Plaster panel and method of using same

Abstract

A plaster panel and a method of using it is disclosed, wherein the plaster panel includes a slab of cementitious composition including a mixture of sizes of cut expanded polystyrene, a quantity of monofilament fiber, and at least one binding agent. At least one layer of a mesh is provided, wherein the resulting panel is light in weight, flexible and strong. Similar panels may be affixed to a building frame by suitable fasteners such as nails or screws, while causing little or no fracturing of the panel.

1 . A plaster panel, comprising:
 a slab of a cementitious composition;   the cementitious composition including a mixture of sizes of cut expanded polystyrene, a quantity of monofilament fiber and at least one binding agent; and   at least one layer of a mesh;   wherein the plaster panel is light in weight, flexible and strong.   
     
     
         2 . A plaster panel of  claim 1 , further including:
 at least two layers of mesh.   
     
     
         3 . A plaster panel of  claim 2 , wherein the cementitious composition including:
 about 1.5% by weight mixture of cut expanded polystyrene;   about 0.5% by weight polypropylene monofilament fiber;   about 35% by weight sand;   about 35% by weight cement;   about 7% by weight acrylic binding agent;   about 0.1% by weight foam control agent; and   a balance of water;   wherein the plaster panel is substantially impervious to moisture penetration and able to receive fasteners with substantially no fracturing of the cementitious composition.   
     
     
         4 . The plaster panel of  claim 1 , wherein the mesh is a reinforcing alkali resistive mesh. 
     
     
         5 . The plaster panel of  claim 2 , wherein two layers of mesh substantially encase the plaster panel. 
     
     
         6 . The plaster panel of  claim 5 , wherein the panel is further includes a third layer of mesh which is embedded within the plaster panel. 
     
     
         7 . The plaster panel of  claim 1 , wherein the cut expanded polystyrene includes cut expanded polystyrene pieces having an average size of about 2286 microns. 
     
     
         8 . The plaster panel of  claim 1 , wherein the cut expanded polystyrene includes about 50% cut expanded polystyrene pieces having a size of about 3175 microns and about 50% cut expanded polystyrene pieces having a size of about 6350 microns. 
     
     
         9 . The plaster panel of  claim 1 , wherein the cut expanded polystyrene is cut from expanded polystyrene with a foam density of about one pound per cubic Toot. 
     
     
         10 . The plaster panel of  claim 3 , wherein the polypropylene monofilament fiber has a specific gravity of 0.91. 
     
     
         11 . The plaster panel of  claim 3 , wherein the sand is a 60 grit construction grade sand. 
     
     
         12 . The plaster panel of  claim 3 , wherein the cement is type 2 Portland cement. 
     
     
         13 . The plaster panel of  claim 3 , wherein the acrylic binding agent is liquid acrylic or aqueous acrylic emulsion. 
     
     
         14 . The plaster panel of  claim 1 , wherein the edges of the plaster panel are interfitting. 
     
     
         15 . The plaster panel of  claim 1 , wherein the edges of the plaster panel are beveled. 
     
     
         16 . The plaster panel of  claim 1 , wherein the board has dimensions of about four feet in width by about eight feet in length by about one-half inch in thickness. 
     
     
         17 . The plaster panel of  claim 1 , wherein the plaster panel has a surface exhibiting a rough stipple finish. 
     
     
         18 . The plaster panel of  claim 1 , wherein the plaster panel has a surface exhibiting a smooth slick finish. 
     
     
         19 . A method of applying two or more plaster panels with complementary opposite edges to a wall of a building, comprising:
 positioning a first plaster panel on the frame of the wall;   attaching the first plaster panel to the wall using fastening devices;   positioning a second plaster panel on the frame of the wall, wherein the second plaster panel is disposed adjacent to the first plaster panel;   interfitting the first plaster panel and second plaster panel along the adjacent edges creating a flush overlapping seam;   attaching the second plaster panel to the wall using fastening devices;   taping the flush overlapping seam of the first and second plaster panel with fiberglass mesh; and   coating the plaster panels with a cementitious composition.   
     
     
         20 . The method of  claim 18 , wherein one or more additional plaster panels with interfitting edges are attached. 
     
     
         21 . A method of applying two or more plaster panels with beveled edges to a wall of a building, comprising:
 positioning a first plaster panel on the frame of the wall;   attaching the first plaster panel to the wall using fastening devices;   positioning a second plaster panel on the frame of the wall, wherein the second plaster panel is disposed adjacent to the first plaster panel creating a seam integration cavity;   attaching the second plaster panel to the wall using fastening devices;   taping the seam integration cavity of the first and second plaster panel with fiberglass mesh; and   coating the plaster panels with a cementitious composition.   
     
     
         22 . The method of  claim 20 , wherein one or more additional plaster panels with beveled edges are attached.