Wall and Method

Abstract

A wall having a 3D wire mesh panel having a core with a 3D wire mesh matrix extending through and out the core, and a structural material, such as concrete, envelopes the panel. A form positioned about the panel is used to introduce the concrete to the panel during production. Methods for producing the wall, which include producing the wall vertically at a desired location.

Claims

1. A method for producing a wall comprising the steps of: partially filling a form with uncured concrete; positioning a 3D wire mesh panel onto the uncured concrete in the form; allowing the panel to settle into the uncured concrete so there is uncured concrete below and around all sides of the panel and the uncured concrete bonds with the panel; pouring additional uncured concrete onto the panel in the form to cover over the panel; letting the uncured concrete about the panel cure; and separating the panel with the cured concrete about the panel from the form.

2. The method of claim 1 including the step of preparing the panel.

3. The method of claim 2 including the step of preparing the form to receive the panel.

4. The method of claim 3 wherein the preparing the panel step includes the step of clipping joints and seams of the panel.

5. The method of claim 4 wherein the preparing the panel step includes the step of adding U shaped mesh to an outer edge of the panel.

6. The method of claim 5 wherein the preparing the panel step includes the step of clipping and cutting a window or door or opening in the panel.

7. The method of claim 6 wherein the preparing the form step includes preparing inner borders within a perimeter of the form where the inner borders conform with a window or door or opening in the panel.

8. The method of claim 7 including after the pouring step there is the step of finishing or stamping the uncured concrete.

9. The method of claim 8 wherein the allowing step includes the step of vibrating the panel so the panel settles into the uncured concrete.

10. The method of claim 9 wherein the panel has a core with a 3D wire mesh matrix extending through and out the core.

11. The method of claim 10 wherein the panel provides sound dampening and temperature insulation.

12. The method of claim 11 wherein the core is formed of styrene foam.

13. The method of claim 12 including after the pouring step, there is the step of screeding the uncured concrete.

14. A wall comprising: a 3D wire mesh panel having a core with a 3D wire mesh matrix extending through and out the core and having a front side, a rear side, a top side, a bottom side, a left side, and a right side; and structural material disposed about the panel covering the front side, the rear side, the top side, the bottom side, the left side, and the right side.

15. The wall of claim 14 wherein each side is flat, and the structural material is concrete.

16. The wall of claim 15 including an opening extending through the front side and the rear side and the concrete over the front side and rear side which defines a window or a door.

17. The wall of claim 16 which is freestanding and transportable.

18. A wall of claim 17 including a form positioned about the top side, bottom side, right side, and left side, and in contact with the concrete covering the top side, bottom side, right side, and left side, the form defining an outer border of the wall.

19. The wall of claim 18 has dimensions of about 4′×20′×8″, and weighs less than 4,600 lbs. with no openings and supports loads of more than 50,000 lbs.

20. The wall of claim 19 including eyes extending from the front side for lifting the wall.

21. The wall of claim 15 including a form positioned about the panel with the structural material disposed between the panel and form.

22. The wall of claim 21 wherein the form includes a front foam sheet disposed adjacent to and in spaced relationship with the front side and a rear foam sheet disposed adjacent to and in spaced relation with the rear side.

23. The wall of claim 22 including a right end board and a left end board adjacent to and in spaced relationship with the right side and the left side, respectively.

24. The wall of claim 23 including bracing positioned about the form to hold the form in place.

25. The wall of claim 24 including and enclosure enveloping, positioned around and in spaced relationship with the right end board, left end board, right foam sheet and left foam sheet, and wherein the structural material is disposed between the enclosure and the right end board, left end board, front foam sheet and rear foam sheet.

26. A method for producing a wall comprising the steps of: positioning a 3D wire mesh panel vertically at a desired location, the panel having a core with a 3D wire mesh matrix extending through and out the core; building a foam form about the panel; pouring a structural material between the panel and foam form; and letting the structural material harden about the panel.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] FIG. 1 shows an empty form.

[0009] FIG. 2 shows the 3D wire mesh panel.

[0010] FIG. 3 shows the initial placement of uncured concrete into the form from a first pour of uncured concrete.

