Coated construction substrates

Abstract

Construction substrates that have one or more coatings are disclosed, which can be used to construct fence systems. In one embodiment the coating is an adhesive mixture that is magnetically induced to attract a magnetic template. The template that is magnetic or magnetically attracted, that is applied to a construction substrate, is used to create a pattern when a subsequent coating is applied to the substrate. It is emphasized that this abstract is provided to comply with the rules requiring an abstract that will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope of meaning of the claims. 37 CFR 1.72(b).

Description

RELATED APPLICATION

[0001] This application is a continuation-in-part of U.S. patent application Ser. No. 09/915,101 filed Jul. 25, 2001.

[0002] This invention relates, generally to the construction of coated construction substrates and to fencing components using coated construction substrates.

[0003] Structures, roads, driveways, sidewalks, fences, roofs, floors, panels and the like have been coated in some way to improve their function and/or appearance. Fences, on the other hand, are generally constructed of wood or vinyl products in a multitude of forms such as rail fences, blockade fences, etc. Fences are typically used to indicate boundary areas or at least are located proximate boundary lines.

[0004] Alternatives to fences are permanent walls where footing are poured and a structure is built, which may have a brick facing or other decorative facing. This type of alternative is significantly more expensive than constructing a fence.

[0005] The present invention is directed to a fence which obtains the benefits of a decorative wall, such as a brick wall, yet is constructed like a fence structure, thereby achieving significant cost savings over the more permanent walls. The fence structure includes a structural substrate or panel having a coating, wherein the panels are installed between the posts anchored to the ground surface or partially buried in the ground. This same structural substrate can be used as a wall, siding, a panel, a roof, an interlocking roof panel (tile) a floor, a ceiling, a road, a driveway, a sidewalk, and the like. The structural substrate can be rigid such as cement or flexible such as a metal or plastic sheet or either flexible or rigid such as wood. The invention comprises the features that will be exemplified in the description hereinafter set forth, and the scope of the invention will be set forth in the claims. According to the invention, the coating comprises:

[0006] a) an acrylic polymer,

[0007] b) a chlorinated rubber such as neoprene, and

[0008] c) sand.

[0009] To form a pattern on the structural substrate, two coatings are preferably applied to the structural substrate. The first coating, or bond or adhesive coating, contains:

[0010] a) an acrylic polymer,

[0011] b) a chlorinated rubber, such as neoprene,

[0012] c) sand, and,

[0013] d) a first colorant.

[0014] The second coating or non-adhesive coating, contains:

[0015] a) an acrylic polymer,

[0016] b) sand, and,

[0017] c) a colorant, preferably of a different color than the first colorant. The colorant can be the natural color of the composition.

[0018] The second coating forms a discontinuous coating on the first coating in the form of a pattern. A third coating can be applied to the top coating on the substrate as a sealing coat, such as a water repellant sealer. Examples are THOMSON water sealer, and DRYVIT sealer.

[0019] According to the invention, the structural substrate can have a magnetic coating. The magnetic coating, also an adhesive coating, contains:

[0020] a) an acrylic polymer,

[0021] b) a chlorinated rubber such as neoprene,

[0022] c) sand, and

[0023] d) a finely divided magnetic material on a surface of the structural substrate. The structural substrate may have either a horizontal surface application or a vertical surface application.

[0024] Instead of the acrylic polymer, a cementitious grout (liquid) admixture such as UT 91-1 made by DRYVIT and finish coat may be used.

[0025] A magnetic template is used in a method of applying a fluid composition to a magnetic structural substrate. The fluid composition contains:

[0026] a) an acrylic polymer,

[0027] b) a chlorinated rubber such as neoprene, and,

[0028] c) sand.

[0029] As stated above, instead of the acrylic polymer, a liquid admixture of a cementitious grout such as UT 91-1 made by DRYVIT and finish coat may be used.

[0030] Illustrative of the invention, the method includes placing a magnetic template on the magnetic structural substrate, then applying the fluid composition. By magnetic is meant magnetic or magnetically attractable. Where the two are used in combination at least one is magnetic. The other can be magnetic or magnetically attractable.

