The present invention is directed to the construction industry, and more particularly to a durable wall system and construction method.
Most traditional residential construction is still carried out utilizing conventional methods and materials such as wood or metal frame structural components, masonry block, precast concrete panels, and cast-in-place concrete forms. These types of construction are universally recognized, but they require a high degree of sophistication and training in order for them to be useful. Most of these traditional construction methods are both costly and time-consuming.
Large numbers of “prefab” or “modular” building systems have been brought to the market in recent years. These systems require a central manufacturing facility, and experience high acquisition and transportation costs for all the necessary materials. These modular construction methods also sacrifice the ultimate durability and longevity of the resulting structure, where too much emphasis has been placed on cost-reduction in order to meet limited construction budgets.
There has been some utilization of pressurized concrete or “shotcrete” for wall construction over the past few years. Shotcrete has unique qualities such as high strength, crack resistance, prolonged durability, and low permeability, making it much more water resistant and more resistant to seismic activity than other forms of concrete. There have been several wall systems over the years that use shotcrete or pressurized concrete, none of which has been highly successful.
The two most common types of shotcrete wall systems use either a Styrofoam core to which shotcrete is applied, or a steel panel of some description to which shotcrete is applied. Both of these methods generally require shotcrete to be applied to both sides of the wall. The Styrofoam panel system is inherently weaker, and therefore, makes it less durable and less suitable where high wind or seismic conditions exist. The systems that use various types of steel mesh to which the shotcrete is applied are much stronger, and as a result, they are more durable. The problem with these systems is that it is more difficult to apply the shotcrete to the walls because there is no rigid panel or diaphragm on which to place the shotcrete during the application process. The more the panels or diaphragms move during application, the more difficult it is to get the shotcrete to adhere to the panel surface, where the flexing of the panels increases the rebound effect of the shotcrete, resulting in unacceptable amounts of wasted concrete.
There is still much room for improvement when utilizing shotcrete to form the primary walls in any type of structure. The construction market needs a concrete and steel mesh building system that is strong, fast, and economical. The necessary building system and process to achieve these goals cannot require excessive amounts of costly skilled labor and cannot create excessive amounts of wasted materials.
The present invention is a building technology consisting of a process used for the rapid construction of virtually any type of structure that requires a concrete foundation along with an integrated, contiguous steel and concrete wall assembly. The primary application of this building process is geared toward the rapid construction of affordable, low-maintenance, and highly durable single-family and multi-family dwellings.
For simplicity, the building process and system components are herein described in terms of assembling a single wall section and foundation slab section between two fixed points. In practical application in the field, however, it will be used to construct a complete foundation slab and an integrated series of conjoined walls that will constitute the entire shell or frame of a completed dwelling structure. The walls can include all of the interior walls as well as the exterior structural walls, where applicable.
First, a suitable concrete foundation, or floor slab, consisting primarily of concrete and steel, must be constructed, the specific ingredients, thickness and strength of which will be determined by soil type and conditions, and related geological, topographical and climatological conditions at a given construction site. The key elements that must be imbedded in the foundation, which are necessary for the construction of the integrated wall system above it, are as follows.
Steel rebar dowels with a standard angled hook, hereinafter called “dowels”, are cut to a specified length and must be imbedded in the foundation at each directional change of the structure, and at various points along the wall and foundation where intersecting walls will connect to the primary wall. These dowels, serving as tie-in rods, will protrude above the surface of the foundation and extend upward two to three feet, as required to meet any applicable engineering overlap requirements. The protruding dowels are positioned in the foundation so as to extend upward directly at the center of the wall as it relates to the external surface edge of the foundation slab.
Additional steel reinforcement is then positioned and embedded in the foundation along the entire length of the foundation slab. This reinforcement will be in the form of a continuous strip of welded-wire fabric, and/or rebar placed at various intervals, depending upon strength requirements. This reinforcing steel will extend above the surface of the foundation or floor slab up to three feet, depending on engineering and code requirements, and will be positioned so that it will be at, or close to, the center of the intended vertical walls. Concrete is then poured within a series of forming boards outlining the entire perimeter of the intended dwelling structure, to form the foundation slab, and is then allowed sufficient time to cure and harden in order to permit further construction and assembly activities on top of the foundation slab.