[0011] FIG. 4 shows the placement of the panel onto the uncured concrete in the form from the initial placement of the uncured concrete.

[0012] FIG. 5 shows the placement of the uncured concrete from the second pour onto the top of the panel already in the form.

[0013] FIG. 6 shows the wall with the cured concrete about the panel in the form.

[0014] FIG. 7 shows the wall separated from the form.

[0015] FIG. 8 shows the panel being prepared to receive the uncured concrete.

[0016] FIG. 9 shows a perspective overhead view of the panel being prepared to receive the uncured concrete.

[0017] FIG. 10 shows a perspective right side view of the panel being prepared to receive the uncured concrete.

[0018] FIG. 11 shows a perspective view of the form positioned about the panel and held in place by bracing.

[0019] FIG. 12 shows a perspective view of the form positioned about the panel and held in place by even more bracing than shown in FIG. 11.

[0020] FIG. 13 shows a finished wall that is separated from the form which is freestanding and positioned vertically.

[0021] FIG. 14 shows a perspective top view of the top side of the panel and form after the uncured concrete has been poured into the form and has had time to cure.

[0022] FIG. 15 is an overhead view of the wall separated from the form with the concrete cured and showing the width of the wall being 10 inches.

[0023] FIG. 16 shows an overhead view of another embodiment of the panel with the form and an enclosure.

[0024] FIG. 17 shows an overhead view of a wall formed from the form and enclosure of FIG. 16 with a partial cutaway view of the cement.

DETAILED DESCRIPTION OF THE INVENTION

[0025] Referring now to the drawings wherein like reference numerals refer to similar or identical parts throughout the several views, and more specifically to FIGS. 6 and 7 thereof, there is shown wall 10. The wall 10 comprises a 3D wire mesh panel 84 having a core 72 with a 3D wire mesh matrix 74 extending through and out the core 72 and having a front side 12, a rear side 14, a top side 16, a bottom side 18, a left side 20, and a right side 22. The wall 10 comprises structural material disposed about the panel 70 covering the front side 12, the rear side 14, the top side 16, the bottom side 18, the left side 20, and the right side 22.

[0026] Each side may be flat, and the structural material is concrete. The wall 10 may include an opening 60 extending through the front side 12 and rear side 14 and concrete over the front side 12 and rear side 14 which defines a window or a door. The wall 10 may be freestanding and transportable. The wall 10 may include a form 50 positioned about the top side 16, bottom side 18, right side 22, and left side 20, and in contact with the concrete covering the top side 16, bottom side 18, right side 22, and left side 20. The form 50 defines an outer border 54 of the wall 10. The wall 10 may have dimensions of about 4′×20′×8″, and may weigh less than 4,600 lbs. with no openings 60 and may support loads of more than 50000 lbs. The wall 10 may include eyes 86 extending from the front side 12 for lifting the wall 10.

[0027] In an alternative embodiment, as shown in FIGS. 8-15, the wall 10 may include a form 50 positioned about the panel 70 with the structural material disposed between the panel 70 and form 50. The form 50 may include a front foam sheet 24 disposed adjacent to and in spaced relationship with the front side 12 and a rear foam sheet 26 disposed adjacent to and in spaced relation with the rear side 14. The wall 10 may include a right end board 28 and a left end board 30 adjacent to and in spaced relationship with the right side 22 and the left side 20, respectively. The wall 10 may include bracing 32 positioned about the form 50 to hold the form 50 in place. The wall 10 of this embodiment is produced using a 3D panel 70, 2″ or 4″ foam sheets, pencil rods, 2″×4″ boards for the bracing 32. Spacer 36 of the desired thickness are installed between the foam sheets and the panel 70 and are removed during the pouring process.

[0028] By using this wall 10, and the methods described herein, it will create a large savings in the construction building cost and eliminate labor costs for end results. Contractors are able to precast on site or at other locations with little waste of materials. Once the wall 10 is formed, the foam sheets can be left in place for applying the finish desired to the foam, being stucco, brick, stone, etc. The foam can also be removed for a smooth surface finish. The panel 70 gives the wall 10 the proper strength for building requirements and for insulation value to the building. The foam form 50 gives extra insulation value, both temperature and sound, and extends the burn rating time to the structure. Pouring a 2″ or 4″ thickness of concrete, on both sides of the form 50, can be used to produce the wall 10.