[0031] According to the invention, the magnetic template is used in a double coating method of forming a patterned coating on a structural substrate. The first coating is applied by:

[0032] a) applying an adhesive fluid composition containing:

[0033] a1) an acrylic polymer (or liquid admixture as stated above),

[0034] a2) a chlorinated rubber such as neoprene,

[0035] a3) sand, and,

[0036] a4) a finely divided magnetic material to a structural substrate.

[0037] The fluid composition is dried to form a magnetic coating on the structural substrate. Then a magnetically attractable template is placed on the magnetic coating. A second fluid composition is then applied on top of the magnetic coating. The second fluid composition contains:

[0038] d1) an acrylic polymer, and

[0039] d2) sand.

[0040] The second layer is dried and the template is removed to form a pattern.

[0041] In practicing the present invention, a magnetically attractable template is used to form a pattern on a magnetic surface so long as there is mutual attraction between the two surfaces.

[0042] The magnetically attractable or magnetic template is placed on the magnetically attractable or magnetic surface. A coating is then applied to the surface. The template is then removed to form a surface pattern.

[0043] The present invention is also useful in creating a structural substrate having a molded surface on both sides. To a panel having two sides is adhesively secured two foamed plastic sheets, one to each of the two sides by an inner surface of each sheet, leaving the outer surface of each foamed sheet exposed. A molded surface is adhesively secured to each of the outer surfaces of each foamed plastic sheet.

[0044] The invention includes means for connecting the structural substrate or panel used in the fence system to a post. Although the means can be adapted to include a mating half on the side edges of each panel which directly connects with a post on each end of the panel, each post having the corresponding mating half of the connecting means, it is preferable that the connecting means be made in three pieces. That is, similar shaped connectors or members are located on the side edges of each panel and each post. An interlocking third connector or member is then inserted between the post and an adjoining panel. The third connector engages the similar corresponding mating connectors on the post and panel thereby interconnecting the panel to each post as the fence assembly or system is being constructed.

[0045] In the accompanying drawings illustrating embodiments of the present invention:

[0046] FIG. 1 is a cross sectional view of a plastic substrate coated with a sand filled acrylic, chlorinated rubber composition;

[0047] FIG. 2 is a cross sectional view of a cement substrate having two coatings of contrasting colors;

[0048] FIG. 3 is a front view of the coated substrate of FIG. 2 showing the brick pattern formed;

[0049] FIG. 4 is a cross sectional view of the substrate of FIG. 2 having an additional clear sealing coat;

[0050] FIG. 5 is a cross sectional view of a coated substrate having a stencil between coating layers;

[0051] FIG. 6 is a front view of the coated substrate of FIG. 5 with the stencil removed showing grout lines;

[0052] FIG. 7 is a cross sectional view of a procedure for attaching molded surfaces to both sides of a foam plastic sandwich;

[0053] FIG. 8 is a cross sectional view of a substrate coated with a magnetic coating;

[0054] FIG. 9 is a cross sectional view of a large coated wall, a smaller stencil and a coating over the stencil;

[0055] FIG. 10 is a front view of the wall with the stencil removed, showing grout lines;

[0056] FIG. 11 is a front view of a portion of a typical fence installation using the coated panels depicted as a brick facing;

[0057] FIG. 12 is a cross-sectional top view depicting a typical application of a panel connected to a post and an alternative connection of a panel connected to an adjoining panel using a preferred embodiment for the connector means in each case;

[0058] FIG. 13 is an exploded corner view depicting a typical application of the installation of the connector channel member on the side edges of each panel;

[0059] FIG. 14 is a perspective view of an interconnecting member used to join he panels or each panel to a post;

[0060] FIGS. 15a, 15b, 15c and 15d depict examples of typical orientation and alternative connectors that are contemplated in the present invention; and

[0061] FIG. 16 is an exploded cross-sectional portion of one embodiment of a coated panel or substrate contemplated by the present invention.

EXAMPLES

[0062] The following examples are presented to illustrate the invention, which is not intended to be in any way limited thereto, since numerous modifications and variations therein will be apparent to one skilled in the art.