Pieces of steel rebar of suitable gauge, the length of which will describe the approximate height of the intended wall, are then placed on the surface of the foundation slab, next to each of the steel tie-in dowels at each directional change, protruding from the cured foundation slab. Each of these vertical rebar support rods is tied to its corresponding, protruding tie-in dowel, using steel rebar tie wire, so that each vertically-oriented rebar support rod stands unaided.
From this point forward, a single wall section will be described, unless otherwise noted. A specially designed temporary guiderail connector, hereinafter referred to as a “connector”, is placed on top of each vertical steel rebar support rod, at the end of each wall section. Each connector has a steel sleeve which aligns it on the rebar support rod, and the connector is held in place by gravity. Next, a specially designed temporary upper guiderail the approximate length of the wall section, hereinafter referred to simply as a “guiderail”, is slid down in place over the connectors at the top of each end of the wall section, and is held in place by gravity. A locking pin is inserted horizontally through each side of the guiderail where it intersects with each guiderail connector, capturing the connector, and stabilizing the guiderail and connector longitudinally, vertically and horizontally.
A sheet of welded-wire fabric of sufficient gauge and strength which is cut to the approximate height of the intended wall is then placed and aligned vertically on the foundation at the approximate center location for the wall. The welded-wire fabric rests on its edge directly on the concrete foundation floor slab. The welded-wire fabric sheet is secured in place by tying it to the welded-wire fabric and/or rebar tie-in dowel supports which are extending vertically out of the foundation slab. The top edge of the vertically erected welded-wire mesh is secured in place by inserting it into a series of locking devices or protrusions in the underside of the guiderail. The temporary upper guiderail and guiderail connectors simply serve to stabilize the top of the welded-wire mesh wall panel assembly during the subsequent application of concrete to the wall panels described herein below.
At this stage, there is now one primary structural layer of welded-wire fabric running the length and height of each wall section. The primary structural welded-wire fabric sheeting is firmly secured at the bottom to the foundation steel, and stabilized at the top in the underside of the temporary guiderail. Any additional layers of welded-wire mesh called for in a given design that will eventually become part of the aggregate structural panel of each wall will be attached to, and supported by, this primary structural layer of welded-wire mesh.
Roof truss anchors are then fitted up through slots located periodically in the guiderails at predetermined points, based on the applicable roof truss design for the given structure. The roof truss anchors can be temporarily affixed to the upper guiderail and/or may be tied to any portion of the structural steel rebar or mesh components in the wall panel, beneath the guiderail.
Next, sheets of perforated expanded metal mesh, hereinafter referred to as “rib lath”, are then secured vertically to the structural welded-wire mesh, for the entire length of the wall. The rib lath extends from the foundation slab up to the underside of each temporary upper guiderail. The sheets of rib lath have an abundance of perforations or pre-formed slots in it, and serves as the underlying layer of steel mesh material to which concrete will be applied on both sides, typically at a predetermined pressure, from a device such as a shotcrete pump.
Prior to the application of concrete to the rib lath, additional layers of welded-wire fabric of different sizes and configurations can be added to one or both sides of the existing structural wall assembly depending on strength requirements and the thickness of the desired, resulting wall. The combination of structural welded-wire mesh and additional sheets of steel mesh described above are used to reinforce the concrete, and in this application, are also used to stabilize and support the entire structural assembly of each wall until the concrete can be applied, as well as stabilizing the rib lath while the concrete is being applied at a specified level of pressure.
In short, the aggregate wall structure assembly and configuration describe above, hereinafter referred to as a “structural panel”, will consist of one layer of the structural, self-supporting welded-wire fabric, one layer of rib lath, and, optionally, can include one or more additional layers of welded-wire fabric on one or both sides of the rib lath, all of which are secured to, and supported by, the original structural layer of self-supporting welded-wire fabric and vertical rebar support rods.
