Note: Descriptions are shown in the official language in which they were submitted.
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IMPROVED COMPOSITE CONCRETE AND FRAMING SYSTEM AND METHOD
FOR BUILDING CONSTRUCTION
10 BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to systems and methods of building construction and
more
particularly to systems and methods including a composite of concrete,
framing, and other
materials and structures.
2. Description of Related Art
Conventional building construction typically comprises three primary systems
and
methods: (1) wood stud construction; (2) concrete block construction; and (3)
concrete panel
construction. Wood stud construction system requires skilled carpenters to
assemble the
pieces and cut lumber according to structural drawings that require skilled
interpretation.
Concrete block construction, wherein the perimeter of a housing unit is
comprised of arranged
cinder blocks or concrete blocks in a structurally sound fashion, is slow to
put into place and
requires a large number of skilled masons to carry out effectively. Concrete
panel
construction, wherein pre-cast panels are put into place against or in
conjunction with a
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framing system, requires heavy equipment to lift and place the concrete
panels, as well as a
skilled work force to build the structure that provides the framing template
for the panels.
Accordingly, the development of better building systems for constructing low
cost,
efficient and easily built housing units has been slowed by the need for
skilled labor to
assemble the components required for the housing unit. In many locales,
skilled labor is in
short supply and/or prohibitively expensive which has restricted the ability
to construct low
cost housing units en masse, particularly in underdeveloped countries. Other
problems with
present building construction technology include the need to build housing
units at a low cost
and quickly, the ability to build housing units having a resilient
construction that does not
require a great deal of maintenance, is strong structurally, and provides
desired insulation from
the elements. Thus, in many countries, the aspirations of having modernized
housing units
have slowly waned.
Furthermore, present construction methods typically rely on steel stud frames
having
insulation sprayed or placed on the interior side of the stud wall. Such an
arrangement is not
as efficient as possible because heat can be conducted from wall surfaces
directly to the frame
elements, circumventing the surrounding insulation. Providing external
insulation, i.e.
insulation placed on the outside of the stud frame can be helpful, but to date
there has not been
a reliable means to applying such insulation. Further, insulation placed only
externally will not
provide sufficient heat and cold protection and therefore spray or roll
insulation will still have
to be provided on the inside wall. Thus, the construction can be rendered
expensive,
cumbersome, and labor intensive.
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Several attempts have been made at providing cheaper and more efficient
construction
methods, however none have adequately address the need for an easier to
assemble yet
structurally sound and insulative construction. For example, U.S. Patent
4,751,803 to
Zimmerman describes a construction method wherein precast concrete studs
having protruding
fasteners are used to build the framework of the walls of a structure. The
walls are assembled
in a horizontal plane and rigid sheet insulation is attached to concrete studs
and wire mesh is
laid upon the sheet insulation. Concrete is then poured onto the insulation,
the wire, and the
protruding fasteners to form a waterproof outer surface. Beams are bonded to
the studs. After
construction, the structure can be transported to the construction site and
assembled. The
patent also discloses a "jig" for assembling the structure. Thus, while
providing a means for
prefabricating building walls, Zimmerman relies on the use of a jig or form
mold in which
concrete is poured prior to transportation to the construction site. This
severely limits the
accessibility of the invention because the relatively heavy poured concrete
slabs are expensive
and difficult to transport to remote locations, particularly those where
affordable housing is
desired. Further, the complex stud framing structure renders the system
expensive to
manufacture and assemble. Finally, the system does not provide for both
internal and external
insulation of the walls.
U.S. Patent 5,522,194 to Grcmlich describes a planar building panel core
having two
faces coated with a cementitious material whereby the core is a closed-cell
foam insulation
board. A metal grid or lath is laid over the foam before the cement is
applied. The core panel
includes a plurality of spaced metal furring vertical channel members which
are fastened to a
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support structure and a steel reinforcing sheet spanning the face of each
panel, thus comprising a
frame surrounding the foam insulation board. Cement is applied over the metal
grid and the
foam board to result in a unitary construction panel. While providing a
relatively sound system,
this construction invention is flawed in that there is no means for
prefabricating any aspect of the
.. design and it requires extensive assembly of the frame elements around the
foam board during
construction of the system. Assembly cannot be complete using standard hand
tools by unskilled
labor. Further, the foam board is not disposed on the exteriors of the frame
and therefore the
structural rigidity and insulative properties are compromised.
