The present invention relates to wall structures and methods of constructing same and, in particular, to wall structures having internal bracing during construction and superior thermal resistance.
Approximately 50% of the energy consumed in the operation of a building is used to maintain the temperature of the interior spaces. In the cold months, the energy is used for heating, while in the hotter months, the energy is used for cooling. Walls with exceptional thermal resistance, such as those of the present invention, have the potential to significantly reduce the operating energy of a building.
The present invention relates to systems and methods for constructing very high thermal resistivity (“R value”) building walls having interior and exterior membrane surfaces typically of concrete and applied under pressure.
One of the difficulties of constructing such walls is keeping them in place and plumb while they are being erected and while the membranes are being applied.
The prior art practice for keeping walls in place during construction is to use external bracing, primarily using wood or pipe members. The disadvantages of external bracing (regardless of the materials used) is that the bracing makes the application of the outer membrane difficult, requiring substantial effort and time, which translates directly into added expense. External bracing also consumes materials that are typically discarded. Even if some of the bracing materials are reused or recycled, they add nothing to the structural integrity of the wall after it is fully constructed.
U.S. Pat. No. 7,461,488 teaches an internal bracing system using straw bales. While that system has been successfully implemented and is an advance over the prior art, straw bales are inherently non-uniform in size, cumbersome to work with and at risk of attracting and retaining moisture. The present invention provides the advantages of internal bracing without the disadvantages accompanying straw bales and provides a much higher level of thermal resistivity and earthquake stability.
The present invention teaches a wall structure and method for its construction that can provide exceptionally high thermal resistivity and stability under earthquake conditions using internal bracing during construction that permits walls of 30 feet and more to be constructed with little or no external bracing. The ability to construct a wall of the present invention using only internal bracing eliminates the difficulties of applying the outer wall membrane and incorporates members that provide that bracing as internal structural elements of the finished wall.
The high thermal resistance wall of the present invention comprises a pair of generally parallel spaced apart concrete membranes connected by spars with insulated concrete forms (ICFs) having spaced apart ICF panels disposed adjacent to and between the membranes defining an internal wall space and insulating foam filling the internal wall space. In addition, internal bracing structures disposed in the internal wall space during construction remain as structural elements of the finished wall.
The method of constructing the wall comprises: stacking spaced apart ICF panels onto the foundation base wherein each panel has an interior surface and an exterior surface where the interior surfaces define an internal wall space; securing a plurality of bracing ladders at spaced apart locations on the base foundation in the internal wall space adjacent the ICFs; disposing a plurality of spar members across the internal wall space and through the ICF panels; filling the internal wall space with insulating foam; and applying a concrete membrane onto the exterior surfaces of the ICF panels to a thickness that covers portions of the spar members. In a preferred embodiment, the membranes are only applied after the entire wall is otherwise constructed.
The invention achieves its outstanding results by the strategic placement (both vertically and horizontally) and interconnection of a plurality of ladder structures (truss-like members) and various spar members. The ladder structures give the walls sufficient out-of-plane strength to remain erect and plumb during construction both before the outer membrane is applied and while the outer membrane is applied.
The present invention permits the membranes to be applied without the need to work around external bracing, greatly simplifying that process.
It follows, of course, that erecting and dismantling external bracing is eliminated, as are the substantial costs and waste associated therewith.
One of the outstanding features of the present invention is that a wall of any height (from 8 feet to 35 feet or more) can be assembled from small parts that are easily transported to the site. Spars and rebar members are tied or tack welded to form a stiff truss-like system that stabilizes the wall during and after construction.
Accordingly, it is an object of the present invention to provide internal bracing systems and methods for constructing a high R-value wall. It is another object of the present invention to provide internal bracing and methods for constructing a high R-value wall to a height of 35 feet or more without the need for external bracing.
Yet another object of the present invention is to provide systems and methods for constructing a high R-value wall in which permanent internal structural elements act as bracing during construction.
The foregoing and other objectives, features and advantages of the invention will be more readily understood upon consideration of the following detailed description of the invention taken in conjunction with the accompanying drawings.
The following description includes some specific measurements for purposes of illustration only and, except where otherwise indicated, such specific measurements are not to be taken as limitations of the invention. While these dimensions will change for walls of different thicknesses and heights, what does not change is the functional relationship of the various structural members to one another.
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ICFs are used in prior art systems to form a cavity into which concrete is pumped to form the core structural element of a foundation or wall, with reinforcing steel (rebar) disposed between the panel members 14 before concrete placement to give the concrete flexural strength, similar to bridges and high-rise buildings made of concrete.
While there are a number of different brands and configurations of ICFs, those used in the present invention are those available brands that are stackable, constructed from a lightweight foam material and can be adjusted to vary the distance between panel members 14 to create interior wall spaces 18 of different widths 13W. As will be seen by what follows, ICFs 13 are not used in the present invention as concrete forms at all, but rather in a way and for a purpose that enables a novel wall structure to be built having the same or better load-bearing capabilities as a concrete core wall and superior thermal resistance and earthquake stability, as well as other advantages.
