Exterior polymer-based brick building material

A simulated brick comprising:

• a polymeric core member;
• a mesh layer adhered to the core member;
• a basecoat layer covering an entirety of the mesh layer;
• and
• a finish layer covering an entirety of the basecoat layer;
• wherein the core member, the mesh layer, the basecoat layer, and the finish layer together define a brick profile portion having first and second lateral sides extending to a planar outer surface to define a first thickness, and an offset portion extending from the first lateral side of the brick profile portion to a lateral end surface and having an outer surface defining a second thickness smaller than the first thickness, the brick profile portion and the offset portion together defining a planar rectangular base surface extending from the second lateral side of the brick profile portion to the lateral end surface of the offset portion;
• wherein the finish layer defines the first and second lateral sides and the outer surface of the brick profile portion, and the lateral end surface and the outer surface of the offset portion, and the core member defines the base surface.

A method of manufacturing a simulated brick, the method comprising:

• forming a polymeric core member including a brick profile portion having first and second lateral sides extending to a planar outer surface to define a first thickness, and an offset portion extending from the first lateral side of the brick profile portion to a lateral end surface and having an outer surface defining a second thickness smaller than the first thickness, the brick profile portion and the offset portion together defining a planar rectangular base surface extending from the second lateral side of the brick profile portion to the lateral end surface of the offset portion;
• adhering a mesh layer to the first and second lateral sides and the outer surface of the brick profile portion and to the lateral end surface and the outer surface of the offset portion;
• depositing a basecoat layer onto an entirety of the mesh layer;
• and
• depositing a finish layer onto an entirety of the basecoat layer;
• wherein the mesh layer, the basecoat layer, and the finish layer together form a laminate that covers the core member to define the first and second lateral sides and the outer surface of the brick profile portion, and the lateral end surface and the outer surface of the offset portion, and the core member is uncovered by the laminate on the base surface such that the core member defines the base surface.

A wall system comprising:

• a wall substrate including a substantially planar exterior surface;
• and
• at least first and second simulated bricks, each comprising a brick profile portion having first and second lateral sides extending to a planar outer surface to define a first thickness, and an offset portion extending from the first lateral side of the brick profile portion to a lateral end surface and having an outer surface defining a second thickness smaller than the first thickness, the brick profile portion and the offset portion together defining a planar rectangular base surface extending from the second lateral side of the brick profile portion to the lateral end surface of the offset portion, each of the first and second simulated bricks comprising a polymeric core member and a laminate comprising a mesh layer adhered to the core member;
• a basecoat layer covering an entirety of the mesh layer;
• and a finish layer covering an entirety of the basecoat layer, wherein the laminate covers the core member to define the first and second lateral sides and the outer surface of the brick profile portion, and the lateral end surface and the outer surface of the offset portion, and the core member is uncovered by the laminate on the base surface such that the core member defines the base surface;
• wherein the planar rectangular base surfaces of the first and second simulated bricks are adhered to the exterior surface of the wall substrate such that at least a portion of the lateral end surface of the offset portion of the second simulated brick abuts the second lateral side of the brick profile portion of the first simulated brick;
• and
• wherein a grout material is adhered to the outer surface of the offset portion of the second simulated brick.