Example 1

[0063] One gallon of WELDBOND adhesive was mixed thoroughly with one quart of DRYVIT ULTRATEX acrylic sand coating. DRYVIT ULTRATEX acrylic sand coating is comprised of sand in an acrylic emulsion. DRYVIT ULTRATEX acrylic sand coating is believed to have a composition similar to that of DRYVIT acrylic sand coating. DRYVIT acrylic sand coating contains from sixty two to sixty six percent by weight of encapsulated sand, three to seven percent by weight of silicates, twelve to fifteen percent by weight of water, eight and one half percent to ten and two tenths percent by weight of acrylic latex polymer/binder and one to five and one half percent by weight of titanium dioxide. WELDBOND adhesive is comprised of a chlorinated rubber such as neoprene-based contact cement, which contains methyl ethyl ketone (MEK) and toluene. An adhesive roller is used to apply the mixture as a coating 12 to a metal or a plastic panel 10 (See FIG. 1). The coating 12 is allowed to dry and/or cure for up to twenty-four hours. The DRYVIT ULTRATEX is a grout coat. The benefit of the formula is the elasticity and bonding it provides. It is also resistant to mildew and algae growth. The composition is useful for coating flexible panels such as steel, aluminum, and plastic panels such as POLYCOR plastic panels or PLASTICOR plastic panels. POLYCOR plastic panels are believed to be made from polyester resin. PLASTICOR plastic panels contain polypropylene copolymer and polyethylene, and have a thickness of from two to ten millimeters. PLASTICOR is corona treated on both sides to improve adhesion.

Example 2

[0064] Example 1 was repeated using STOSILCO FLEX #S.W.1 acrylic sand coating instead of DRYVIT ULTRATEX. STOSILCO FLEX #S.W.1 is comprised of sand in an acrylic or emulsion and is silicone enhanced. The composition of Example 2 was found to be very useful in bridging hairline cracks in stucco, cement and other substrates.

Example 3

[0065] Example 1 was repeated using DRYVIT acrylic sand coating 14 (see FIGS. 2 and 3) instead of DRYVIT ULTRATEX. DRYVIT has a red or black brick color. A patterned coating of DRYVIT ULTRATEX 16 on a grout colored substrate forms a panel looking like a brick wall 18. The composition of DRYVIT is disclosed above.

Example 4

[0066] Example 3 was repeated and a finish, sealer coat 21 (see FIG. 4) was applied to the decorative panel 18. The sealer can be any commercial masonry sealer such as Thompson Water Sealer or a sealer from Dryvit Systems, Inc.

Example 5

[0067] One gallon of WELDWOOD brand contact cement was mixed with one half quart of DRYVIT ULTRATEX acrylic based sand coating material containing iron filings and having a dark gray color. The contact cement is a chlorinated rubber such as neoprene rubber dissolved and/or dispersed in naphtha and/or other organic solvent such as toluene. The mixture was rolled onto a POLYCOR plastic panel 22 (see FIG. 5) and allowed to dry and/or cure for twenty four hours to form coating 24. DRYVIT ULTRATEX acrylic based sand adhesive coating material was then trowled onto the coated panel to form coating 26. After drying and curing, a magnetic steel grout stencil 28 was placed over the coated panel and another coating of DRYVIT ULTRATEX acrylic based sand finish was applied to form coating 30. After four hours, the magnetic steel stencil 28 was pulled from the coated panel to create grout lines 32.

Example 6

[0068] A plastic panel 34 (see FIG. 7) six feet long, six inches wide and one half inch thick was coated on both sides with two ounces of water activatable MORTON adhesive 36. WELDBOND adhesive or the like could have also been used. The MORTON adhesive 36 was first applied to one side of the plastic panel 34 and subjected to a water mist to activate the adhesive 36 and then the same procedure was applied to the other side to form a sandwich 37 with one fourth inch thick plastic foam 38. Pressure was applied to the sandwich 37 and the sandwich was dried for twenty-four hours.