Concrete is then applied to both sides of the structural panel and allowed to cure. All steel layers of the structural panel and all supporting rebar components are covered and encased completely in concrete, from the foundation slab up to the underside of the temporary upper guiderail, thus establishing the completed walls. Once the concrete is sufficiently cured, the temporary upper guiderails and guiderail connectors that had been used to simply stabilize the structural wall panels are removed, leaving the finished concrete and steel walls ready for the application of roof trusses, and the roofing system called for in the given design specifics.
Other objectives and further advantages and benefits associated with this invention will be apparent, to those skilled in the art, from the description, examples and claims which follow.
The following detailed description depicts a construction process and methodology that provides significant improvements over existing shotcrete panel systems in speed of assembly, simplification, construction stability, and reduction of materials waste. For simplicity, the construction methodology will be demonstrated by describing the assembly of one wall section between two vertical supports. This wall section could represent the wall between two corners of a structure or a representative section of a longer, straight wall.
The present invention involves a building system, implemented via a unique construction method and process, that provides for the construction of a fully integrated foundation and series of exterior and interior walls comprised of steel mesh and pressurized concrete, utilizing specialized, purpose-built, re-useable assembly components. Units can be built from virtually any structural layout or design. This process is particularly desirable for projects where the resulting dwellings or structures must be more durable and cost-effective than traditional construction methods and materials can provide. The subject system of construction allows the builder to erect the integrated foundation and all of the walls of the structure quickly and efficiently, without the need for expensive forms or costly skilled labor. The ability to utilize unskilled labor allows the user to construct a large number of structures in a shorter period of time, and, utilizing re-useable system components in the process, allows for the prompt, reliable and consistent reproduction of a given unit type or design in the field. The reusable components of this system give the user an advantage with respect to speed of construction, consistency, and economy, while also eliminating certain aspects of waste and delay that is typical of more traditional construction processes. Standard engineering applications make this construction process readily acceptable in every state and county in the United States.
The foundation utilized in this invention can be built separately from the floor slab or it can be built and poured monolithically where the foundation and floor slab are poured at the same time. Our diagrams show the monolithic configuration and integrated assembly process. The monolithic foundation and floor slab 10, hereinafter called the “floor slab”, is prepared first as shown in
Once the floor slab 10 is poured and cured, a vertical support rod consisting of a length of steel rebar reinforcing rod 13, herein after referred to as the “vertical support”,
The top strand of the welded-wire fabric sheet 17 is lifted up so that it engages the several aligning tabs 18 located on the underside of the guiderail 15,
One or two rows of reinforcing horizontal rebar 19 are attached to the outside surface of the welded-wire fabric 17 as shown in
Roof truss anchors 20 are placed up through linear slots 21 that are present throughout the guiderail 15,
Sheets of rib lath 22, which is a form of expanded metal mesh, are applied to the inside surface of the welded-wire fabric 17, as shown in
If there are to be any openings in the wall, such as doors and windows, they must be accommodated for at this time. Once the structural panel 23 is in place, openings are cut of sufficient size to provide for the doors and windows in accordance with the given unit design. Door placeholders 50 and window placeholders 51 are placed into each opening, framing out the openings, as follows. The door placeholders 50 and window placeholders 51 can be made out of the same material as the guiderails 15, or they can be made out of aluminum, plastic or wood. If they are to be made out to the same material as the guiderail 15, the corners of the door placeholders 50 and window placeholders 51 are mitered on a 45-degree angle and welded so that there are no open seams. Door placeholders 50 and window placeholders 51 are shown in
The window placeholders 51 are secured in the same manner as the door placeholders 50. The window placeholders 51 are held in place using two window placeholder hangers 55 that are hung over the guiderail 15 and are secured to both sides of the window placeholder 51 with metal screws at a predetermined height. Once the window placeholder 51 is held in position, four locking pins 53 are inserted through the holes 52 in the window placeholder 51. The locking pin receiving sleeves 54 are placed over the terminal end of the locking pins 53. The locking pin receiving sleeves 54 are then tied securely to the outside surface of the welded-wire fabric 17 with steel wire ties.
