CA1080501A - Exterior wall composition - Google Patents
Exterior wall compositionInfo
- Publication number
- CA1080501A CA1080501A CA309,629A CA309629A CA1080501A CA 1080501 A CA1080501 A CA 1080501A CA 309629 A CA309629 A CA 309629A CA 1080501 A CA1080501 A CA 1080501A
- Authority
- CA
- Canada
- Prior art keywords
- wall
- layer
- studs
- concrete
- membrane
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
Links
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
- E04B2/84—Walls made by casting, pouring, or tamping in situ
- E04B2/842—Walls made by casting, pouring, or tamping in situ by projecting or otherwise applying hardenable masses to the exterior of a form leaf
- E04B2/845—Walls made by casting, pouring, or tamping in situ by projecting or otherwise applying hardenable masses to the exterior of a form leaf the form leaf comprising a wire netting, lattice or the like
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
- E04B2/84—Walls made by casting, pouring, or tamping in situ
- E04B2/842—Walls made by casting, pouring, or tamping in situ by projecting or otherwise applying hardenable masses to the exterior of a form leaf
- E04B2/847—Walls made by casting, pouring, or tamping in situ by projecting or otherwise applying hardenable masses to the exterior of a form leaf the form leaf comprising an insulating foam panel
Landscapes
- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Physics & Mathematics (AREA)
- Electromagnetism (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Building Environments (AREA)
Abstract
EXTERIOR WALL COMPOSITION
ABSTRACT OF THE DISCLOSURE
An exterior wall composition for building struc-tures and a method of making same. The wall structure com-prises a lattice framework of rigid load bearing steel studs which are secured together. The studs are provided with inner and outer attachment flanges and an inner wall mem-brane is secured to the inner attachment flanges to define an inner wall surface. A layer of insulating material is sprayed and adhered on an inner face of the inner wall mem-brane between the studs. A reinforcing material layer hav-ing interstices is secured at least to some of the outer attachment flanges of the studs. A layer of concrete material is sprayed on the insulating material and extends outwardly of the reinforcing material layer whereby the studs are embedded between an outer wall surface of the concrete material and the inner wall membrane.
ABSTRACT OF THE DISCLOSURE
An exterior wall composition for building struc-tures and a method of making same. The wall structure com-prises a lattice framework of rigid load bearing steel studs which are secured together. The studs are provided with inner and outer attachment flanges and an inner wall mem-brane is secured to the inner attachment flanges to define an inner wall surface. A layer of insulating material is sprayed and adhered on an inner face of the inner wall mem-brane between the studs. A reinforcing material layer hav-ing interstices is secured at least to some of the outer attachment flanges of the studs. A layer of concrete material is sprayed on the insulating material and extends outwardly of the reinforcing material layer whereby the studs are embedded between an outer wall surface of the concrete material and the inner wall membrane.
Description
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.
_ 2 -F;~ ' la~sal 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 ~080501 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.
~ _ 4 _ ~
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10805U~l 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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,. ~ . . . .
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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 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.
:. . , , ~ .. . .. , .... .
:
,:, 10805iO1 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 ,; .
~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.
_ g _ ,... .
(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.
_ 2 -F;~ ' la~sal 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 ~080501 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.
~ _ 4 _ ~
.
10805U~l 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.
- 4a -'.
. .
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-..
.~
,. ~ . . . .
' , '': - ' , - '- . , ' ':
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 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.
:. . , , ~ .. . .. , .... .
:
,:, 10805iO1 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 ,; .
~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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Claims (10)
1. An exterior wall composition for building structures, comprising a lattice framework of rigid wall structural mem-bers, at least some of said wall structural members having inner and outer attachment means, an inner wall membrane secured to at least some of said inner attachment means of said wall structural members to define an inner wall having a finished outer wall surface, a sprayed layer of insulating material on an inner face of said inner wall membrane between said structural members, a reinforcing material layer having interstices secured to at least some of said outer attachment means to define an outer reinforcing wall membrane, a first sprayed layer of concrete material sprayed on said insulating material and extending outwardly of said reinforcing material layer and cured thereon whereby said wall structural members are completely embedded between said first sprayed layer of concrete material and said inner wall membrane, and a second thinner layer of concrete material containing a bonding addi-tive sprayed on an exterior surface of said first layer to constitute an outer wall surface.