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U-shaped spar member 37 has a generally straight midsection 37a and end sections 37b at approximate right angles to midsection 37a. In its preferred embodiment, the spar 37 is a contiguous structure that spans the interior wall space at a location that disposes its end sections 37b outside of the ICFs 14 (outside of interior wall space 18) and around end sections 30 of cross spar members 28 and 32 (see
Because the spar members 28, 32, 37 and 38 span the interior wall space 18, they create a thermal conductivity path. Even when only two spar sets 33 are used in each location (see below), the amount of heat that can travel through these spar members is surprisingly high when the spars sets 33 are made of a high thermal conductance material such as steel rebar. The use of such high thermal conductivity materials can result in a significant amount of heat transfer and a concomitant reduction in the overall R-value of the wall. In order to prevent this degradation in the R-value, in a preferred embodiment of the invention, all of the spars that comprise spar sets 33 are formed from fiberglass, which is a low heat conductance material compared to steel. Using fiberglass in place of steel rebar has a dramatic reduction in heat transfer across the wall 11 without compromising structural performance.
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Unlike conventional concrete structures having a concrete core that has moderate thermal conductance, the core material of the wall 11 of the present invention is all insulating material (ICFs 13 and foam 53), both having very low thermal conductance.
Foam 53 is applied as a combination of liquids that expand when exposed to the air to fill all of space 18. Such foam systems are known in the building industry and are capable of producing foam in a range of densities. Gaco Western offers a liquid pour system: Low density, rigid polyurethane foam for cavity fill which uses as a Blowing Agent—245fa Enovate. Gaco's product designation is Polyfoam™ CF-200, which is a zero ozone depleting liquid pour system for general use in cavity fill applications. It is co-blown with HFC and water and cures to a low density rigid polyurethane closed cell foam. High density rigid polyurethane closed cell foam is also available. In either case, the closed cell structure of the foam 53 prevents the intrusion of water into the interior wall space 18 that could, if present, diminish the R-value of the wall. In the same way, foam 53 also prevents any insect infestation or other undesirable material from entering the space 18.
The method of the present invention for constructing a wall 11 of superior structural integrity and high thermal resistance (high R-Value) onto a base foundation 12 wherein vertically extending opposing pairs 17p of anchor dowels 17 are cast into and spaced apart along the length 12L of the base foundation 12, comprises:
(1) attaching to the base foundation 12 preassembled vertically oriented mid-wall bracing ladders 23 at spaced apart locations along the length 12L of base foundation 12;
(2) stacking a base run of ICFs 13 several panels 14 high in a running bond onto the base foundation 12 wherein the ICFs 13 define an interior wall space 18 that includes bracing ladders 23;
(3) disposing at spaced apart locations along the length 12L of base foundation 12 adjacent to the anchor dowel pairs 17 and spaced above the base foundation 12, a lower spar set 33a of multiple spar members that span the interior wall space 18 and penetrate the ICF panels 14 locating end sections of the spar members outside of the ICFs 13;
(4) injecting rigid polyurethane foam 53 in the interior wall space 18 and thereby surround the bracing ladders 23 and the portions of the spar sets 33 within the interior wall space 18;
(5) stacking onto the existing foam filled run of ICFs 13 additional runs of ICFs 13 each to a height of several panels 14;
(6) injecting rigid polyurethane foam 53 in the interior wall space 18 of each additional run of ICFs 13 before adding an additional run of ICFs 13;
(7) repeating steps (5 and 6) until one additional run of ICFs 13 would reach within several panel heights of the top 11b of wall 11;
(8) stacking a top run of ICFs onto the uppermost foam filled run of ICFs;
(9) disposing in the top run of ICFs in line with the lower spar sets 33a an upper spar set 33b that spans the interior wall space 18 and penetrates the ICFs 13 locating the end sections of the spars of the upper spar set 33 outside of ICFs 13;
(10) injecting rigid polyurethane foam 53 in the interior wall space 18 of the top run of ICFs 13;
(11) securing next to each anchor dowel 17 a connecting rod 22 that extends vertically to a height that disposes it adjacent an upper spar set 33b;
(12) securing to each connecting rod the end sections of the spars of a lower spar set 33a and an upper spar set 33b;
(13) securing wire fabric 57 exteriorly of surfaces 14b of the panels 14 of ICF 13; and
(14) applying a concrete membrane (typically pneumatically placed shotcrete or gunnite) to the exterior surfaces 14b of the ICF panels 14 to a thickness that encapsulates the anchor dowels 17, connecting rods 22 and end sections of spar sets 33.
Of course, various changes, modifications and alterations in the teachings of the present invention may be contemplated by those skilled in the art without departing from the intended spirit and scope thereof. As such, it is intended that the present invention only be limited by the terms of the appended claims.