[0029] In yet another embodiment, as shown in FIG. 16, the wall 10 may include an enclosure 34 enveloping, positioned around and in spaced relationship with the right foam sheet and left foam sheet, and wherein the structural material is also disposed between the enclosure 34 and the front foam sheet 24 and rear foam sheet 26. FIG. 16 shows an overhead view of the enclosure 34, which can be comprised of plywood sheets 92, adjacent to and in spaced relationship with the right foam sheet and left foam sheet. Spacers 36 are used to maintain the desired distance between the plywood sheets 92 and the right and left foam sheets. The right end board 28 and left end board 30 contact the ends of the plywood sheets 92 to close off the enclosure 34 so none of the poured uncured concrete can escape through the right and left sides. Uncured concrete 88 is poured into the enclosure 34 through the top side so it flows between the plywood sheets 92 and the right and left foam sheets and the panel 70 and the right end and a left end boards to capture the right and left foam sheets in the uncured concrete 88 poured about the panel 70. FIG. 17 shows an overhead view of a wall 10 formed from the form 50 and enclosure 34 of FIG. 16 with a partial cutaway view of the cured concrete 90.

[0030] The present invention pertains to a method for producing a wall 10. The method comprises the steps of partially filling a form 50 with uncured concrete 88. There is the step of positioning a 3D wire mesh panel 84 onto the uncured concrete 88 in the form 50. There is the step of allowing the panel 70 to settle into the uncured concrete 88 so there is uncured concrete 88 below and around all sides of the panel 70 and the uncured concrete 88 bonds with the panel 70. There is the step of pouring additional uncured concrete 88 onto the panel 70 in the form 50 to cover over the panel 70. There is the step of letting the uncured concrete 88 about the panel 70 cure. There is the step of separating the panel 70 with the cured concrete 90 about the panel 70 from the form 50.

[0031] There may be the step of preparing the panel 70. There may be the step of preparing the form 50 to receive the panel 70. The preparing the panel 70 step may include the step of clipping joints and seams 82 of the panel 70. The preparing the panel 70 step may include the step of adding U shaped mesh to an outer edge of the panel 70. The preparing the panel 70 step may include the step of clipping and cutting a window or door or opening 60 in the panel 70.

[0032] The preparing the form 50 step may include preparing inner borders 66 within a perimeter of the form 50 where the inner borders 66 conform 50 with a window or door or opening 60 in the panel 70. After the pouring step, there may be the step of finishing or stamping the uncured concrete 88. The allowing step may include the step of vibrating the panel 70 so the panel 70 settles into the uncured concrete 88. After the pouring step, there may be the step of screeding the uncured concrete 88.

[0033] The panel 70 may have a core 72 with a 3D wire mesh matrix 74 extending through and out the core 72. The panel 70 may provide sound dampening and temperature insulation. The core 72 pay me formed of styrene foam.

[0034] The present invention is a precast wall 10 that is significantly lighter than existing precast walls, but just as capable of meeting all the current requirements in commercial and residential buildings. For example, a rectangular shaped wall 10 of the present invention with no opening 60s at 4′×20′×8″, would weigh less than 4,600 lbs., or even less than 4,000 lbs., or even less than 3,700 lbs., or even weigh as little as about 3,200 lbs. In comparison, a wall of the same size but precast completely with concrete and no panel 70 or any core 72 or wire mesh matrix 74, would weigh about 6,000 lbs.

[0035] Furthermore, the precast wall 10 has a sound dampening core 72 embedded in the panel 70 with the styrene foam used to make the panels 70. The precast wall 10 provides an additional source of insulation that is not currently available.

[0036] The ability to utilize the techniques of forming and pouring in place, and additionally the ability to utilize the engineered wall 10 to precast onsite or offsite described herein allows for a wall 10 that offers more to a customer in terms of use and the ability to move. The customer can utilize smaller equipment to move and handle, plus the added benefit of sound and insulation.