2. An exterior wall composition as claimed in claim 1, wherein said concrete material has a compressive strength of from about 3,000 p.s.i, to about 10,000 p.s.i.
3. An exterior wall composition as claimed in claim 1, wherein said rigid structural members are load bearing gal-vanized steel studs secured together to form said lattice framework.
4. An exterior wall composition as claimed in claim 3, wherein said studs each have an inner and outer flange inter-connected by a transverse web and formed integral therewith, said inner and outer attachment means being constituted by said inner and outer flange, respectively.
5. An exterior wall composition as claimed in claim 4, wherein said inner wall membrane is formed from sheet material which is secured to said inner flange of at least some of said studs by self-drilling and tapping screws.
6. An exterior wall composition as claimed in claim 1, wherein said insulating material is a urethane material form-ing a vapor barrier, said reinforcing material being galvan-ized wire mesh attached to said outer flange of at least some of said studs.
7. An exterior wall composition as claimed in claim 1, wherein there is further provided an insulating thermal barrier layer between said inward face of said inner wall membrane and said layer of insulating material, a plurality of expan-sion joints in said outer wall surface of said concrete material, said outer wall surface further having a fine stucco concrete finishing layer.
8. A method of making an exterior wall for building structures, said method comprising the steps of:
i) forming a lattice framework of rigid wall structural members with at least some of said members having inner and outer attach-ment means, ii) securing an inner wall membrane to said inner attachment means of said structural members to define an inner wall having a finished outer wall surface, iii) spraying a layer of insulating foam material on an inward face of said inner wall membrane between said structural members, iv) securing a reinforcing material layer having interstices to said outer attachment means to define an outer reinforcing wall membrane, v) spraying a first layer of concrete material on said insulating material through said inter-stices with said layer of concrete extending outwardly of said reinforcing material layer, vi) curing said first layer of concrete material for a period of at least about 12 to 24 hours, and vii) spraying a second thinner layer of said con-crete material having a bonding additive onto said first layer to form an outer wall sur-face, said concrete material having a compres-sive strength of from about 3,000 p.s.i. to about 10,000 p.s.i.
i) forming a lattice framework of rigid wall structural members with at least some of said members having inner and outer attach-ment means, ii) securing an inner wall membrane to said inner attachment means of said structural members to define an inner wall having a finished outer wall surface, iii) spraying a layer of insulating foam material on an inward face of said inner wall membrane between said structural members, iv) securing a reinforcing material layer having interstices to said outer attachment means to define an outer reinforcing wall membrane, v) spraying a first layer of concrete material on said insulating material through said inter-stices with said layer of concrete extending outwardly of said reinforcing material layer, vi) curing said first layer of concrete material for a period of at least about 12 to 24 hours, and vii) spraying a second thinner layer of said con-crete material having a bonding additive onto said first layer to form an outer wall sur-face, said concrete material having a compres-sive strength of from about 3,000 p.s.i. to about 10,000 p.s.i.
9. A method as claimed in claim 8, wherein said step (i) comprises welding a plurality of load bearing galvanized steel studs together, said step (ii) comprises securing a plurality of wall boards to at least some of said studs; and wherein a plurality of expansion joints are made in said outer wall surface, and applying a finish stucco finish layer on said outer wall surface.
10. A method as claimed in claim 8, wherein after step (ii) and before step (iii) there is provided the step of securing an insulating thermal barrier layer on an inward face of said inner wall membrane, said layer of insulating material being sprayed onto said thermal barrier layer.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA309,629A CA1080501A (en) | 1978-08-18 | 1978-08-18 | Exterior wall composition |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA309,629A CA1080501A (en) | 1978-08-18 | 1978-08-18 | Exterior wall composition |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1080501A true CA1080501A (en) | 1980-07-01 |
Family
ID=4112151
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA309,629A Expired CA1080501A (en) | 1978-08-18 | 1978-08-18 | Exterior wall composition |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA1080501A (en) |
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1978
- 1978-08-18 CA CA309,629A patent/CA1080501A/en not_active Expired
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