portion of saidconnecting structure are designed to be directly connectable to form said connecting structure, soas to reduce a tendency of said undercut anchor from damaging walls defining said undercut holewhen a torque is applied onto said engaging element.
2. The kit of claim 1, wherein said cementitious material engaging element isthreaded at said distal end and wherein said normal vector component is formed at least in part bya threaded surface of said distal end.
3. The kit of any one of claims 1-2, being fabricated entirely from metal.
4. The kit of claim 1, further comprising a load dispersion element connectable to, orintegrally formed with, said flaring element or said undercut anchor, wherein said load dispersionelement is configured to disperse load over a surface area of said load dispersion element, saidsurface area being at least twice the surface area of said undercut hole, so as to reduce loadimposed by said undercut anchor on walls defining said undercut hole.
5. The kit of any one of claims 1-4, wherein said second portion of said connectingstructure is a connecting element selected from the group consisting of a washer shaped element,a closed ring, an open ring, a loop and a helix.
6. The kit of any one of claims 1-4, wherein said first portion of said connectingstructure is a screw head.
7. The kit of any one of claims 1-6, wherein said flaring element is a threadedelement configured to be received through said second portion of said connecting structure andinto said undercut anchor to fix said cementitious material engaging element onto said backsurface of the end cladding element.
8. The kit of any of claims 1-7, further comprising a securing plate and a removableend cladding element securing agent for temporarily securing said end cladding element to aformwork.
9. The kit of any one of claims 1-7, further comprising sealing strips.
10. A wet cladding method of constructing a cladded wall, the method comprising:(a) providing a plurality of kits according to any one of claims 1-8;(b) providing a plurality of end cladding elements formed with undercut holes in backsurfaces of said plurality of end cladding elements;(c) providing a formwork having an outer sheet and an inner sheet;(d) arranging said plurality of end cladding elements with a front surface thereofagainst a back surface of said outer sheet of said formwork;(e) engaging said plurality of kits in said undercut holes;(f) securing said inner sheet and said outer sheet of said formwork to one anotherwith formwork securing elements;(g) applying said cementitious material into said formwork;(h) allowing said cementitious material to harden with said cementitious materialengaging elements penetrating therein, thereby providing said mechanical fixing and chemicalbonding of the end cladding elements to said cementitious material when the cementitiousmaterial is hardened, thereby constructing the cladded wall.
11. The wet cladding method of claim 10, wherein said applying is effected with aconcrete pump.
12. The wet cladding method of any of claims 10 - 11, further comprisingultrasonically vibrating said cementitious material before said cementitious material is hardened.
13. The wet cladding method of claim 10, further comprising spacing said plurality ofend cladding elements with spacers spaced on said back surface said outer sheet of saidformwork.
14. The wet cladding method of claim 13, wherein said spacers are integrally formedwith or permanently attached to said outer sheet of said formwork.
15. The wet cladding method of any of claims 10-13, further comprising placing areinforcement metal mesh between said plurality of end cladding elements and said inner sheet ofsaid formwork and tying said metal mesh to said formwork.
16. A wet cladding method for constructing a cladded wall, the method comprising:(a) providing a plurality of kits according to any one of claims 1-7;(b) providing a plurality of end cladding elements formed with undercut holes on backsurfaces of said plurality of end cladding elements;(c) placing said plurality of end cladding elements inside an area defined by ahorizontal framework;(d) engaging said plurality of kits in said undercut holes;(e) applying said cementitious material onto said back surfaces;(f) allowing said cementitious material to harden with said cementitious materialengaging elements of said kits penetrating therein, thereby providing mechanical fixing andchemical bonding of said plurality of end cladding elements to said cementitious material oncehardened, thereby constructing the cladded wall.
17. The method of claim 16, further comprising applying a plurality of water sealingstrips onto back surfaces of said plurality of end cladding elements, said water sealing stripsconfigured to seal gaps between adjacent said plurality of end cladding elements.
18. A wet cladding method for constructing a cladded wall, the method comprising:(a) providing a plurality of kits according to any one of claims 1-8; (b) providing a plurality of end cladding elements formed with undercut holes onback surfaces of said plurality of end cladding elements;(c) applying cementitious material into a horizontal framework;(d) engaging said plurality of kits in said undercut holes;(e) placing said plurality of end cladding elements with a back surface thereof ontosaid cementitious material;(f) allowing said cementitious material to harden with said cementitious materialengaging elements of said kits penetrating therein, thereby providing mechanical fixing andchemical bonding of said plurality of end cladding elements to said cementitious material oncehardened, thereby constructing the cladded wall.