An alternate method of securing the window placeholders 51 in their proper position is to place the locking pins 53 through the holes 52, and place the locking pin receiving sleeves 54 over the terminal end of the locking pins 53. The window placeholder 51 is then held in place while the locking pin receiving sleeves 54 are tied to the outside surface of the welded-wire fabric 17 using steel wire ties. Utilizing this method, the two window placeholder hangers 55 would not be required. Either of these two methods of attaching the door placeholders 50 and window placeholders 51 can be utilized no matter what material is used for the construction of the door placeholders 50 and window placeholders 51. In the event additional or other openings are required in a wall panel for air conditioning units, vents, and other unit construction features that may be called for in a given unit design, the same style of placeholders will be fabricated and used with the same assembly process utilized for the door placeholders 50 and window placeholders 51.
A corner gauge bracket 26, which is an “L” shaped device the width of the wall running in each direction, is placed at each corner of the wall panel, as shown in
Shotcrete is now sprayed the on both sides of the structural panels 23 throughout the structure. Excess shotcrete is screeded or shaved off flat, using the gauge locators 27, the edge of the guiderail 15, and the outside surface of the floor slab 10, as guides for the screeding and surface-leveling process, throughout the structure. Once the concrete has had sufficient time to cure, the gauge locators 27, the locking pins 16, the corner gauge brackets 26, the guiderails 15, and the guiderail connectors 14 are all removed, and may then be reused on the next structure. The locking pins 53 for the door placeholders 50 and window placeholders 51 are removed. The door placeholders 50 and window placeholders 51 are removed as well. The remaining structure, once cured, consists of a solid, level, concrete-and-steel wall frame describing the entire structure, with the roof truss anchors 20 embedded in and extending above the top of the walls, ready to receive and connect to the roof trusses.
The construction method and process described above can also be performed by the use of a set of alternative, pre-drilled guiderails and guiderail connectors which utilize a series of temporary locking pins that are inserted down through the top of the special pre-drilled guiderails, and protrude downward below the guiderails on either side of the top of the structural panels 23, to temporarily stabilize the structural panels 23 at the top, from both sides. The alternative, pre-drilled locking pin guiderails 70 are hereinafter referred to as “locking pin guiderails,” as seen in
The foundation utilized in this invention can be built separately from the floor slab or it can be built and poured monolithically where the foundation and floor slab are poured at the same time. Our diagrams show the monolithic configuration and integrated assembly process. The monolithic foundation and floor slab 10, hereinafter called the “floor slab”, is prepared first as shown in
Once the floor slab 10 is poured and cured, a vertical support rod consisting of a length of steel rebar reinforcing rod 13, herein after referred to as the “vertical support”,
Once the locking pin guiderails 70 are in place, the series of outside locking pins 61 are inserted down into the series of outside locking pin holes 59 along the locking pin guardrails 70,
One or two rows of reinforcing horizontal rebar 19 are attached to the outside surface of the welded-wire fabric 17 as shown in
Roof truss anchors 20 are placed up through linear slots 21 in the locking pin guiderails 70,
Sheets of rib lath 22, which is a form of expanded metal mesh, are applied to the inside surface of the welded-wire fabric 17, as shown in
If there are to be any openings in the wall, such as doors and windows, they must be accommodated for at this time. Once the structural panel 23 is in place, openings are cut of sufficient size to provide for the doors and windows in accordance with the given unit design. Door placeholders 50 and window placeholders 51 are placed into each opening, framing out the openings, as follows: The door placeholders 50 and window placeholders 51 can be made out of the same material as the locking pin guiderails 70, or they can be made out of aluminum, plastic or wood. If they are to be made out to the same material as the locking pin guiderail 70, the corners of the door placeholders 50 and window placeholders 51 are mitered on a 45-degree angle and welded so that there are no open seams. Door placeholders 50 and window placeholders 51 are shown in
The window placeholders 51 are secured in the same manner as the door placeholders 50. The window placeholders 51 are held in place using two window placeholder hangers 55 that are hung over the locking pin guiderail 70 and are secured to both sides of the window placeholder 51 with metal screws at a predetermined height,
An alternate method of securing the window placeholders 51 in their proper position is to place the locking pins 53 through the holes 52, and place the locking pin receiving sleeves 54 over the terminal end of the locking pins 53,
