The present disclosure relates generally to systems and methods of stonework installation. More particularly, the present disclosure relates to systems and methods for attaching natural stone veneers to wall surfaces.
A current method for installing thin natural stone veneers requires that the wall surfaces be prepared in advance of installation by attaching metal lath to the wall followed by a “scratch coat” of mortar/grout. After the scratch coat has been applied and is given time to dry, the stone installer applies adhesive mortar to the back of each piece of natural stone veneer to be installed. The installer then places the piece of stone in the appropriate location on the wall and the stone adheres to the scratch coat. This process tends to be slow, messy, and tedious. The appearance and quality of the installation is highly dependent on the skill and artistry of the installer. Each piece is normally hand selected and often shaped to fit into a pattern that is developed by the installer as the installer proceeds.
A major problem associated with the installation of “adhered veneer” is that of adhesion (cracking of the scratch coat or adhesion bond). Adhesion can especially be a problem on larger walls since larger surface areas tend to deflect more due to wind and other loading forces.
Another challenge that is inherent in the conventional installation of natural stone is that the sizes of the pieces of stone are completely random. The pattern for the stonework is normally developed by the installer as the installer proceeds on the jobsite. The design of the pattern for the installation of the stone and the appearance of the wall, therefore, is completely dependent upon the experience and the capabilities of the installer and can be unpredictable. Thus, depending upon the skills, the experience, and the capabilities of a given installer, costs and appearance can vary greatly.
Improved methods of stonework installation, especially in the area of thin natural stone veneer installation, are desired.
One aspect of the present disclosure relates to novel methods for attaching natural stone veneers to wall surfaces. More specifically, one example method includes mounting a piece of natural stone to a base plate, wherein the base plate has an outer peripheral dimension that is greater than the outer dimension of the piece of natural stone. After the piece of natural stone is mounted to the base plate, the base plate is attached to a wall surface with fasteners through those portions of the base plate that extend past the periphery of the piece of natural stone. According to an example method, the natural stone veneers can be installed in an overlapping arrangement similar to installation of shingles. The installer can generally start at the lower portion of a wall and move upwardly, with the natural stone portions of the upper veneers overlapping the base plate portions of the lower veneers. This type of an overlapping arrangement can be beneficial with water run-off and limit trapping of water that can otherwise seep into the wall. After installation, the joints between each individual piece of veneer can be caulked or grouted.
According to another aspect of the disclosure, a method of attaching a natural stone to a wall surface is disclosed. The method comprises attaching a first piece of natural stone to a first base plate so as to leave at least a portion of the first base plate uncovered by the first piece of natural stone and attaching the first base plate to the wall surface with a fastener extending through the uncovered portion of the first base plate.
According to yet another aspect of the disclosure, a method of manufacturing a stone veneer configured for attachment to a wall surface is disclosed. The method comprises attaching at least one piece of natural stone to a base plate so as to leave at least a portion of the base plate uncovered by the at least one piece of natural stone.
According to yet another aspect of the disclosure, a natural stone veneer configured for attachment to a wall surface is disclosed. The natural stone veneer comprises a piece of natural stone attached to a base plate so as to leave at least a portion of the base plate uncovered by the piece of natural stone.
According to yet another aspect of the disclosure, a wall comprising natural stone veneers is provided. The wall defines a wall surface. A first piece of natural stone attached to a first base plate so as to leave at least a portion of the first base plate uncovered by the first piece of natural stone is attached to the wall surface with a fastener extending through the uncovered portion of the first base plate. A second piece of natural stone attached to a second base plate so as to leave at least a portion of the second base plate uncovered by the second piece of natural stone is attached to the wall surface so as to overlap the uncovered portion of the first base plate with a portion of the second base plate that is covered by the second piece of natural stone. Both being natural stones, the second piece of natural stone defines a different configuration than the first piece of natural stone such as surface texture. In certain embodiments, the second piece of natural stone defines a different peripheral size than the first piece of natural stone.
According to yet another aspect of the disclosure, a method or process of stonework installation is provided, wherein the method includes designing a pattern of stonework for a given wall and using a guide applied or projected onto the wall that associates the designed pattern with pieces of natural stone veneers to facilitate the installation process. According to one aspect, the pattern may be designed using a computer program. According to another aspect, the pieces of natural stone may be selected and cut in accordance with the designed pattern prior to the installation process, wherein an installer would need to purchase only those pieces of natural stone required to complete the project. According to another aspect, the patterns may be designed using natural stones or natural stone veneers of prescribed standard heights and lengths, wherein the stones or veneers of prescribed standard heights and lengths may be used to create a variety of different looking patterns depending upon how the stones or veneers are arranged on the pattern(s).
Examples representative of a variety of inventive aspects are set forth in the description that follows. The inventive aspects relate to individual features as well as combinations of features. It is to be understood that both the forgoing general description and the following detailed description merely provide examples of how the inventive aspects may be put into practice, and are not intended to limit the broad spirit and scope of the inventive aspects.
