Method of forming concrete walls for buildings

[0002] This invention relates to a method of forming vertically extending concrete walls for buildings from concrete applied pneumatically.

[0003] U.S. Pat. Nos. 4,970,838; 5,033,248; and 5,335,472 are directed to a method for forming concrete walls for buildings from concrete applied pneumatically and utilizing a plurality of prefabricated modules. The prefabricated modules are constructed offsite and transported to the construction site. An outer rectangular frame is fitted about a layer of insulating material with wire mesh material secured to the frame on opposed sides of the insulating material to form the prefabricated module. The prefabricated rectangular modules are mounted on site with the outer metal frame positioned between upper and lower channel-shaped support members defining the upper and lower ends of the walls. Concrete is applied pneumatically against the modules with an outer layer of concrete being about two or three inches in thickness. Reinforced concrete columns are formed between adjacent modules. Concrete may be applied pneumatically to the interior of the wall or, if desired, wallboard may be secured to the interior surface of the modules. Each prefabricated module thus has an outer rectangular metal frame extending about its entire outer periphery.

[0004] The present invention is directed to a method of forming a concrete wall for buildings in which the wall is formed entirely on site without the use of prefabricated modules. As a result, a prefabricated rectangular frame about the entire periphery of the insulating member, such as polystyrene, is not required.

[0005] The wall is formed between a lower channel-shaped base plate and an upper channel-shaped top plate. First, the insulation layer preferably formed of polystyrene is pre-cut for fitting between the upper and lower channel-shaped horizontal support plates. Metal side frame member or studs, preferably formed of aluminum have a channel shape with inturned lips or tabs extending inwardly from the flanges of the channel-shaped side frame members. The inturned lips are snapped about opposed sides of the insulation panel to form a unit. Next, the unit of an insulation layer and opposed side frame members are fitted between the upper and lower channel-shaped metal support plates and secured therebetween by metal screws through adjacent flanges of the plates and frame members. A plurality of such units may be mounted between upper and lower channel-shaped plates horizontally spaced about eight (8) inches from each other and reinforced columns are formed in the space between adjacent units. For this purpose, a small mesh screen having openings about {fraction (1/16)}th inch in width is secured to flanges of adjacent units to form a backing for the pneumatically applied concrete. If desired, wallboard panels may be secured to the interior surface of the insulation panel to form the interior surface of the wall.

[0006] It is an object of the invention to provide a concrete wall for a building which may be installed in a minimum of time with minimal cost.

[0007] Another object of the present invention is to provide a construction unit for walls which is assembled on site to receive pneumatically applied concrete.

[0008] Further objects, features and advantages of the invention will be apparent from he following specification and drawings.

[0009] FIG. 1 is a vertical section of a portion of a vertical wall for a reinforced concrete building utilizing construction members which are fabricated on site for the vertical wall of the building;

[0010] FIG. 2 is perspective view of a front portion of the reinforced concrete building in FIG. 1 showing two spaced units having a column therebetween with concrete on one side of the unit and a drywall panel on the other side, the concrete being broken away to show various construction members;

[0011] FIG. 3 is a section taken generally along the line 3—3 of FIG. 2;

[0012] FIG. 4 is a sectional view similar to FIG. 3 but showing a metal plate instead of a wire screen to provide a backing for the concrete column;

[0013] FIG. 5 is an exploded view of the construction members showing a wall unit being formed on site for installation between a pair of upper and lower channel-shaped support plates;

[0014] FIG. 6 is a perspective view of a rear portion of the reinforced concrete building with wallboard broken away to show nailing strips for the wallboard defined by channel-shaped members;

[0015] FIG. 7 is a section taken generally along line 7—7 of FIG. 6; and

[0016] FIG. 8 is a section taken generally along line 8—8 of FIG. 6.

[0017] Referring to the drawings for a better understanding of the invention, a reinforced concrete building as shown particularly at 10 includes a lower concrete floor slab 12 supported by a footing or pier 14. A vertical wall as shown generally at 16 and a roof as shown generally at 18 including a gable 20. Horizontally extending joist 22 extends between walls of the building 10. A wooden nailing member 23 is provided adjacent the outer end of joist 22. A wooden strip 25 is provided on a ledge of foundation 14 to provide a bottom edge for the concrete of vertical wall 16.