[0037] The precast wall/tilt up wall would be cast either onsite by the contractor or could be constructed off site and shipped to the site. Both approaches would be performed the same way. With reference to FIGS. 1-7, first, the precast form 50 or box would already be built to the specification of the project. Second, the panels 70 would be installed in the precast form 50. This would consist of clipping all the joints and seams 82, adding U shaped mesh to the outer edge of the panels 70 and clipping, then cutting any window/door or opening 60 in the panel 70. Once this is complete, any additional engineering specs would be installed per the engineered construction plans for that specific project. Third, the precast panel 70 would then be lifted out of the form 50 and positioned to the side to allow the uncured concrete 88 to be poured into the precast form 50. Once the uncured concrete 88 is placed in the form 50, the panel 70 is then picked up and put back into the form 50. At this point, the panel 70 would be vibrated in to make sure the panels 70 are settled into the uncured concrete 88 to get the correct coverage of concrete around the panel 70 to get the correct bond from the panel 70 to the concrete. Fourth, the final layer or top portion of uncured concrete 88 would be poured over the panel 70 to the desired thickness required by the project and then it would be screeded off. The uncured concrete 88 would then be either flat finished or stamped depending upon the project. Fifth, once the concrete has cured about the precast panel 70, the now formed wall 10 would then be lifted out of the form 50 and either shipped to the job site or placed as either a precast panel 70 or tilt up panel 70 based on the job.

[0038] FIG. 1 shows an empty form 50. The size and configuration of the form 50 is based on the ultimate wall that will be produced. The form 50 is made by outer boards 52 connected together in a configuration that matches the configuration of the wall 10 which is being produced to define an outer border 54. The outer boards 52 are held in place by slats 56 placed against the outside 58 of the outer boards 52. For any opening 60, such as a door or a window, there are inner boards 62 that are placed in the interior 64 of the perimeter of the form 50 defined by the outer boards 52 to define an inner border 66. The inner boards 62 are connected together in a configuration that matches the configuration of the opening 60 of the wall 10. The inner boards 62 are held in place by slats 56 placed against the inside 68 of the inner boards 62.

[0039] FIG. 2 shows the 3D wire mesh panel 84. The panel 70 has a 2 inch or a 4-inch-thick foam core 72 with a welded wire mesh matrix 74 extending through and out the core 72. The opening 60, in this case a door or a window, has been cut out of the panel 70. U shaped wire mesh 76 is wrapped about all open edges 78 of the panel 70 to close off the sides of the panel 70. Flat wire mesh patches 80 are attached to any seams 82 in the panel 70. The seams 82 are formed from smaller 3D wire mesh panels 84 which are positioned aside each other, with the flat wire mesh patches 80 positioned over the adjacent sides of the smaller 3D wire mesh panels 84. The flat wire mesh patches 80 are wired to the adjacent smaller panels 70 to join the seams 82 or welded or brazed to the adjacent smaller panels 70 to join the seams 82. There are also tilt up eyes 86 extending from the surface of the wire mesh matrix 74. An example of a 3D 2i43 wire mesh panel 70 that can be used can be purchased from Strata Worldwide located in Sandy Springs Georgia and is called the EVG-3D® Panel 70, which comprises a 3D welded wire mesh matrix 74, fitted with an expanded and non-flammable polystyrene core 72. The strength and rigidity of the panel 70 results from inner diagonal truss wires welded to both mesh layers on each side.

[0040] FIG. 3 shows the initial placement of uncured concrete 88 into the form 50 from a first pour of uncured concrete 88. The initial placement of the uncured concrete 88 involved pouring uncured concrete 88 into the form 50 until the uncured concrete 88 is about 2 inches thick throughout the inside 68 of the form 50.

[0041] FIG. 4 shows the placement of the panel 70 onto the uncured concrete 88 in the form 50 from the initial placement of the uncured concrete 88. The panel 70 is then vibrated into the uncured concrete 88. A concrete pencil vibrator is used to help settle the panel 70 in the uncured concrete 88.

[0042] FIG. 5 shows the placement of the uncured concrete 88 from the second pour onto the top of the panel 70 already in the form 50. The second pour of the uncured concrete 88 provides about 2 inches of uncured concrete 88 in addition to the uncured concrete 88 from the first pour. The panel 70 in the uncured concrete 88 is again vibrated and then finished.