[0069] A decorative coating is prepared by Spraying Gordon #808 water based carnauba wax 40 onto a rubber mold 42, then waiting for a few minutes, then spreading sixteen ounces of DRYVIT ULTRATEX polymer finish 44 with a trowel into the mold and allowing the ULTRATEX polymer 44 to dry about twenty four hours.

[0070] MORTON 640 adhesive 46 was trowled onto the DRYVIT ULTRATEX 44 polymer in the mold and onto one side of the plastic sandwich 37. The mold was placed on one side of the sandwich with the ULTRATEX coated surfaces 46 in contact and pressure was applied overnight.

[0071] An edge of the polymer in the mold was gently grabbed and the mold 42 was pulled to separate the mold 42 from the molded surface on the sandwich 37. The procedure was repeated to form a molded surface on the other side of the sandwich. The procedure was used to make imitation wood.

[0072] The plastic panel 34 can be flexible or rigid.

Example 7

[0073] Mixing one gallon of WELDBOND adhesive with one quart of DRYVIT ULTRATEX acrylic sand material is an example of a material 48 (see FIG. 8) that can be used to form a substrate for a magnetic stencil. The WELDBOND adhesive is a contact cement. Twelve ounces of the above mixture are then mixed with eighteen ounces of magnetic paint. The final product is then troweled onto a structure, such as a driveway, sidewalk, roof, panel or a wall 50 to form a magnetic coating on the structure.

Example 8

[0074] Three ounces of the WELDBOND adhesive and the DRYVIT ULTRATEX mixture of Example 7 are mixed with six ounces of iron shavings to form a magnetic final product.

Example 9

[0075] A magnetic paint formulation is prepared by mixing one gallon of WELDWOOD DAP adhesive with one quart of DRYVIT ULTRATEX acrylic sand material. To the mixture is added two times the weight of the mixture of magnetic or magnetizable shavings, filings or powder. The material 52 (see FIG. 9) is trowled on the entire surface of a wall 54 and allowed to cure and dry for twenty-four hours. A magnetic stencil 56 made of magnetized steel is applied to a three foot by four foot section of the wall 54 and DRYVIT sand filled acrylic latex alone 57, which has a brick color, is applied. After the DRYVIT sand filled acrylic latex dries, the stencil 56 is removed leaving a grout pattern 58 (see FIG. 10) between the imitation bricks 60. WELDWOOD DAP adhesive is believed to be a contact cement containing a halogenated rubber in naphtha and/or other organic solvent such as toluene. The contact cement can also be in the form of an emulsion in water.

[0076] Any finely divided magnetic material or magnetizable material such as shavings, filings, or powder can be used in any formulation of the present invention. The magnetizable material can be made magnetic using a solenoid. A solenoid can also be used to magnetize a magnetizable panel. By magnetic stencil is meant any stencil that is attracted by a magnetic field and/or any stencil that is magnetized.

[0077] Other components can be present in the compositions of the present invention such as titanium dioxide, perlite, marble, silica, and calcium carbonate, to name but a few. The components, including sand can be encapsulated in an organic polymer to aid in forming a dispersion in the coating compositions of the present invention.

[0078] Referring to the Figures related to the fence system, that is, FIGS. 11-16, one embodiment of the fence system 100 includes a post member 102 to which a side edge 106 of a fence panel 108 is joined when assembled. As described above, the fence panel 108 in this embodiment may be a structural substrate 108a having a coating 108b on each surface 108c thereof. The coating 108b may include an acrylic polymer, a chlorinated rubber such as neoprene, and sand.

[0079] The structural substrate 108a may be flexible or rigid and made one of metal, plastic, foam, wood and a combination thereof. Typically, a fence panel 108 may be as little as ½ inch thick to as much as 8 or more inches thick, depending on customer requirements.

[0080] The fence system 100 further comprises means 110 for interconnecting each side edge 106 of the fence panel 108 to one of the post member 104 and another side edge 106 of another fence panel 104.