Similarly, U.S. Patent 6,519,904 to Phi/lips describes a vertical reinforced
concrete wall
having a plurality of insulating panels horizontally spaced from each other
formed of a
polystyrene material. A pair of channel-shaped vertical side members are
fitted over the
respective side edges of the insulating panel during onsite installation. The
panels are then
mounted between a pair of opposed upper and lower channel-shaped track members
which
extend horizontally to define the upper and lowers ends of the vertical wall.
A wire mesh is
attached to the outside of the side members and horizontal members and
concrete is applied over
the wire mesh, insulation board, and framing members. Again, the complex
framing structure is
disposed around the foamboard and includes numerous interconnected parts which
renders the
system difficult to assemble and not amenable to affordable housing
construction by unskilled
workers. Finally, the construction method does not provide both internal and
external insulation
.. at the wall surface.
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In contrast, the present invention provides an improved building construction
system
and method designed to addressed the problems outlined above and provides a
systemized
product that provides housing for residential or commercial use, can be
economically
constructed, does not need high level and expensive skilled labor, is
extremely strong and
weather resistant, has excellent internal and external thermal insulation
capabilities, and
requires low maintenance. It is, therefore, to the effective resolution of the
aforementioned
problems and shortcomings of the prior art that the present invention is
directed. However, in
view of the building construction system and methods in existence at the time
of the present
invention, it was not obvious to those persons of ordinary skill in the
pertinent art as to how
the identified needs could be fulfilled in an advantageous manner.
SUMMARY OF THE INVENTION
The present invention provides a composite building construction system,
comprising:
a frame, wallboard, and a concrete layer. The wallboard comprises an outer
portion and inset
portion wherein the wallboard is attached to the frame with the outer portion
covering an
exterior side of the frame and the inset portion is disposed within the frame.
The wallboard
thus provides exterior and interior insulation for the system. The wallboard
may be attached
to the frame by an adhesive or by common fasteners. The concrete layer is
sprayed on to the
outer portion of said wallboard, forming a strong durable composite
construction system.
In some embodiments, one or more rebar supports are attached to the frame at
the
exterior side of said frame and are spaced apart from the wallboard. The rebar
supports are
secured to the frame by one or more key bolts which pass through the wallboard
and into the
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frame and are lockingly engaged with the frame. The frame may include key
holes with
correspond to the lock ends of the key bolts, which bolts may be secured by
inserting and
rotating them within the frame. A wire grid may be attached to the one or more
key bolts and
is spaced apart from the wallboard and the rebar supports whereby the grid and
the rebar
provide a support structure for the concrete layer. In some embodiments, the
concrete layer is
3 inches thick.
In some embodiments, the frame includes a plurality of outer framing members
and
one or more cross members. The inset portion of the wallboard includes one or
more channels
configured to accommodate the one or more cross members of the frame and thus
fit snugly
inside the frame. In some embodiments, the outer framing members and the one
or more
cross members include one or more apertures for the routing of electrical
wires or plumbing
and the apertures are adapted to receive conduits for protecting the
electrical wires and the
plumbing. The wallboard may also include channels to accommodate the conduits.
One or
more guide wires may be attached to the frame by key bolts at he exterior side
of said frame,
the guide wires spaced apart from said wallboard and adapted to indicate the
depth of the
concrete layer to be applied.
In some embodiments, the frame sections are manufactured using a computer
system
that prefabricates and codes the frame sections for easy assembly. The
interior side of the
frames is configured to receive drywall or other finishing material. In some
embodiments, the
frame comprises high tensile steel and the wallboard comprises expanded
polystyrene. The
wallboard may be dimensioned such that the depth of the inset portion is
greater than the depth
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outer portion of said wallboard. In any event, the wallboard provides
significant external and
internal insulation: a substantial advantage over the prior art.