The accompanying drawings are included to provide a further understanding of the inventive aspects of the present disclosure and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present disclosure and together with the description serve to further explain the principles of the disclosure. Other aspects of the present disclosure and many of the advantages of the present disclosure will be readily appreciated as the present disclosure becomes better understood by reference to the following Detailed Description when considered in connection with the accompanying drawings, and wherein:
According to one example system and method of the present disclosure, the natural stone veneer 10 shown in
Providing the natural stone veneer 10 to an installer in the form illustrated in
According to an example method of the present disclosure, the natural stone veneers 10 can be installed in an overlapping arrangement similar to installation of shingles. The installer can generally start at a lower portion of a wall 12 and move upwardly, with the natural stone portion 16 of an adjacent upper veneer 10 overlapping the base plate portion 14 of the lower veneer 10, covering the fasteners 24 of the lower veneer 10. This type of an overlapping arrangement can be beneficial with water run-off and limit trapping of water that can otherwise seep into the wall 12. After installation, the joints between each individual piece of veneer 10 can be sealed with caulk or grout 28.
When a stone veneer such as the veneer 10a shown in
Another embodiment of a natural stone veneer 10c is illustrated in
As noted above, depending upon the relative sizes of the base plate 14 and the natural stone 16 and depending upon which portions of the base plate that are cut or trimmed, different types of veneer pieces 10, wherein different portions of the base plate 14 project past the periphery of the natural stone 16, can be provided. As discussed above,
According to one non-limiting example, once the natural stone veneer is trimmed to a final form for installation, the base plate 14 may have a width of about 22 inches and a height of about 10 inches. A stone 16 having a width of about 19.5 inches and a height of about 7.5 inches may be positioned on the base plate 14. Since it may be desired to leave about 0.25 inches on all sides of the stone 16 for placement of a sealant, such as grout, between joints, the total wall coverage provided by the stone piece 16 and the grout 28 would be about 8 inches by 20 inches. The remaining 2 inches of base plate 14 extending from, for example, the top and right side of the stone 16 could then be used for mounting the veneer piece 10. The noted sizes simply represent one example embodiment of a natural stone veneer and other sizes can certainly be used according to the desired stonework pattern and application.
According to one example embodiment, the natural stone 16 includes a front face 11 having a texture that is generally rougher than the rear face 13 that is configured to be attached to the base plate 14. According to another example embodiment, the natural stone 16 includes a front face 11, a right face 15, a left face 17, a top face 19, and a bottom face 21 each having a texture that is generally rougher than the rear face 13 that is configured to be attached to the base plate 14.
According to the method of stonework installation of the present application, after a piece of natural stone 16 is mounted to the base plate 14, the base plate 14 may be attached to a wall surface 12 using fasteners 24 such as nails or screws. The portions 20 of the base plates 14 that extend out past the stones 16 may be provided with holes or openings 26 for receiving the fasteners 24. Gaskets may be used with the fasteners 24 for sealing purposes.
The term natural stone is used herein to refer to any non man-made stone occurring naturally in the environment such as granite, marble, etc. As such, no two pieces of natural stone will share exactly the same configuration. Each piece of natural stone might have a different surface texture, appearance, weight, etc. The term non man-made generally excludes those stones, faux stones, or stone substitutes that are non-natural and artificially manufactured such as brick, tile, cement, etc. However, it should be noted that the term non man-made does not exclude processes such as machining, routing, or cutting to provide the natural stone in the desired sizes and shapes. As noted above, the natural stones discussed in the present application may be machined so as to provide a rear face that has a smoother texture than the rest of the faces of the natural stone for attachment to a base plate.
It should also be noted that although the present disclosure discusses the attachment of a single piece of natural stone 16 to a base plate 14, in other embodiments, one or more pieces of natural stone 16 may be attached to a single base plate 14 to form the stone veneer 10.
According to one example method of stonework installation, a thin natural stone 16 would be machined by a supplier to fit within predetermined desired stonework pattern or layout 22. Depending upon the pattern 22 desired, different types, different sizes, and different shapes of stones 16 can be used.
Each thin stone piece 16 would be fixed, using appropriate high performance adhesive 18, to the base plate 14. The base plate 14 would be provided in a size that accommodates the size of stone 16 being used. As discussed above, once the veneer is manufactured and provided to an installer, different portions of the base plate may be trimmed or cut to make the pieces ready for installation. As such, veneer pieces such as 10a, 10c, or transition piece such as 10b can be produced. The extensions 20 of the base plate 14 are used to mechanically attach the natural stone veneers 10 to the wall surface 12 using fasteners 24 such as gasketed screws or nails. According to the example method, an installer would generally start at the bottom of the wall 12 and move up and also sideways away from the initial veneer 10, with the upper veneers 10 lapping over the lower veneers 10. As noted above, if veneers such as 10a or 10c are used, the veneers would also overlap adjacent veneers along a side-to-side direction. The overlapping configuration may limit water leakage into the wall 12.
