Rock facade panel and methods of manufacturing a rock facade...

E - Fixed Constructions – 04 – F

Patent

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E04F 13/00 (2006.01) B28B 1/14 (2006.01) B44F 9/00 (2006.01) B44F 9/04 (2006.01)

Patent

CA 2433505

The invention provides a building panel having a simulated natural rock face, for use as a rock facade in wall construction applications, and methods of manufacturing same. The wall panel is manufactured in a mold containing a masonry-permeable mesh, preferably flexible. In one embodiment the bottom of the mold is provided with the profile of the natural rock facade and the masonry permeable mesh is positioned spaced from the bottom of the mold, and a settable material is poured into the mold, creating the rock facade and simultaneously embedding the mesh in each simulated rock face to integrate the panel. In a further embodiment the mesh is placed over the bottom of a mold, the settable material is poured over the mesh, and the rock facade pattern is pressed or stamped into the top surface of the settable material to create the desired pattern. Optionally the panel has a backing board having holes, the settable material intruding through the holes to anchor the rock facade (and embedded mesh) to the backing board. In the preferred embodiment the panel is provided with top and bottom edges having complementary profiles containing a repeating pattern so that panels can be laid against one another in either a linear or a staggered (overlapping) fashion, and the side edges of the panel are complementary and fit into the repeating portion of the top and bottom edge profile, so that the building panels can be laid either vertically or horizontally.

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