A housing unit or building may be constructed by providing one or more frame
sections each prefabricated and coded according to a building plan. The frame
sections are
assembled together to form a housing structure. Then the wallboard is attached
to the frame
sections, the rebar supports and wire grid is attached to the wallboard, the
guide wire is
installed and then concrete is sprayed over the wire grid, rebar, and
wallboard until the
relatively thick concrete layer is formed. Optionally, the guide wire may be
used to indicate
the depth of the concrete to be applied. Once the concrete has been cured, it
can be finished
with paint, stucco, or other known housing unit finish materials. The interior
side of the frame
can be finished with drywall.
The structural integrity of the present construction system is greatly
enhanced due to
the relatively thick concrete layer applied to the wallboard-frame
combination. The
completely structure is capable of withstanding hurricane force winds,
earthquakes, and other
weather conditions whereby the structure exceeds national and local building
codes to that
effect. The present invention provides a substantial improvement over the
prior art with
respect to the simplicity and cost of construction, as it does not require
skilled laborers such as
masons, carpenters, and the like. The prefabrication and coding of the frame
sections
enhances the ease-of-build even more. More importantly, the expanded wallboard
provides
both internal and external insulation in a single easy to assemble piece which
also provides a
surface for adhesion to the concrete layer. The combined internal and external
insulative
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properties of the wallboard provide a significant advantage over known
building construction
systems and also provide enhanced modularity and ease of installation.
Accordingly, it is an object of the present invention to provide a
structurally sound and
insulative building construction composite.
It is yet another object of the present invention to provide a building
construction
system and method that does not require skilled labors to assemble and
construct.
It is yet another object of the present invention to provide a building
construction
system and method that includes a relatively thick concrete layer provide
substantial structural
rigidity at a decreased cost.
It is yet another object of the present invention to provide a building
construction
system and method that provides internal and external insulation without the
need for
insulation batting or spray insulation applications.
It is yet another object of the present invention to provide a building
construction
system and method that incorporates a unitary wallboard piece having an outer
portion for
.. external insulation and concrete adherence as well as an inset portion
received with the frame
for internal insulation.
It is yet another object of the present invention to provide a building
construction
system and method that utilizing locking key bolts received in frame sections
which allow for
the rapid assembly of rebar supports and wire guides to further enhance the
speed, accuracy,
and quality of the building construction system and method.
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It is yet another object of the present invention to provide a building
construction
system and method that can be assembled more quickly than typical construction
methods,
even with the use of unskilled laborers.
In accordance with these and other objects which will become apparent
hereinafter, the
instant invention will now be described with particular reference to the
accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded schematic of one embodiment of the building construction
system of the present invention.
HG. 2 is a cross-sectional cutaway view of one embodiment of the building
construction system of the present invention.
HG. 3 is a perspective view of one embodiment of the building construction
system of
the present invention.
HG. 4 is another perspective view of one embodiment of the system of the
present
invention.
FIG. 5 is a perspective view of one aspects of the frame and wallboard
configuration of
the present invention.
FIG. 6 is a perspective view of one embodiment of the wallboard of the present
invention showing the inset portion, outer portion, and channels.
FIGS. 7A-7C depict various embodiments of the key bolts and the key hold
engagement used with the frame of the present invention.
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FIG. 8 is a perspective view of another embodiment of the present invention,
utilizing
support arches useful for concrete application.
FIG. 9 is a schematic of a concrete layer being sprayed onto the
wallboard/frame in
accordance with the present system and method.
DETAILED DESCRIPTION
The present invention overcomes the disadvantages of the prior art by
incorporating a
combination of sprayed concrete onto an internal and external insulating board
which is
cladding a steel stud frame. With reference to FIG. 1, shown is an exploded
schematic of one
embodiment of the system of the present invention arranged and constructed in
accordance
with one embodiment of the method of the present invention. Shown is a
section, or a portion
of a composite construction system 1, comprising a frame 10, a wallboard 11, a
support grid
12, and a concrete layer 13. The system 1 is provided as a wall structure for
a building or
housing unit and will typically be assembled in sections as described in
detail below.