[0081] Although a post member 104 may have one means 110 for interconnecting a fence panel 108 to it, intermediate post members 104 can have at least two means 110 for interconnecting the side edge 106 of adjoining fence panels 108. In this case, the at least two means 110 for interconnecting the side edge 106 of adjoining fence panels 108 on the post member 104 can be oriented so as to allow for the installation of adjoining fence panels 108 in one of a linear orientation, an approximate perpendicular orientation, a desired angular orientation 112 and a combination thereof, as represented by FIGS. 15a-15d. The post members are modified to accommodate two-way, three-way and four-way connections.

[0082] The post members 104 may be made from wood, concrete, polymeric material, steel, aluminum, and combinations thereof. They may be square-shaped, rectangular-shaped, at least partially arcuate-shaped, and otherwise shaped to accommodate the installation or a desired aesthetic design.

[0083] The means 110 for interconnecting each side edge 106 of the fence panel 108 to one of the post member 104 and another side edge 106 of another fence panel 108 typically comprises a first engagement portion 114 along each edge 106 of the fence panel 108 and at least one similarly shaped engagement portion 114 on each post member 104. Also included is a mating second engagement portion 116 adapted to engage with one of the first engagement portion 114 on one side edge 106 of the fence panel 108 and another first engagement portion 114 on an adjoining side edge 106 of another fence panel 108 (as represented in FIG. 12) and of the first engagement portion 114 on one side edge 106 of the fence panel 108 and the first engagement portion 114 on the post member 104.

[0084] Each first engagement portion 114 along each edge 106 of each fence panel 108 is preferably a channel member 118 formed with two opposite facing spaced-apart generally L-shaped members 120 protruding therefrom, each first engagement portion 114 on each post member comprises two opposite facing spaced-apart generally L-shaped members 120 protruding from the post member 104, thereby forming a female connector on each of the fence panels 108 and each post member 104. Each mating second engagement portion 116 is preferably an elongated channel member formed in a generally H-shape cross-section as depicted in FIG. 14, thereby forming a male connector to join the fence components together. This generally H-shaped cross-sectional channel member may be hollow or solid throughout, or it may have a hollow core filled with a filler material. It may be made from a variety of materials including aluminum, polymeric materials, steel and other materials or combination of materials suitable to interconnect the fence components, while maintaining its proper installation.

[0085] Although the preferred embodiment as described above, of the first engagement portion essentially make this portion a female connector and the mating second engagement portion essentially makes this portion the male connector, it is contemplated that the portions may be reversed so that the male connectors are on the panels and post members and the mating portion is an elongate member with the a total of 4 spaced-apart L-shaped members, two of which share a common planar portion of the connector with the other two.

[0086] Other embodiments contemplated by the present invention generally include the same features and structure described above for the fence components related to the post and interconnecting means 110 with variations of the coatings 108b on the fence panels 108.

[0087] Examples include an embodiment where the fence panel 108 is a structural substrate 108a having two coatings 108b on each surface 108c thereof, the first coating comprising an acrylic polymer, a chlorinated rubber such as neoprene, sand, and a first colorant; and the second coating comprising an acrylic polymer, sand and a colorant of a different color than the first coating and the second coating forms a pattern on the first coating.

[0088] Another embodiment is where the fence panel 108 is a structural substrate 108a having three coatings 108b on each surface 108c thereof, the first coating comprising an acrylic polymer, a chlorinated rubber such as neoprene, sand and a first colorant; and the second coating comprising an acrylic polymer, sand and a colorant of a different color than the first coating and the second coating forms a pattern on the first coating; and the third coating comprising a sealing coat. An additional embodiment to this one is where the second coating forms a discontinuous coating on the first coating.

[0089] Another embodiment is where the fence panel 108 is a structural substrate 108a having a coating 108b on each surface 108c thereof, the coating 108b comprising an acrylic polymer, a chlorinated rubber such as neoprene, sand and a finely divided magnetic material.