The stones 16 and the base plates 14 would be cut to appropriate sizes and shapes for attachment around windows and doors. When the installation of the stone layout 22 is completed, the joints between each individual veneer piece would be caulked or grouted for sealing.
One of the challenges that are inherent in the conventional installation of natural stone is that the sizes of the pieces of stone that an installer has at the jobsite and has available for completing a project are completely random. The pattern for the stonework is normally developed by the installer as the installer proceeds on a given wall. The design of the pattern for the stonework and the appearance of the wall, therefore, are completely dependent upon the experience and the capabilities of the installer, which can lead to varying results.
Referring to
It should be noted that the below described process is simply one example embodiment of a stonework installation process and that other similar processes or those that utilize less than all of the prescribed steps are meant to be covered by the given disclosure.
According to one example embodiment, the dimensions of a given wall for the stonework installation may first be determined. The design of the stonework for the wall using pieces of natural stone in a variety of heights, lengths, types, and colors may be created. According to certain embodiments, the stonework or at least a portion of the stonework may be designed using standard stone heights and/or lengths to reduce the variability of the stones that eventually need to be cut for the project. For example, the natural stones or the natural stone veneers of standard heights and lengths may be used to create a variety of different looking patterns depending upon how the standard stones or veneers are arranged on the patterns.
As noted above, in creating the design of the stonework, a certain pattern for the stone layout or a number of patterns may be created, wherein the patterns, when combined or duplicated, fit the overall stonework design for the wall. The entire stonework design may include a single pattern or a number of different patterns in combination in coming up with the overall look. As noted previously, the pattern or patterns may be created using stones of standard heights and lengths, wherein different looking patterns may be created depending upon how the stones of standard heights and lengths are arranged on the patterns.
In creating the overall stonework design or the individual pattern(s), a computer program or software may be used. The dimension of a given wall or a wall area including the wall length, the wall height, door sizes and locations, window sizes and locations, corner locations may be entered into the program. The pattern(s) or the overall stonework design may be overlaid onto a given wall, taking account all of the given dimensions and features of the wall, such as windows and doors. Or, the pattern(s) or the overall look of the stonework installation can be designed using the computer program or software as the user proceeds.
According to an example embodiment, the computer program or software would have the capability to allow a user to design the pattern(s) as the user proceeds or overlay an already designed pattern onto the image of a given wall. The computer program or software would also have the capability to calculate, based on the pattern(s) being used for the wall, the number of pieces of each size, type, and color of stone needed to complete the project. This process would enable an installer to identify the pieces that must be cut to fit the project pattern as well as the desired dimensions for these pieces and would allow the installer to purchase only the number of pieces of natural stone required to complete the project.
After the stones have been purchased and cut to the desired dimensions, during installation, a physical guide applied or projected onto the wall that associates the designed pattern(s) with the pieces of natural stone veneers to facilitate the installation process may be used, wherein the overall design or the individual pattern(s) could be physically applied to the given wall. According to one example embodiment, the pattern(s) or the design could be printed upon a substrate to be fastened to the wall to be used as a physical guide for the installer. The physical guide may also include a pattern image projected onto the wall surface. The guide may include horizontal grid lines spaced at distances dependent upon the height of the pieces in the pattern(s). The guide may include vertical grid lines spaced at distances dependent upon the increments of length in the pattern(s). Specification of the location of each piece of stone by size, type, and color, wherein the information specified on the grid could be physically recorded on the natural stone veneers, could be used.
In this manner, the advantages of the method of natural stone veneer installation described above are combined with those of the patterning process, wherein the patterning process may include the use of a design program or software and a physical guide that associates the designed pattern(s) with the precut and prepared stone veneer pieces. The combination can improve the efficiency of the installation process and enable an installer to better control the aesthetic results of and the costs associated with the project.
It will be understood that the above described methods of natural stone veneer installation are examples of inventive methods in accordance with the present disclosure. Certain aspects of the methods may be modified depending upon the application.
The above specification provides examples of how certain inventive aspects may be put into practice. It will be appreciated that the inventive aspects can be practiced in other ways than those specifically shown and described herein without departing from the spirit and scope of the inventive aspects.
This application is a continuation of U.S. patent application Ser. No. 14/034,135, filed, Sep. 23, 2013, which is a continuation of U.S. patent application Ser. No. 13/410,026, filed Mar. 1, 2012. U.S. patent application Ser. No. 13/410,026 claims the benefit of U.S. Provisional Application No. 61/560,100, filed Nov. 15, 2011, and U.S. Provisional Application No. 61/449,391, filed Mar. 4, 2011. The above-mentioned applications are incorporated herein by reference in their entirety.
Number | Date | Country | |
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61560100 | Nov 2011 | US | |
61449391 | Mar 2011 | US |
Number | Date | Country | |
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Parent | 14034135 | Sep 2013 | US |
Child | 14523213 | US | |
Parent | 13410026 | Mar 2012 | US |
Child | 14034135 | US |