Prefabricated composite wall panel and method and apparatus for manufacture and installation thereof

TLDR: In this article, a grout placement screed having multiple holes arranged in a desired mortar pattern is positioned on the thin finish elements and pulverulent grout is deposited through the holes of the screed and into spaces between the finish elements.

Abstract: A prefabricated composite wall panel has a desired exterior finish defined by thin finish elements of brick, stone or any other suitable material and is adapted for mounting to the wall structure of a building framework by screws or other suitable fasteners. During panel manufacture thin wall finish elements are positioned at predetermined sites within the mold and aligned by alignment members in a pattern defining grout spaces. A grout placement screed having multiple holes arranged in a desired mortar pattern is positioned on the thin finish elements and pulverulent grout is deposited through the holes of the screed and into spaces between the finish elements. After removal of the screed the pulverulent grout is compacted and a liquid uncured polymeric mixture is applied as a contiguous substrate to the back surface of the panel and serves to retain the masonry elements and grout in place and to provide a moisture and air barrier that minimizes the potential for leakage or wicking of water or air infiltration through assembled panels of a wall structure. Finished panels having empty filler element spaces at side edges thereof are fixed to a wall or wall framework of a building with straight edges in abutment and filler elements are positioned to cover joints between the panels.