[0090] A still another embodiment is where the fence panel 108 is a structural substrate 108a having a molded surface 108d on each surface 108c thereof, the structural substrate 108a comprising a panel (similar to that depicted in FIG. 7) having two sides, foamed plastic sheets adhesively secured to each of the two sides by an inner surface of each sheet, leaving an outer surface of each sheet exposed, and a molded surface adhesively secured to each of the outer surfaces of each foamed plastic sheet. An additional embodiment to this one is where the molded surface comprises a sand filled acrylic polymer.

[0091] It should be understood that the preceding is merely a detailed description of the embodiments to the present invention and that numerous changes to the disclosed embodiments can be made in accordance with the disclosure herein without departing from the spirit and scope of the invention. The preceding description therefore, is not meant to limit the scope of the invention. Rather, the scope of the invention is to be determined only by the appended claims and their equivalents.

Claims

1. A fence system comprising:

a post member to which a side edge of a fence panel is joined when assembled;

the fence panel being a structural substrate having a coating on each surface thereof, the coating comprising an acrylic polymer, a chlorinated rubber such as neoprene, and sand;

means for interconnecting each side edge of the fence panel to one of the post member and another side edge of another fence panel.

2. The fence system according to claim 1, wherein the structural substrate is one of flexible and rigid.

3. The fence system according to claim 1, wherein the structural substrate is made from one of metal, plastic, foam, wood and a combination thereof.

4. The fence system according to claim 1, wherein the post member has at least two means for interconnecting the side edge of adjoining fence panels.

5. The fence system according to claim 4, wherein the at least two means for interconnecting the side edge of adjoining fence panels on the post member are oriented so as to allow for the installation of adjoining fence panels in one of a linear orientation, an approximate perpendicular orientation, a desired angular orientation and a combination thereof.

6. The fence system according to claim 1, wherein the means for interconnecting each side edge of the fence panel to one of the post member and another side edge of another fence panel comprises:

a first engagement portion along each edge of the fence panel and at least one similarly shaped engagement portion on each post member; and

a mating second engagement portion adapted to engage with one of the first engagement portion on one side edge of the fence panel and another first engagement portion on an adjoining side edge of another fence panel and of the first engagement portion on one side edge of the fence panel and the first engagement portion on the post member.

7. The fence system according to claim 6,

wherein each first engagement portion along each edge of each fence panel is a channel member formed with two opposite facing spaced-apart generally L-shaped members protruding therefrom and each first engagement portion on each post member comprises two opposite facing spaced-apart generally L-shaped members protruding from the post member, thereby forming a female connector on each of the fence panel and the post member, and

wherein each mating second engagement portion is an elongated channel member formed in a generally H-shape cross-section, thereby forming a male connector.

8. The fence system according to claim 7, wherein the first engagement portion and the mating second engagement portion are made from one of aluminum, steel and polymeric material.

9. A fence system comprising:

a post member to which a side edge of a fence panel is joined when assembled;

the fence panel being a structural substrate having two coatings on each surface thereof, the first coating comprising an acrylic polymer, a chlorinated rubber such as neoprene, sand, and a first colorant; and the second coating comprising an acrylic polymer, sand and a colorant of a different color than the first coating and the second coating forms a pattern on the first coating;

means for interconnecting each side edge of the fence panel to one of the post member and another side edge of another fence panel.

10. The fence system according to claim 9, wherein the structural substrate is one of flexible and rigid.

11. The fence system according to claim 9, wherein the structural substrate is made from one of metal, plastic, foam, wood and a combination thereof.

12. The fence system according to claim 9, wherein the second coating forms a discontinuous coating on the first coating.

13. The fence system according to claim 9, wherein the post member has at least two means for interconnecting the side edge of adjoining fence panels.

14. The fence system according to claim 13, wherein the at least two means for interconnecting the side edge of adjoining fence panels on the post member are oriented so as to allow for the installation of adjoining fence panels in one of a linear orientation, an approximate perpendicular orientation, a desired angular orientation and a combination thereof.

15. The fence system according to claim 9, wherein the means for interconnecting each side edge of the fence panel to one of the post member and another side edge of another fence panel comprises:

a first engagement portion along each edge of the fence panel and at least one similarly shaped engagement portion on each post member; and

a mating second engagement portion adapted to engage with one of the first engagement portion on one side edge of the fence panel and another first engagement portion on an adjoining side edge of another fence panel and of the first engagement portion on one side edge of the fence panel and the first engagement portion on the post member.