With reference to FIGS. 1 and 2, the wallboard 11 is secured to and disposed
on an
exterior side 101 of the frame 10. In some embodiments, wallboard 11 is
secured to frame 10
by an adhesive such as an epoxy or clue. In some embodiments, wallboard 11 is
further
fastened to frame 10 by one or more key bolts 30 received through wallboard 11
and
terminating within a portion of frame 10. A plurality of bolts 30 may be
provided through
wallboard 11 and into frame 10 to provide a secure attachment of the two
components.
Specifically, the bolts 30 may include eyelets that are configured to receive
and secure rebar
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support 14 and/or guide wire 15 which provide additional support and guidance
for the
application of the concrete layer 13, as discussed in further detail below. In
some
embodiments, the key bolts 30 are configured to lockingly engage pre-
fabricated key holes
provided in the frame 10 to allow for ease of installation, as further
described below.
However, other fasteners may be used instead of bolts, such as screws, nails,
staples, and the
like.
Also provided in some embodiments is the support grid 12 which is spaced apart
from
but attached to wallboard 11. Grid 12 may comprise a wire mesh grid, a rebar
grid, or similar
rigid grid that provides additional structural support for concrete layer 13.
In some
embodiments, grid 12 is attached to either rebar support 14 or one or more
bolts 30 by ties 35
which are received around both the grid 12 and either the rebar support 14 or
a bolt 30. Other
means of connecting the grid 12 may be employed, including brackets, screws,
bolts, staples,
and the like. In some embodiments, the wire grid 12 is disposed between the
wallboard 11
and the guide wire 15 such that the guide wire 15 is on the outside of the
system 1. The rebar
support 14 is disposed between the wallboard 11 and the grid 12. Further, it
is appreciated
that one or more rebar supports 14 may be provided, with corresponding bolts,
and the rebar
supports 14 may be disposed horizontally and/or vertically, or in a frame-like
manner around
the periphery of the frame 10.
In some embodiments, concrete layer 13 is sprayed over grid 12 such that the
concrete
adheres to wallboard 11 and has a thickness extending away from wallboard 11.
Grid 12
and/or rebar 14 provide structural support for the adherence of concrete layer
13 to wallboard
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11. In some embodiments, concrete layer 13 is applied in multiple thin-layer
applications in
order to assure adherence and structural rigidity with respect to wallboard
11. The guide wire
15 is disposed across the wallboard and may provide guidance during the
application of the
concrete layer 13, i.e. to delimit the desired depth of concrete layer 13
application. As
depicted in FIG. 2, concrete layer 13 is applied such that grid 12 and rebar
14 is disposed
within the concrete layer 13; or, said differently, concrete layer 13 is
disposed on either side of
grid 12 and/or rebar 14 and, in many cases, will be disposed through grid 12
wherein grid 12
includes interstitial gaps 121 (FIG. 1) by way of its grid configuration. In
some embodiments,
it is preferred that concrete layer 13 have a thickness of approximately 2-3
inches extending
from the wallboard however the thickness may vary depending on the desired
application and
building plan. The grid 12 provides support for and catches the concrete layer
13 during
application to prevent the concrete from sliding down the wall surface. The
rebar supports 14
provide structural reinforcement once the concrete layer 13 has set. In FIG.
2, it is appreciated
that the guide wire 15 provides a designation of the depth of concrete layer
13 to be applied.
In some embodiments, the guide wire 15 will be flush with the outer edge of
the concrete layer
13. However, for illustrative purposes in FIG. 2, the guide wire 15 is shown
to be contained
inside the concrete layer somewhat ¨ such a configuration is not required nor
should the depth
of the concrete layer 13 and relationship to guide wire 15 be limited to that
shown in FIG. 2.
In some embodiments, the stud frame 10 of the present invention is constructed
through use of a fabricating machine which forms the studs from coiled metal
(steel,
aluminum, and the like) and marks the components with coding to allow for
quick, easily
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assembled construction by workers who do not need high level construction
skills, rather they
need only to match the markings for assembly. FIG. 4 shows an example of one
section of
frame 10 shown having a generally square or rectangular shape. Shown is frame
10 from the
perspective of interior side 102 with wallboard 11 attached to the exterior
side of frame 10.