[0018] Side wall 16 is formed of a pair of units 24 which are inserted between channel-shaped upper frame track member 26 and lower channel-shaped track frame member 28. Track members 26 and 28 have flanges 29. Each unit 24 is formed on site before units 24 are positioned between upper and lower horizontal track member 26 and 28. Each unit consists of an insulation panel or layer 30 formed of a foam material, such as polystyrene, and opposed vertical side members 32 and 34 as shown particularly in FIGS. 5 and 7. Each vertical side member 32 and 34 is formed of a channel-shape having a body 36 and side flanges 38. Each flange 38 has an inturned lip or tab 40 which bites into foam panel 30 when side members 32 and 34 are pressed into engagement with a vertical side of insulation panel 30 thereby to retain vertical side members 32 and 34 in position on insulation panel 30. Units 34 are positioned and secured between upper and lower horizontal frame members 26 and 28 in horizontal spaced relation to each other to provide a column 42 between opposed vertical side members 32, 34 of adjacent units 24 as shown in FIG. 2. Cutouts or openings 43 are provided in flange 38 for the flow of concrete to provide a bond for the concrete column 42. Flanges 38 of vertical side member 32 are secured to flanges 29 of track members 26 and 28 by suitable screw fasteners shown at 33.

[0019] A wire mesh layer generally indicated at 44 is composed of connected wire members 46 to form four inch by four inch openings. Wire mesh layer 44 is mounted on flanges 29 of upper and lower horizontal track members 26 and 28, and flanges 38 of vertical side members 32 and 34 by suitable staples.

[0020] To form concrete column 42 between adjacent ends 24, a pair of reinforcing bars 48 extend from foundation 14 as shown particularly in FIG. 2. Intermediate reinforcing bars 49 are connected thereto and are bent at their upper ends to form end portions 33 as shown particularly in FIG. 1 and intermediate reinforcing bars 49 extending therefrom extend through suitable openings in upper track member 24 and are bent to form end portions 33 of the roof 18. A screen wire backing 50 as shown particularly in FIG. 3 has openings about {fraction (1/16)}th inch in width and is secured to flanges 38 of vertical members 32 and 34. The openings in wire screen backing 50 are filled immediately with concrete upon the pneumatic application of concrete to prevent or minimize any blow through of concrete. If desired, a solid plate 52 as shown in FIG. 4 may be substituted for screen wire backing 50 and likewise may be stapled to flanges 38 of vertical side members 32 and 34.

[0021] Wallboard panels 54 are shown as mounted on the inner surface of wall 16 and are secured to flanges 38 of vertical members 32, 34 and flanges 29 of horizontal track members 26 and 28 by suitable staples or nails. In addition, foam material 30 of each unit 24 has a separate nailing strip 56 comprising a channel-shaped member similar to track members 26, 28. Nailing strip 56 as shown in FIG. 8 has a body 58 with flanges or legs 60 extending therefrom. Vertical nailing strip 56 may be pressed against foam layer 30 with legs 60 biting into layer 30 for holding nailing strip 56 in position. Suitable staples or nails may be utilized to secure wallboard panel 54 to nailing strips 56.

[0022] From the above it is apparent that vertical wall 16 is formed entirely on site without the use of any prefabricated module which are fabricated offsite and transported to the site for assembly. Units 24 are first formed on site by the mounting of vertical side members 32 and 34 on insulation layer 30 which is formed of a foam material such as polystyrene. Inturned lips 40 such as shown in FIG. 7 tend to dig or bite into foam material 30 when side members 32 and 34 are pressed into position on the sides of insulating layer 30. Thus, side members 32 and 34 are easily fitted within channel-shaped track members 26 and 28 where flanges 38 of members 32 and 34 are secured by suitable fasteners, such as screws 33, to flanges 29 of track members 26 and 28.

[0023] Concrete 60 is applied pneumatically from the outer side of each wall 16 against insulation panel 30, vertical side members 32, 34 and against wire screen 50 or plate 52 in the space between adjacent opposed side members 32 and 34 to form column 42 between units 24 to cover units 24 and provide a concrete thickness of around one inch outside units 24. The outer concrete surface is screened to a smooth or rough finish as desired on all walls. Then, if desired, a drywall panel 54 is secured to the inner side of wall 16 and is secured to nailing strips 54 and flanges 38 of vertical members 32 and 34 by suitable fasteners, such as nails or staples. In some instances, wallboard layer 54 will not be mounted on the inner surface of wall 16. When wallboard panels 54 are utilized, it is preferable to use metal plate 52 as a backing member for column 42 as a smooth inner surface is provided by plate 52 for wallboard panel 54. It is apparent that a minimum of building members are required for the construction of a vertical reinforced concrete wall in accordance with the present invention.

[0024] While a preferred embodiment of the present invention has been illustrated in detail, it is apparent that modifications and adaptations of the preferred embodiment will occur to those skilled in the art. However, it is to be expressly understood that such modifications and adaptations are within the spirit and scope of the present invention as set forth in the following claims.