16. The fence system according to claim 15,

wherein each first engagement portion along each edge of each fence panel is a channel member formed with two opposite facing spaced-apart generally L-shaped members protruding therefrom and each first engagement portion on each post member comprises two opposite facing spaced-apart generally L-shaped members protruding from the post member, thereby forming a female connector on each of the fence panel and the post member, and

wherein each mating second engagement portion is an elongated channel member formed in a generally H-shape cross-section, thereby forming a male connector.

17. The fence system according to claim 16, wherein the first engagement portion and the mating second engagement portion are made from one of aluminum, steel and polymeric material.

18. A fence system comprising:

a post member to which a side edge of a fence panel is joined when assembled;

the fence panel being a structural substrate having three coatings on each surface thereof, the first coating comprising an acrylic polymer, a chlorinated rubber such as neoprene, sand and a first colorant; and the second coating comprising an acrylic polymer, sand and a colorant of a different color than the first coating and the second coating forms a pattern on the first coating; and the third coating comprising a sealing coat;

means for interconnecting each side edge of the fence panel to one of the post member and another side edge of another fence panel.

19. The fence system according to claim 18, wherein the structural substrate is one of flexible and rigid.

20. The fence system according to claim 18, wherein the structural substrate is made from one of metal, plastic, foam, wood and a combination thereof.

21. The fence system according to claim 18, wherein the second coating forms a discontinuous coating on the first coating.

22. The fence system according to claim 18, wherein the post member has at least two means for interconnecting the side edge of adjoining fence panels.

23. The fence system according to claim 22, wherein the at least two means for interconnecting the side edge of adjoining fence panels on the post member are oriented so as to allow for the installation of adjoining fence panels in one of a linear orientation, an approximate perpendicular orientation, a desired angular orientation and a combination thereof.

24. The fence system according to claim 18, wherein the means for interconnecting each side edge of the fence panel to one of the post member and another side edge of another fence panel comprises:

a first engagement portion along each edge of the fence panel and at least one similarly shaped engagement portion on each post member; and

a mating second engagement portion adapted to engage with one of the first engagement portion on one side edge of the fence panel and another first engagement portion on an adjoining side edge of another fence panel and of the first engagement portion on one side edge of the fence panel and the first engagement portion on the post member.

25. The fence system according to claim 24,

wherein each first engagement portion along each edge of each fence panel is a channel member formed with two opposite facing spaced-apart generally L-shaped members protruding therefrom and each first engagement portion on each post member comprises two opposite facing spaced-apart generally L-shaped members protruding from the post member, thereby forming a female connector on each of the fence panel and the post member, and

wherein each mating second engagement portion is an elongated channel member formed in a generally H-shape cross-section, thereby forming a male connector.

26. The fence system according to claim 25, wherein the first engagement portion and the mating second engagement portion are made from one of aluminum, steel and polymeric material.

27. A fence system comprising:

a post member to which a side edge of a fence panel is joined when assembled;

the fence panel being a structural substrate having a coating on each surface thereof, the coating comprising:

one of an acrylic polymer and a liquid admixture of a cementitious grout material and finish coat;

a chlorinated rubber such as neoprene;

sand; and

a finely divided magnetic material;

means for interconnecting each side edge of the fence panel to one of the post member and another side edge of another fence panel.

28. The fence system according to claim 27, wherein the structural substrate is one of flexible and rigid.

29. The fence system according to claim 27, wherein the structural substrate is made from one of metal, plastic, foam, wood and a combination thereof.

30. The fence system according to claim 27, wherein the post member has at least two means for interconnecting the side edge of adjoining fence panels.

31. The fence system according to claim 30, wherein the at least two means for interconnecting the side edge of adjoining fence panels on the post member are oriented so as to allow for the installation of adjoining fence panels in one of a linear orientation, an approximate perpendicular orientation, a desired angular orientation and a combination thereof.