Frame 10 may include outer framing members 103 and one or more cross members
104,
which functions as studs, providing a riding structural support system for
building
construction.
Wallboard 11 comprises an insulative material and is configured to provide
both
external and internal insulation for the construction system in a unitary
piece. As shown in
Figures 1, 2, 4. 5 and 6 wallboard 11 is configured as having an outer portion
111 and an inset
portion 112 wherein the inset portion 112 is configured to be received within
the interior
cavities 140 of the frame 10 and the outer portion is disposed on the exterior
side of the frame
10. In some embodiments, the inset portion 112 and the outer portion 111 are
unitary and
integral, constructed homogenously as wallboard 11. The outer portion 111
provides external
insulation and provides a surface for the concrete layer 13 to adhere to. The
inset portion 112
provides internal insulation and adds rigidity to construction system 1 once
assembled. In
some embodiments, the inset portion 112 is deeper than the outer portion 111,
for example the
inset portion 112 may have a depth of 2 inches extending into the frame 10
whereas the outer
portion 111 has a depth of 1 inch extending outward from the frame 10.
In some embodiments, the inset portion 112 includes one or more channels 113
which
are configured to accommodate the cross members 104 of the frame 10. This
allows the inset
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portion 112 wallboard 11 to fit snugly and securely within the internal
cavities 140 of frame
with minimal movement, which eases construction and assembly and provides
added
rigidity and stability to the construction system 1. FIG. 5 demonstrates the
configuration of
the outer portion 111 and inset portion 112 of wallboard 11 as well as the
fitment of same
5 inside the internal cavities 140 of frame 10 by way of channels 113. FIG. 6
shows the
wallboard 11 along, with outer portion 111, inset portion 112, and channels
113. It is
appreciated that the relative thickness of outer portion 1 1 1 and inset
portion 112 can vary
depending on the desired application and desire structural and insulative
properties. Further,
the configuration, size, and shape of the channels 113 can vary depending on
the configuration
10 of frame 10. Accordingly, the present invention is not limited to the
configurations shown in
the figures.
In some embodiments, the framing members 103 and 104 include one or more
apertures 105 punched there-through. The apertures 105 are configured to
receive and channel
electrical wiring, plumbing, and the like. In some embodiments, conduits 106
are provided
through apertures 105 and provide protection for wiring or plumbing passed
there-through. As
shown in FIG. 4, in some embodiments the inset portion 112 of wallboard 11 has
a depth that
accommodate and does not block apertures 105 and conduits 106, which conduits
are adjacent
to the inside surface of the wallboard 11. In other embodiments, it may be
desired for the
depth of inset portion 112 to be somewhat deeper where it would otherwise
cover up or block
the apertures 105. However, in this case, additional channels 113 can be
provided which align
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with apertures 105 and therefore accommodate conduits 106 similar to how the
channels 113
accommodate the cross members 104 of frame 10.
In some embodiments, the inside of the frame 10 at interior side 102 of frame
10 may
receive and contain insulation material 107 which may be poured, sprayed, or
applied in sheets
or rolls thereto. In some embodiments, the insulation will be applied to the
back of inset
portion 112 of the wallboard 11, which is disposed within the frame 10.
However, insulation
material 107 may not be necessary in situations and climates where the
wallboard 11 with
inset portion 112 provides sufficient insulation. Accordingly, the material
selected for
wallboard 11 may vary depending on desired insulative characteristics as
further discussed
below. Additionally, the depth of inset portion 112 of wallboard 11 can be
increased in order
to increase its ability to insulate, depending on the desired application and
installation.
It is further appreciated that the interior side 102 of frame 10 is typically
the side facing
the inside of the particular building or home and the exterior side 101 (which
receives
wallboard 11, grid 12, and cement layer 13) is the exterior of the building or
home. The
interior side 102 may be finished with typical interior wall material such as
drywall,
plasterboard, sheet rock, and the like.