A corner gauge bracket 26, which is an “L” shaped device the width of the wall running in each direction, is placed at each corner of the wall panel, as shown in
Shotcrete is now sprayed the on both sides of the structural panels 23 throughout the structure,
The building system allows for the rapid, cost-effective construction of solid concrete-and-steel walls that are seamlessly integrated with the foundation and construction pad. The construction process incorporates stabilizing elements that hold a primary layer or sheet of welded-wire fabric in place. Expanded metal mesh, or rib lath, is attached to, and supported by, the primary layer of welded-wire fabric. Additional layers of welded-wire fabric can be added to either side of the primary layer depending on strength requirements for each specific construction application or project. The primary layer of welded-wire fabric is of sufficient gauge and strength to ensure that each of the wall framing sections are capable of standing vertically during the assembly process without the need for additional vertical support. The primary layer of welded-wire fabric rests on a flat substrate, or foundation. The foundation is prepared using steel rebar that has been strategically placed at specified intervals for support and reinforcement before the pad is poured. The foundation rebar dowels extend vertically out of the surface of the foundation at or close to the center of each wall section being constructed into the foundation. The rebar foundation steel dowels protruding from the foundation structure are attached to the lower portion of the primary layer of welded-wire fabric. Uniquely-designed, interlocking temporary upper guiderails for the welded-wire fabric, held in place by vertical rebar support rods, are placed at the top of each section of wall framing. The temporary guiderails are utilized to stabilize the top edge of the primary layer of welded-wire fabric during the concrete application process. The rib lath is then attached to the surface of the primary layer of welded-wire fabric. The welded-wire fabric and rib lath collectively form the basic “structural panel” of each wall section. Strength requirements for a given structure and the width of the wall may require additional layers of welded-wire fabric to be added to one or both sides of the basic structural panel. When fully assembled, the tightly-bound layers of welded-wire fabric and rib lath mesh forms a continuous, uninterrupted structural panel which constitutes the framing or shell of the structure. Pressurized concrete is then evenly applied to all of the inside and outside surfaces of the structural panels throughout the structure, first to one side of the structural panels and then to the opposite side of the panels. The rib lath is manufactured so that the series of perforations or slots in it are of such a size and shape that will allow sufficient concrete to penetrate, or flow partially through it, to the opposite side of the rib lath. This ensures that concrete from one side of the mesh flows through and adheres to the concrete applied on the opposite side of the rib lath mesh, and blends together during the curing process. Once the concrete has cured sufficiently, the upper stabilizing guide rails are removed. The resulting steel mesh and concrete external walls of the structure are seamless and can intersect in virtually any configuration. Each structure can also contain integrated internal walls of the same construction process and materials, in virtually any configuration.
Detailed embodiments of the instant invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms. Therefore, specific functional and structural details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure.
One skilled in the art will readily appreciate that the present invention is well adapted to carry out the objectives and obtain the ends and advantages mentioned, as well as those inherent therein. The embodiments, methods, procedures and techniques described herein are presently representative of the preferred embodiments, are intended to be exemplary, and are not intended as limitations on the scope. Changes therein and other uses will occur to those skilled in the art which are encompassed within the spirit of the invention and are defined by the scope of the appended claims. Although the invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments. Indeed, various modifications of the described modes for carrying out the invention which are obvious to those skilled in the art are intended to be within the scope of the following claims.
In accordance with 37 C.F.R. 1.76, a claim of priority is included in an Application Data Sheet filed concurrently herewith. Accordingly, the present invention is a continuation-in-part of U.S. patent application Ser. No. 14/137,347 entitled “Durable Wall Construction” filed Dec. 20, 2013 and related to U.S. patent application Ser. No. 14/178,070 entitled “Multi-story Durable Wall Construction” filed Feb. 11, 2014, the contents of these patent applications are incorporated herein by reference.
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Number | Date | Country | |
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Parent | 14137347 | Dec 2013 | US |
Child | 14248950 | US |