Cladding panel

Abstract

A prefabricated reinforced brick panel has a plurality of bricks arranged in a spaced-apart array with mortar between the bricks. The array comprises a number of superimposed rows of bricks. The bricks in each row are staggered relative to the bricks in each adjacent row of bricks. Each brick has a number of vertical through holes extending between a top and a bottom of the brick. These through holes are aligned in the array and vertical reinforcing bars are inserted into aligned holes and extend between a top and a bottom of the panel. Two offset vertical reinforcing bars pass through each brick. Transverse reinforcing bars are mounted in the mortar between rows of bricks.

1 . A method for manufacturing a prefabricated reinforced masonry panel, including the steps:
 laying a plurality of bricks face down on a horizontal support surface of a panel forming bed in a spaced-apart array leaving gaps between the bricks for reception of mortar,   said array comprising a number of juxtaposed rows of bricks,   the bricks in each row of bricks being staggered relative to the bricks in each adjacent row of bricks,   each brick having a plurality of spaced-apart through holes extending between a top and a bottom of the brick,   overlapping said holes in adjacent rows of bricks when forming said array,   inserting a number of spaced-apart outer vertical reinforcing bars through said overlapping holes in the bricks in alignment,   said outer vertical reinforcing bars extending between a top row of the bricks and a bottom row of the bricks in said array of bricks,   laying a first transverse reinforcing bar across said outer vertical reinforcing bars along at least one of the gaps between rows of bricks,   inserting a number of inner vertical reinforcing bars through said overlapping holes in the bricks in alignment,   said inner vertical reinforcing bars extending between the top row of bricks and the bottom row of bricks in said array of bricks and spaced above the outer vertical reinforcing bars on the bed,   preparing a liquid mortar and pouring said liquid mortar into the gaps between the bricks and through the holes in the bricks,   allowing the mortar to set to form the prefabricated reinforced masonry panel, and   removing the prefabricated reinforced masonry panel from the bed.   
   
   
       2 . The method as claimed in  claim 1 , wherein the method includes laterally offsetting the inner and outer vertical reinforcing bars. 
   
   
       3 . The method as claimed in  claim 1 , wherein the method includes inserting two vertical reinforcing bars through each brick. 
   
   
       4 . The method as claimed in  claim 3 , wherein the method includes inserting one outer vertical reinforcing bar and one inner vertical reinforcing bar through each brick. 
   
   
       5 . The method as claimed in  claim 1 , wherein the method includes laying a second transverse reinforcing bar across said inner vertical reinforcing bars along at least one of the gaps between rows of bricks prior to pouring the liquid mortar into the gaps between the bricks. 
   
   
       6 . The method as claimed in  claim 1 , wherein the method includes laying first and second transverse reinforcing bars in all the gaps between the rows of bricks. 
   
   
       7 . The method as claimed in  claim 1 , wherein each transverse reinforcing bar extends between opposite sides of the brick array. 
   
   
       8 . The method as claimed in  claim 1 , wherein the reinforcing bars comprise rebar. 
   
   
       9 . The method as claimed  claim 1 , wherein the method includes preparing a liquid mortar by mixing together a fine sand, cement and water. 
   
   
       10 . The method as claimed in  claim 1 , wherein the method includes the step of arranging the bricks on the bed for forming an ope in the wall panel. 
   
   
       11 . The method as claimed in  claim 1 , wherein the method includes providing means for sealing between a face of each brick and the bed. 
   
   
       12 . The method as claimed in  claim 11 , wherein said sealing means extends into the gaps between the bricks. 
   
   
       13 . The method as claimed in  claim 12 , wherein said sealing means comprises resilient sealing elements mounted on the bed in the gaps between the bricks. 
   
   
       14 . A prefabricated reinforced masonry panel, including:
 a plurality of bricks arranged in a spaced-apart array of bricks with mortar between the bricks,   said array comprising a number of superimposed rows of bricks,   the bricks in each row of bricks being staggered relative to the bricks in each adjacent row of bricks,   each brick having a plurality of through holes extending between a top and a bottom of the brick,   holes in each brick being in alignment with associated holes in vertically adjacent bricks,   a transverse reinforcing bar mounted between at least two adjacent rows of bricks,   a number of spaced-apart vertical reinforcing bars extending through aligned holes in the bricks between a top row of the bricks and a bottom row of the bricks in the brick array,   two vertical reinforcing bars extending through each full brick in the array.   
   
   
       15 . The prefabricated reinforced masonry panel as claimed in  claim 14 , wherein an outer vertical reinforcing bar and an inner vertical reinforcing bar extend through each brick, said outer vertical reinforcing bar and inner vertical reinforcing bar engaging holes in the brick spaced-apart at either side of a longitudinal axis of the brick. 
   
   
       16 . The prefabricated reinforced masonry panel as claimed in  claim 15 , wherein the outer vertical reinforcing bar and the inner vertical reinforcing bar are laterally offset in each brick, engaging longitudinally spaced-apart holes in the brick. 
   
   
       17 . The prefabricated reinforced masonry panel as claimed in  claim 14 , wherein a pair of spaced-apart transverse reinforcing bars are mounted between at least two adjacent rows of brick. 
   
   
       18 . The prefabricated reinforced masonry panel as claimed in  claim 14 , wherein pairs of spaced-apart transverse reinforcing bars are mounted between all the rows of bricks.