32. The fence system according to claim 27, wherein the means for interconnecting each side edge of the fence panel to one of the post member and another side edge of another fence panel comprises:

a first engagement portion along each edge of the fence panel and at least one similarly shaped engagement portion on each post member; and

a mating second engagement portion adapted to engage with one of the first engagement portion on one side edge of the fence panel and another first engagement portion on an adjoining side edge of another fence panel and of the first engagement portion on one side edge of the fence panel and the first engagement portion on the post member.

33. The fence system according to claim 32,

wherein each first engagement portion along each edge of each fence panel is a channel member formed with two opposite facing spaced-apart generally L-shaped members protruding therefrom and each first engagement portion on each post member comprises two opposite facing spaced-apart generally L-shaped members protruding from the post member, thereby forming a female connector on each of the fence panel and the post member, and

wherein each mating second engagement portion is an elongated channel member formed in a generally H-shape cross-section, thereby forming a male connector.

34. The fence system according to claim 33, wherein the first engagement portion and the mating second engagement portion are made from one of aluminum, steel and polymeric material.

35. A fence system comprising:

a post member to which a side edge of a fence panel is joined when assembled;

the fence panel being a structural substrate having a molded surface on each surface thereof, the structural substrate comprising a panel having two sides, foamed plastic sheets adhesively secured to each of the two sides by an inner surface of each sheet, leaving an outer surface of each sheet exposed, and a molded surface adhesively secured to each of the outer surfaces of each foamed plastic sheet;

means for interconnecting each side edge of the fence panel to one of the post member and another side edge of another fence panel.

36. The fence system according to claim 35, wherein the structural substrate is one of flexible and rigid.

37. The fence system according to claim 35, wherein the structural substrate is made from one of metal, plastic, foam, wood and a combination thereof.

38. The fence system according to claim 35, wherein the molded surface comprises a sand filled acrylic polymer.

39. The fence system according to claim 35, wherein the post member has at least two means for interconnecting the side edge of adjoining fence panels.

40. The fence system according to claim 39, wherein the at least two means for interconnecting the side edge of adjoining fence panels on the post member are oriented so as to allow for the installation of adjoining fence panels in one of a linear orientation, an approximate perpendicular orientation, a desired angular orientation and a combination thereof.

41. The fence system according to claim 40, wherein the means for interconnecting each side edge of the fence panel to one of the post member and another side edge of another fence panel comprises:

a first engagement portion along each edge of the fence panel and at least one similarly shaped engagement portion on each post member; and

a mating second engagement portion adapted to engage with one of the first engagement portion on one side edge of the fence panel and another first engagement portion on an adjoining side edge of another fence panel and of the first engagement portion on one side edge of the fence panel and the first engagement portion on the post member.

42. The fence system according to claim 41,

wherein each first engagement portion along each edge of each fence panel is a channel member formed with two opposite facing spaced-apart generally L-shaped members protruding therefrom and each first engagement portion on each post member comprises two opposite facing spaced-apart generally L-shaped members protruding from the post member, thereby forming a female connector on each of the fence panel and the post member, and

wherein each mating second engagement portion is an elongated channel member formed in a generally H-shape cross-section, thereby forming a male connector.

43. The fence system according to claim 42, wherein the first engagement portion and the mating second engagement portion are made from one of aluminum, steel and polymeric material.

44. A structural substrate having a coating, the coating comprising:

a liquid admixture of a cementitious grout material and finish coat;

a chlorinated rubber such as neoprene;

sand; and

a finely divided magnetic material.

45. A method of forming a patterned coating on a structural substrate comprising:

applying a fluid composition containing:

a liquid admixture of a cementitious grout material and finish coat,

a chlorinated rubber such as neoprene,

sand, and

a finely divided magnetic material to a structural substrate;

drying the fluid composition to form a magnetic coating on the structural substrate;

placing a magnetic template on the magnetic coating on the coated structural substrate;

applying a second fluid composition on the magnetic coating, the second fluid composition containing:

an acrylic polymer, and

sand;

drying the second layer; and

removing the template to form a pattern.