The result of the present invention is a combined building or housing frame 10
structure covered with an insulating exterior wallboard 11 to which a sprayed
concrete layer
13 has been applied. Each frame 10 as described above comprises at least a
portion of a wall
of a building or housing structure. This configuration provides substantial
strength and
durability and exceeds typical hurricane, earthquake and other weather
strength rating
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requirements presently used throughout the world. This enhanced strength is
achieved
primarily due to the relatively thick concrete layer 13 combined with the
rigid frame 10 and
further combined with the extended-depth wallboard 11 which provide internal
insulation at
the frame. In accordance with the present invention, a housing unit can be
assembled in a
matter of three or four days rather than months by utilizing the building
construction system
and method of the present invention; minimal skill is needed by the assembly
crews and
fabrication can be customized to meet local codes, plumbing and electrical
requirements. Most
single family units are anticipated to be in the twelve hundred to fifteen
hundred square feet of
living space. The units can be built as independent units or in multiple
family configurations
and, in that sense, the particular size and configuration of a given housing
unit built in
accordance with the present invention is not limiting.
To further enhance the ease of assembly of the construction system 1 of the
present
invention, the frame 10 is configured to lockingly receive a plurality of
bolts 30 having various
configurations. In some embodiments, the bolts 30 are received in flanges of
the frame 10 at
various points along the frame 10 as desired for the particular application.
With reference
back to FIG. 1, shown are two sets of bolts 30 wherein the first set is
configured to receive and
retain a rebar support 14 and a second set is configured to receive and retain
a guide wire 15.
With reference to FIGS. 7A-7C, shown are various embodiments key hole/key bolt
30
configuration of the present invention. FIG. 7A depicts one embodiment of a
key bolt 30
configured as a stud screed bolt. The proximal end of the bolt 30 includes a
bow-tie or
bubble-like male connector 31 and the distal end includes a receiving eyelet
32. A bolt flange
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33 may be provided proximal to the male connector 31. In this embodiment, the
receiving
eyelet 32 is relatively small and is configured to receive guide wire 15. FIG.
7B depicts
another embodiment of a key bolt 30 configured as a support bolt. The proximal
end includes
a bow-tie or bubble-like male connector 31 and the distal end includes a
receiving eyelet 32.
Again, a bolt flange 33 may be provided proximal to the male connector 31. In
this
embodiment, the eyelet 32 is somewhat larger and is configured to receive and
engage a rebar
support 14.
As shown in FIG. 7C. frame 10 may include one or more flanges 301 which may
comprise stamped or bent portions of the frame 10. One or more key holes 302
are provided
through flanges 301 and provide a point of entry for the male connector 31 of
key bolts 30. In
some embodiments, a key bolt 30 passes through wallboard 11 and into the key
hole 31 of
frame 10 and is then rotated 90 degrees such that the male connector is
lockingly engaged with
the flange 301 of frame 10. The key hole 302 ¨ key bolt 30 arrangement
provides a simple
and easy to operate means of attaching rebar and guide wire to the frame 10,
which provides
added support and concrete application guidance for the construction system 1.
It is
appreciated that the key holes 302 could be provided anywhere on the frame 10
and do not
necessarily have to be on the flange 301. Further, with reference back to
FIGS. 1-4, it is
appreciated that two or more key bolts can be used in conjunction to support a
rebar support
14 and/or a guide wire 15. In some embodiments, the key holes 302 are provided
at
equidistant points along the frame 10 and the key bolts 30 are provided
therein such that the
weight of the rebar 14 and/or guide wire 15 can be equally supported along the
frame.
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It is further appreciated that, in some embodiments, the length of the key
bolts 30
utilized for the guide wire 15 are substantially longer than the length of the
key bolts 30 used
support the rebar 14. This configuration allows the guide wire 15 to extend
well beyond the
wallboard 11 surface in order to delineate the maximum depth or thickness of
concrete layer
13 to be applied. Accordingly, a variety of varying length key bolt 30 for
guide wire 15 can be
utilized to provide a guide for various desired depths of the concrete layer
13.
