Note: Descriptions are shown in the official language in which they were submitted.
iO80501
BACKGROUND OF THE INVENTION
(a) Field of the Invention
The present invention relate~ to an exterior wall
composition for building structures and a method of making
same and more particularly a wall composition wherein con-
crete is sprayed on an inner wall mem~rane which is secured
to a lattice framework of load bearing steel studs.
(b) Description of Prior Art
Various types of wall structures are known utiliz-
ing concrete. Some of these wall structures are formed by
precast concrete slabæ interconnected together and an insul-
ating layer i9 then adhered to an inner face of the slabs
with a finish board material secured thereover. The con-
crete ~labs are usually held together by steel inserts ,
provided at strategic locations cr else the slabs are formed
with joints which intermesh with joints of adjoining sla~s
to interlock. Open joints are then grouted and a seal is
formed by applying a sealing compound. A disadvantage of
such methods is that it is required to make the concrete
slabs at a remote factory and transport these on site.
Also, large machinery is required to erect the concrete
component parts of the structure. A further disadvantage
is that the inside finishing of such structures is complex
requiring the securement of struts to set concrete. Further-
more, molds are required to make the concrete slabs.
Other concrete wall compositions are known where
concrete is poured within a form which is erected on site.
A disadvantage of this type of wall construction is that
form work is required which is an expensive and time con-
suming operation, Further, an inner and/or outer finished
wall must be constructed after the forms are removed once
the concrete has set.
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SUMMARY OF INVENTION
It is a feature of the present invention to
provide an exterior wall composition for building struc-
tures and a method of making same which is an improvement
over existing prior art concrete wall structures and methods
of making same.
According to the above feature, from a broad
aspect, the present invention provides an exterior wall
composition for building structures having a lattice frame-
work of rigid wall structural members. At least some ofthe wall structural members have inner and outer attach-
ment means. An inner wall membrane is secured to at least
some of the inner attachment means of the wall structural
members to define an inner wall having a finished outer
wall surface. A sprayed layer of insulating material is
provided on the inner face of the inner wall membrance bet-
ween the structural members. A reinforcing material layer
having interstices is secured to at least some of the outer
attachment means to define an outer reinforcing wall mem-
brane. A first sprayed layer of concrete material is sprayedon the insulating material and extends outwardly of the re-
inforcing material layer and cured thereon whereby the wall
structural members are completely embedded between the first
sprayed layer of concrete material and the inner wall mem-
brane. A second thinner layer of concrete material contain-
ing a bonding additive is sprayed on an exterior surface of
the first layer to constitute an outer wall surface.
According to a further broad aspect of the present
invention, there is provided a method of making an exterior
wall for building structures. The method comprises the steps
of forming a lattice framework of rigid wall structural mem-
bers with at least some of the members having inner and outer
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attachment means. An inner wall membrane is secured to the
inner attachment means of the structural mem~ers to define
an inner wall having a finished outer wall surface. A layer
of insulating foam material is sprayed on an inward face
of the inner wall membrane between the structural members. A
reinforcing material layer having interstices is secured to
the outer attachment means to define an outer reinforcing
wall membrane. A first layer of concrete material is sprayed
on the insulating material through the interstices with the
layer of concrete extending outwardly of the reinforcing
material layer. The first layer of concrete material is
cured for a period of at least about 12 to 24 hours. A second
thinner layer of concrete material having a bonding additive
is sprayed onto the first layer to form an outer wall surface.
The concrete material has a compressive strength of from
about 3,000 p.s,i. to about 10,000 p.s.i.
BRIEF DESCRIPTIO~ OF DRAWINGS
A preferred embodiment of the present invention
will now be described with reference to the accompanying
drawings which are examples thereof and wherein:
FIGURE 1 is a cross-section view of the exterior
wall composition,
FIGURE 2 is a cross-section view of a modifi-
cation of the wall composition of
Figure 1, and
FIGURE 3 is a cross-section view of a still
further modification of the wall compo-
sition of Figure 1.
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DESCRIPTION OF PREFERRED EMBODIMENTS
Referring now to the drawings and more parti-
cularly to Figure 1, there is shown generally at 10 the
exterior wall composition of the present invention. The
wall composition comprises a lattice framework constructed
from a plurality of rigid wall structural members 11, herein
con~tituted by load bearing galvanized steel studs of
generally U-shaped configuration. The studs 11 are spaced
vertically along a wall every sixteen or twenty-four inches,
as is customary in wooden frame building structures, whereby
to receive joints of building material every four feet and
to provide a securement means every sixteen or twenty-four
inches.
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The load bearing steel ~tuds 11 each define, in
cross-section, an inner flange 12 and an outer flange 13
fonmed integral and interconnected by a tran~verse web 14.
The inner and outer flangec 12 and 13 respectively, con-
stitute attachment means, as will be descri~ed later.
Although the studs are herein shown as being of U-shaped
cros~-section, other cross-sections are possible to provide
~uitable attachment mean~ and interconnection among them-
selves. Al~o, the interconnection of the studs in the
lattice framework may be done by welding, bolting or other
suitable fa~tening means well known in the art,
An inner wall membrane 15, herein constituted by
gyproc type sheeting, or other suitable material, is secured
to the inner flange 12 of the studs 11. The inner wall
membrane 15 has an outer finished surface 16 and an inner
surface 17. me membrane 15 is secured to the flange 12 by
suitable means, such as self-drilling and tapping screws 40 ~ ,-
as shown in Figure 2.