19. The method of claims 16 or 18, wherein said applying is effected with a concretepump.
20. The method of any of claims 16-19, further comprising placing a reinforcementmetal mesh inside said cementitious material.
21. A wet cladding method, the method comprising:(a) providing a plurality of kits according to any one of claims 1-7;(b) providing a plurality of end cladding elements formed with undercut holes in backsurfaces of said plurality of end cladding elements;(c) providing a plurality of formworks, each said formwork having an outer sheet andan inner sheet;(d) placing said plurality of end cladding elements with a front surface thereof againsta back surface of said outer sheet of each said formwork;(e) engaging said plurality of kits in said undercut holes;(f) securing said plurality of end cladding elements to said outer sheet of each saidformwork so as to form a plurality of assemblages;(g) hoisting said plurality of assemblages to a floor under construction and placingsaid plurality of assemblages adjacent to one another;(h) placing a plurality of reinforcing elements against said back surface of saidplurality of end cladding elements;(i) optionally placing heat insulating building blocks against said plurality ofreinforcing elements; (j) securing each said inner sheet and each respective said outer sheet of said pluralityof formworks to one another with formwork securing elements, so as to form a continuousformwork unit;(k) applying said cementitious material into said continuous formwork unit;(l) allowing said cementitious material to harden with said cementitious materialengaging element penetrating therein, thereby providing said mechanical fixing and chemicalbonding of the end cladding elements to said cementitious material once hardened.
22. The wet cladding method of claim 21, further comprising securing said plurality ofend cladding elements with securing plates and removable end cladding element securing agentto said outer sheet of said formwork.
23. The wet cladding method of any one of claims 21-22, further comprising applyinga plurality of water sealing strips onto said back surfaces of said plurality of end claddingelements, said water sealing strips configured to seal gaps between adjacent said plurality of endcladding elements, so as to prevent leakage of said cementitious material between said a frontsurface of said plurality of end cladding elements and said outer sheet of said formwork and towater seal the structure once said cementitious material is hardened.
24. A method of wet cladding a wall, the method comprising:(a) providing a plurality of kits according to any one of claims 1-8;(b) providing a plurality of end cladding elements formed with undercut holes in backsurfaces of said plurality of end cladding elements;(c) engaging a reinforcement metal mesh onto a backup wall to be cladded;(d) engaging said kits in said undercut holes; and(e) applying said cementitious material between said back surfaces of said plurality ofend cladding elements and said wall with said cementitious material engaging elementspenetrating into the cementitious material;(f) allowing said cementitious material to harden with said cementitious materialengaging elements penetrating therein, thereby providing mechanical fixing and chemicalbonding of said plurality of end cladding elements to the cementitious material when saidcementitious material is hardened, thereby wet cladding the backup wall.
25. The wet cladding method of claim 24, further comprising spacing said plurality ofend cladding elements with spacers.
26. The wet cladding method of claim 25, further comprising removing cementitiousmaterial leakages from a front surface of said plurality of end cladding elements.
27. The wet cladding method of claim 26, wherein said cementitious materialengaging elements penetrate beyond and engages said reinforcement metal mesh.
28. A structure constructed using the methods of any one of claims 10-27.
29. The structure of claim 28, wherein said plurality of end cladding elements are tilesof a synthetic material.
30. The method or structure of any of claims 10-29, wherein said chemical bondingpull strength exceeds 1 MegaPascal (MPs) per mm.
31. The method or structure of any of claims 10-30, wherein at least eleven kits areprovided per 35 kg of end cladding element.
32. The method or structure of any of claims 10-31, wherein a pulling strength of saidcladding element is at least 100 Kg/m. Dr. Gal Ehrlich Patent Attorney G.E. Ehrlich (1995) Ltd. 35 HaMasger Street Sky Tower, 13th Floor Tel Aviv 6721407
IL320323A 2021-08-22 2025-04-17 Kits, systems and methods for cladding walls and structures manufactured in this way IL320323A (en)

Applications Claiming Priority (3)

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IL28578621 2021-08-22
IL288212A IL288212A (en) 2020-11-18 2021-11-17 Construction of insulated walls by wet cladding
IL288213A IL288213B2 (en) 2020-11-18 2021-11-17 Wall cladding kits, systems, methods and structures formed therewith

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IL319875A IL319875A (en) 2021-08-22 2025-03-26 Construction of insulated walls by wet cladding
IL320324A IL320324A (en) 2021-08-22 2025-04-17 Construction of walls with cladding and insulation
IL320323A IL320323A (en) 2021-08-22 2025-04-17 Kits, systems and methods for cladding walls and structures manufactured in this way
IL320325A IL320325A (en) 2021-08-22 2025-04-17 Methods for cladding exterior walls
IL322874A IL322874A (en) 2021-08-22 2025-08-20 Wall cladding kits, systems, methods and structures formed therewith

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