[0043] FIG. 6 shows the finished wall 10 with the cured concrete 90 about the panel 70. The form 50 is then removed from the wall 10 so the wall 10 is then ready to be ultimately used in the structure being created with the wall 10.

[0044] FIG. 7 shows the finished wall 10 separated from the form 50.

[0045] In regard to an alternative embodiment, the present invention pertains to a method for producing a wall 10. The method comprises the steps of positioning a 3D wire mesh panel 84 vertically at a desired location. The panel 70 has a core 72 with a 3D wire mesh matrix 74 extending through and out the core 72. There is the step of building a foam form 50 about the panel 70. There is the step of pouring a structural material between the panel 70 and foam form 50. There is the step of letting the structural material harden about the panel 70.

[0046] FIG. 8 shows the panel 70 being prepared to receive the uncured concrete 88. The core 72 is in the center with the wire mesh of the 3D wire mesh matrix 74 shown on the front side 12 and the rear side 14 of the core 72. The right side 22 of the core 72 is shown in FIG. 8. The front foam sheet 24 is adjacent to the front side 12 with a spacer 36 positioned between the front side 12 and the front foam sheet 24 and the rear foam sheet 26 is adjacent to the rear side 14 with spacer 36 positioned between the rear side 14 and the rear foam sheet 26. Bars 38 extend out from the front foam sheet 24, and also the rear foam sheet 26 (not shown). The bars 38 are used to attach the bracing 32 to the form 50 to hold the form 50 and the panel 70 together while the uncured concrete 88 is poured and then allowed to cure. The bars 38 extend through the foam sheets and the panel 70.

[0047] FIG. 9 shows a perspective overhead view of the panel 70 being prepared to receive the uncured concrete 88. The core 72 is in the center with the 3D wire mesh matrix 74 extending through the core 72 and on the front and rear side 14 of the core 72. In FIG. 9, the top side 16 and the rear side 14 of the core 72 are shown. There are spacers 36 disposed between the panel 70 and the front and rear foam sheets 26. The right end board 28 is shown in place along the right side 22 to close off the form 50 so no uncured concrete 88 and escape.

[0048] FIG. 10 shows a perspective right side 22 view of the panel 70 being prepared to receive the uncured concrete 88. Some of the bracing 32 is in place to hold the form 50 to the panel 70.

[0049] FIG. 11 shows a perspective view of the form 50 positioned about the panel 70 and held in place by bracing 32. The bottom side 18 of the panel 70 can rest on spacers 36 so uncured concrete 88 can flow under the bottom side 18 and cover the bottom side 18.

[0050] FIG. 12 shows a perspective view of the form 50 positioned about the panel 70 and held in place by even more bracing 32 than shown in FIG. 11.

[0051] FIG. 13 shows a finished wall 10 that is separated from the form 50 which is freestanding and positioned vertically.

[0052] FIG. 14 shows a perspective top view of the top side 16 of the panel 70 and form 50 after the uncured concrete 88 has been poured into the form 50 and has had time to cure.

[0053] FIG. 15 is an overhead view of the wall 10 separated from the form 50 with the concrete cured and showing the width of the wall 10 being 10 inches.

[0054] The wall 10 acts as a sound barrier due to the core 72. The wall 10 can be precast traditionally or onsite. Equipment required to move, and set would be significantly less due to the lower weight of the wall 10 compared to existing walls 10. Overall cost would be less due to overall concrete consumption. The wall 10 is used in general civil construction, such as office builds, large commercial applications, etc. In residential construction, the wall 10 may be precast utilizing the foam form 50 onsite. By keeping the foam form 50, its presence as part of the walls allows for even better insulation, and creates a base to apply brick, stucco, stone etc. This allows for less labor to form 50 and strip forms 50, added R value, better sound barrier, and in short, a lower cost to the end user in materials and labor cost.

[0055] Although the invention has been described in detail in the foregoing embodiments for the purpose of illustration, it is to be understood that such detail is solely for that purpose and that variations can be made therein by those skilled in the art without departing from the spirit and scope of the invention except as it may be described by the following claims.