The wall configuration, square footages, windows, doors, electrical, plumbing,
ventilation and other requirements are placed into a take off for analyses by
a computer
software program for calculation of number of feet needed for frames 10, frame
10 dimensions
and placement, cut outs for placement of plumbing and electrical wires,
placement of
windows, doors and ventilation needs, as well as sizing to meet local and
national codes and
best practices for the location where the homes are going to be built. The
result of the multi-
stage analyses is a computerized output of frame 10 requirements that can be
fed into a frame
fabricating machine. The frame fabricating machine then can produce the frames
10 in
sections, including the cross-members and outer members needed for the
construction of the
unit. The frames are typically fabricated from rolled coils of sheet metal
material such as steel
or aluminum but may also comprise wood or other materials as suitable for the
particular
application. In some embodiments, a steel frame section having a 3-inch
concrete layer
applied thereto is capable of withstanding at least 50,000 psi of pressure and
therefore is
preferred as a weather-rated material in certain applications. As the entire
frame structure is
fabricated typically in discrete sections, the frame sections are marked at
each end with a
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coding number. Headers and sills are likewise marked with numbers at all
locations where
they will interact with the frame sections or any bracing pieces, cross-
members, and the like.
Typically, the frame 10 sections are produced in the order of assembly, so
that the pieces are
assembled in the order of fabrication.
When constructing an actual building, the unit's foundation and base is
prepared,
which may be concrete slab or a framed structural deck that can be covered
with wooden
boards, insulated boards or other decking materials, which optionally can be
covered with
concrete spray material and troweled. The walls of the building or housing
structure are
provided as frame 10 sections in accordance with the present system and method
are typically
assembled flat on the ground using screw drill guns that fasten the frames to
headers, sills or
other reinforcing pieces. When the wall's exposed side is completed in
assembly, it is tilled up,
screw drilling the frame 10 sections together until completed and the wall put
into place. By
repeating this process, each wall of the building or housing unit is assembled
and may
comprise one or more sections of frame 10. The workers only need to match the
markings on
the end of the frame sections and other components to correctly assemble the
walls or other
structures. After the walls are standing, a header assembly, if needed, can be
installed to give
stability to the wall panels, and the roof trusses can be placed. Roof trusses
are assembled in
the same manner as the wall units.
The exterior sides 101 of frames 10 are then covered with the wallboard 11,
therefore
providing internal and external insulating properties, which inset portion 112
of the wallboard
11 is received in the cavities 140 of the frame 10. The wallboard 11 may be
secured to the
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frame 10 by an adhesive, epoxy, or the like. The wallboard may be further
affixed to the
frame 10 sections with fasteners and/or, in some embodiments, key bolts 30 may
be provided
through the wallboard therefore providing two purposes (1) provide additional
fastening of the
wallboard 11 to the frame and (2) provide a means to attach rebar 14 and/or
guide wire 15 to
the assembly. If rebar supports 14 are desired, the supports are provided into
the eyelets of the
one or more key bolts 30. Grid 12 may be then fastened to the bolts 30 or the
rebar 14 by wire
ties 35, whereby the grid 12 helps with the application of concrete layer 13
and adds tensile
strength to the concrete layer 13. If a guide wire 15 is desired, it is
secured through the eyelets
of one or more key bolts and thus the guide wire 15 may define the depth of
concrete layer 13
to be applied over the wallboard 11. It is appreciated the wallboard 11 is
configured with
channels 113 that match the configuration of the frame 10, including any cross
members 104
and conduits 106 as desired.
The concrete layer 13, in some embodiments, is applied by a spraying
application and
depicted in FIG. 9. Multiple thin layers of concrete may be applied until the
concrete layer 13
has a suitable thickness, for example 2-3 inches. In some embodiments, the
guide wire 15
designates the depth of the concrete application. It is desirable for the grid
12 and the rebar 14
to be located substantially in the middle of the concrete layer and thus the
grid 12 and rebar 14
are spaced apart from the wallboard 11 and the final outer wall surface of the
concrete layer
13. Once the concrete layer 13 has cured, the housing structure is formed and
finishing can
take place. Roof frame 10 sections may be constructed in a similar manner but
would
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typically be covered with a roofing material of choice as wallboard 11,
preferably a material
that provides good water resistance and good insulation.