A layer of insulating material 18 is sprayed and
adhered on the inner surface 17 of the membrane 15. The
insulating material may be urethane insulation or other
type insulation which can be sprayed. Alternatively,
although not preferable, the insulating layer 18 may be of
rigid ~heet-like form and cut and attached to the inner
surface 17 of the membrane 15. As shown, the insulating
material extends between adjacent studs 11 in the lattice
framework, where a solid wall is required.
A reinforcing material layer, herein a galvanized
wire mesh 19 having interstices (openings) therein is
secured over the solid wall area and attached to the outer
flange 13 of the studs 11 by suitable fastening or attach-
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ment means (not shown). A first layer 20 of concrete
(gunite) material 21 is sprayed onto the back face 22 of
the insulating material 18 through the interstices in the
galvanized wire mesh 19 and extends just beyond the wire
mesh 19. Thus, the outer skin of the first layer 20 is
reinforced by the galvanized wire mesh 19 to provide a
reinforced outer surface to substantially prevent cracking,
particularly in the area of the studs 11. After the first
layer 20 is cured, a second layer 22 of concrete (gunite)
material 21 i~ Aprayed over the first layer 20. The second
layer 22 of the concrete 21 includes a suitable bonding
additive such as that identified by the registered trade-
mark "Sika Top" of the Sika Company. Further, the concrete
material 21 i9 preferably of a compressive strength of
from about 3,000 p.s.i. to about 10,000 p.s.i. An outer
layer 23 of stucco-type finish or painting is added to the
outer surface 24 of the second layer 21 to create a
desired exterior finish for the building. Further, expan-
sion joints 25 are made in the concrete to conceal and
control cracking of large concrete spans. A suitable seal-
ing material 26 is inserted in the expansion joints 25.
Preferably these expansion joints are made in alignment with
some of the stud members. -
As can be seen in Figure 1 the studs 11 are
embedded between the outer wall surface layer 23 or 22 and
the inner wall membrane 15.
Referring now to Figure 2, there is shown a modi-
fication of the embodiment of Figure 1 and wherein an in-
sulating thermal barrier membrane 41 is secured to the
inner surface 17 of the membrane 15 or to the studs 11 under
the membrane 15. Such a thermal barrier 41 may be provided
1080501
depending on the climatic condition where the building
structure is located. Also, as shown in Figure 2, the
inner flange 12 provides the attachment means for the self-
drilling screws 40 which secure the inner wall membrane 15
thereto. Also, as ~hown the joint of the gyproc boards
15 are taped with perforated tape and jointing compound 42
is applied to conceal the joint and to form a smooth wall
surface which can then be finished with either paint, wall-
paper, ceramic tiles, wood panelling or whatever material
i5 d0Sired.
The method of making this exterior wall compo-
sition 10 does not require expert skills, uses known
material and permits quick erection. To erect a building
structure the floor slab is firstly poured with necessary
service~ included therein, The exterior wall composition
10 is essentially a solid insulated concrete-steel panel
assembled on site. Firstly, the basic lattice fræmework
of load ~earing steel studs 11 is shipped to the site pre-
cut to the proper lengths and assembled on site by suit-
able means such as welding. The steel stud lattice frame-
work is attached to the base slab (not shown) by means of
low velocity steel studs driven into the concrete with
gun powder. After the lattice framework has been assembled
; with door, window openings, etc. the inner wall membrane 15
is secured to the inner side of the studs 11 over the area
where the solid wall is required. The insulating material
18 is then sprayed over the inner surface 17 of the membrane
15 to a desired thickness depending on the insulating
property required. Of course, the width of the studs 11
depends on the thickness of the wall required for the
particular building structure.
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The next step in the process is to secure the
galvanized wire mesh 19 to the outer flange 13 of some of
the studs whereby to hold the wire mesh sheet in place over
the area where a solid wall is required. The first layer
20 of concrete ~gunite) is applied to the desired thickness,
in thi~ particular example 2 1/4 inch, and is sprayed through
the interstices of the wire mesh and against the backface
22 of the insulating material 18. After a curing and set-
ting time of from about 12 to 24 hours, a second layer 22
of concrete, herein approximately 3/4 inch in thickness,
is sprayed and wood-float finished onto the first layer 20.
The second layer of concrete contains a chemical additive
to assure a good bonding and to eliminate cracking in the
final surface. Of course, under ideal climatic conditions
and with suitable concrete aggregates it is possible to
utilize only one concrete layer 21. An outer stucco-
finish 23 may then be applied to the second finish, if
desired. This outer coating 23 may also be coloured or
patterned, if desired.
Of course, all suitable conduits for wiring or
plumbing is installed within the lattice framework before
installing the inner wall membrane 15. Additionally, the
insulating thermal barrier 41 may be applied to the inner
surface 17 of the membrane 15 prior to the step of spray-
ing the urethane insulation 18, if desired.
Referring now to Figure 3, there is shown a still
further modification of the embodiment of Figure 1 and
wherein the inner wall membrane 15' is constituted by an
outer layer of gyproc 15'` and an inner layer 18' of
rigid insulating foam material. This membrane 15' is
secured by suitable fasteners to the inner flange 12 of the
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~081~501
structural members 11 by ~uitable fasteners. A~ shown,
with this type of membrane construction the structural
members 11 may be of smaller width resulting in a material
cost saving, Further, there is less labour content in the
fabrication of the wall as the insulation layer 18' is
already part of the membrane. The concrete (gunite)
material 21 i9 sprayed in the usual manner and extends
beyond the wire mesh 19. The exterior surface of the con~
crete wall is finished as described above with reference
to the other Figure,
It is within the ambit of the present invention
to provide any obvious modifications of the examples of
the pre~erred embodiment as illustrated ~y Figures 1 and 2
herein, provided such modifications fall within the scope
of the broad claims appended hereto.
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