Fiber reinforced concrete stone panel system

Abstract

A method of forming an exterior wall of a building, including the wall, includes the step of mounting a fiber-reinforced panel to the building. The panel has a plurality of masonry units protruding from the face thereof that are spaced from one another with a groove between each of the masonry units. The method includes mounting a second, similar panel to the building spaced from the first panel with a groove therebetween, and injecting mortar into the grooves between the masonry units and the groove between the panels. The mortar covers the grooves between masonry units and the groove between panels to look the same, thereby making it difficult to distinguish the repeat pattern.

1 . A method of forming an exterior wall of a habitable building having a substructure made of vertical support members, the method comprising:
 (a) mounting a first concrete panel to the substructure, the first panel having a plurality of adjacent masonry units protruding from the face thereof that are separated by a groove formed between each of said masonry units and the next adjacent masonry unit;   (b) mounting a second concrete panel to the substructure, the second panel having a plurality of adjacent masonry units protruding from the face thereof that are separated by a groove formed between each of said masonry units and the next adjacent masonry unit, wherein at least one of the masonry units of the first panel is separated from at least one of the masonry units of the second panel by a groove; and   (c) injecting mortar into the grooves between the masonry units on each panel and into the groove between said at least one of the masonry units of the first panel and said at least one of the masonry units of the second panel.   
     
     
         2 . The method in accordance with  claim 1 , wherein the step of mounting the panels comprises inserting fasteners through the panels into the substructure. 
     
     
         3 . The method in accordance with  claim 2 , wherein the step of inserting fasteners further comprises driving screws through the panels in the grooves between masonry units. 
     
     
         4 . The method in accordance with  claim 1 , further comprising cutting a third panel to fit between the second panel and a building structure. 
     
     
         5 . The method in accordance with  claim 1 , further comprising:
 (a) mounting a corner panel to the substructure, the corner panel having a plurality of masonry units protruding from the face thereof and separated by a groove formed between each of said masonry units and the next adjacent masonry unit, wherein at least one of the masonry units of the corner panel is separated from at least one of the masonry units of one of said panels by a groove; and   (b) injecting mortar into the grooves between the masonry units on each panel and into the groove between said at least one of the masonry units of the corner panel and said at least one of the masonry units of said one of said panels.   
     
     
         6 . The method in accordance with  claim 5 , further comprising mounting a masonry unit in a gap formed between two of said panels. 
     
     
         7 . An exterior wall of a habitable building having a substructure made of vertical support members, the wall comprising:
 (a) a first concrete panel mounted to the substructure, the first panel having a plurality of adjacent masonry units protruding from the face thereof that are separated by a groove formed between each of said masonry units and the next adjacent masonry unit;   (b) a second concrete panel mounted to the substructure, the second panel having a plurality of adjacent masonry units protruding from the face thereof that are separated by a groove formed between each of said masonry units and the next adjacent masonry unit, wherein at least one of the masonry units of the first panel is separated from at least one of the masonry units of the second panel by a groove; and   (c) mortar in the grooves between the masonry units on each panel and in the groove between said at least one of the masonry units of the first panel and said at least one of the masonry units of the second panel.   
     
     
         8 . The wall in accordance with  claim 7 , wherein each of the panels are fiber reinforced and the masonry units are an integral part of the respective panels. 
     
     
         9 . The wall in accordance with  claim 7 , further comprising flashing extending from an upper edge of the second panel, and an overlapping lip that extends from a lower edge of the first panel over the flashing. 
     
     
         10 . The wall in accordance with  claim 7 , further comprising flashing that extends from a left edge of the second panel, and an overlapping lip that extends from a right edge of the first panel over the flashing. 
     
     
         11 . The wall in accordance with  claim 9 , further comprising fasteners extending through the panels into the substructure. 
     
     
         12 . The wall in accordance with  claim 11 , wherein the fasteners further comprise screws extending through the flashing. 
     
     
         13 . The wall in accordance with  claim 9 , further comprising a third panel mounted between the second panel and a building structure. 
     
     
         14 . The wall in accordance with  claim 9 , further comprising:
 (a) a corner panel mounted to the substructure, the corner panel having a plurality of masonry units protruding from the face thereof and separated by a groove formed between each of said masonry units and the next adjacent masonry unit, wherein at least one of the masonry units of the corner panel is separated from at least one of the masonry units of one of said panels by a groove; and   (b) mortar in the grooves between the masonry units on each panel and in the groove between said at least one of the masonry units of the corner panel and said at least one of the masonry units of said one of said panels.   
     
     
         15 . The method in accordance with  claim 14 , further comprising a masonry unit mounted in a gap formed between two of said panels. 
     
     
         16 . The wall in accordance with  claim 15 , further comprising a plurality of spacers extending from one of said panels to the other of said panels for limiting the size of the groove between said panels. 
     
     
         17 . A wall panel for forming an exterior surface of a building, the wall panel comprising a fiber-reinforced concrete rear plate and a plurality of masonry units protruding from a face of the rear plate, each of said masonry units being spaced from the next adjacent masonry unit by a groove for receiving mortar, wherein shoulders are formed on the periphery of the panel adjacent each of said masonry units for forming a groove that can receive mortar when the wall panel is mounted to the building. 
     
     
         18 . The wall panel in accordance with  claim 17 , further comprising a flashing formed on at least one edge of the rear plate for being received under a masonry unit of another wall panel. 
     
     
         19 . The wall panel in accordance with  claim 17 , further comprising at least one rib formed on a major surface of the rear plate and protruding in a direction substantially opposite the masonry units for positioning the wall panel against the building. 
     
     
         20 . The wall panel in accordance with  claim 17 , wherein the rear plate and the masonary units comprise a one-piece unitary structure.