With reference to FIG. 8, to further assist in the concrete layer 13
application and
particularly with respect to multiple story or multiple level applications,
one or more support
arches 70 may be secured to one or more bolts 30. The arches 70 may comprise
strips of metal
or other rigid material and have a width that extends outwardly from the
surface of the
wallboard 11. The arches 70 may be disposed between the wallboard 11 and the
wire grid 12
and are provided in order to catch the concrete layer 13 during the spraying
application. The
geometry and location of the arches 70 is not limited, and other similar
strips may be provided
on the wallboard 11 to effectuate this purpose.
The wallboard 11 may comprise a variety of building construction materials
known in
the art and is particularly useful because it provides both external and
internal insulation in a
single, easy to install piece. ln some embodiments, the wallboard 11 comprises
a suitable
expanded polystyrene material providing insulative properties. In some
embodiments. the
wallboard 11 comprises what is known in the art as "blueboard" which is
configured to accept
and react with the cement layer 13 for optimal adhesion and durability. Other
foam-like
materials may be utilized as wallboard 11 and such materials may be chemically
treated to
accept adherence of cement. As is known in the art, "blueboard" is typically a
foam-board
insulation material comprising polyisocyanurate, extruded polystyrene,
expanded polystyrene
foam, and combinations thereof. The wallboard 11 material may be selected
according to its
"R-value" or thermal resistance value and may preferably have an R-value
between 4.5 and
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5.0, which is typical of blueboard known in the art. However, in some
embodiments the
wallboard 11 comprises primarily expanded polystyrene which may have an R
value of 12 or
greater, depending on the overall thickness. Such an R-value provides a
significant
improvement over typical construction methods. It is appreciated, that other
materials
including composite styrofoam, foam and foam-like boards known in the art are
contemplated,
provided they have improved insulation, strength, and plaster/cement adherence
characteristics. In any event, it is appreciate that the present invention
provides a significant
advantage over the prior art because the wallboard 11 provides both internal
and external
insulation as well as providing a surface for the concrete layer 13 to adhere
to.
The application of the concrete layer 13 is quickest and most efficient when
sprayed, as
shown in FIG. 9. The concrete mix can be customized with additives to get
better adherence to
the wallboard 11 and can be adjusted as to drying time. Further use of
elastomeric additives to
the concrete reduces cracking of the concrete surface, and helps in creating a
watertight
envelope. The thickness of the concrete is a function of the strength desired
and for
commercial type installation it may be increased.
As mentioned above, interior walls can be covered with typical drywall
materials and
if additional insulation is desired it can accomplished by using blown in
insulation, batting, or
board type, installed on the interior side 102 of the frame 10. However,
additional insulation
is not necessary in most instances because of the substantial external and
internal insulative
properties of the extended wallboard 11. The exterior concrete, after curing,
can be painted or
finished with a finishing material such as stucco to provide the desired
appearance. When
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constructing multiple identical units, the product can be quickly assembled
and made ready for
use. The method of construction of the units consists of fabricating the
frames, marking the
frames, assembling the frames in the walls, trusses and assemblies, covering
the exterior walls
with the wall board, adding the grid to the exterior surface of the wall
board; spraying the
exterior with wall board with the desired amount of cement; allowing the
concrete to cure. By
following these steps a very strong structure for an affordable quickly built
housing or
commercial units is obtained.
The combined concrete, with board and frame structure creates a composite
structure
with unexpected strong properties to resist earthquake, hurricane and other
disruptive effects
as well as provide incredible internal and external insulative properties for
the given weight
and cost of the materials. The final product has superior strength for a
housing unit that can be
quickly and economically constructed with a labor for having minimal skill
sets. There are
numerous variations that can be employed with respect to the materials
selected in order to
meet the local conditions and to accommodate the need being addressed.
The instant invention has been shown and described herein in what is
considered to be
the most practical and preferred embodiments. It is recognized, however, that
departures may
be made therefrom within the scope of the invention and that obvious
modifications will occur
to a person skilled in the art.
