US20200157814A1 - Composite foam and concrete wall and method constructing the same - Google Patents
Composite foam and concrete wall and method constructing the same Download PDFInfo
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- US20200157814A1 US20200157814A1 US16/749,403 US202016749403A US2020157814A1 US 20200157814 A1 US20200157814 A1 US 20200157814A1 US 202016749403 A US202016749403 A US 202016749403A US 2020157814 A1 US2020157814 A1 US 2020157814A1
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/02—Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements
- E04B1/14—Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements the elements being composed of two or more materials
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
- E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
- E04C2/288—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and concrete, stone or stone-like material
-
- 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
- E04B2/02—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls built-up from layers of building elements
- E04B2/14—Walls having cavities in, but not between, the elements, i.e. each cavity being enclosed by at least four sides forming part of one single element
- E04B2/24—Walls having cavities in, but not between, the elements, i.e. each cavity being enclosed by at least four sides forming part of one single element the walls being characterised by fillings in some of the cavities forming load-bearing pillars or beams
-
- 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
- E04B2/02—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls built-up from layers of building elements
- E04B2/28—Walls having cavities between, but not in, the elements; Walls of elements each consisting of two or more parts kept in distance by means of spacers, all parts being solid
- E04B2/38—Walls having cavities between, but not in, the elements; Walls of elements each consisting of two or more parts kept in distance by means of spacers, all parts being solid the walls being characterised by fillings in some of the cavities forming load-bearing pillars or beams
-
- 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
- E04B2/02—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls built-up from layers of building elements
- E04B2/42—Walls having cavities between, as well as in, the elements; Walls of elements each consisting of two or more parts, kept in distance by means of spacers, at least one of the parts having cavities
- E04B2/52—Walls having cavities between, as well as in, the elements; Walls of elements each consisting of two or more parts, kept in distance by means of spacers, at least one of the parts having cavities the walls being characterised by fillings in some of the cavities forming load-bearing pillars or beams
-
- 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
- E04B2/56—Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members
- E04B2/64—Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members with elongated members of concrete
-
- 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
- E04B2/56—Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members
- E04B2/64—Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members with elongated members of concrete
- E04B2/68—Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members with elongated members of concrete made by filling-up wall cavities
Definitions
- the present disclosure relates to a composite foam and concrete foundation and a composite foam and concrete wall and a method of mounting the wall to the foundation.
- Construction of a typical footing is very labor intensive and can take a considerable amount of time to construct.
- the typical structure requires a hole to be excavated to a desired depth such that a footing can be constructed that will not be affected by frost or other conditions created by the climate. However, in some construction projects excavation of the soil is not required.
- the footing is then typically placed concrete. Once cured, a foundation wall, typically cinder blocks secured with mortar, a cementious wall or a masonary wall is then constructed with the footings providing the necessary support for the structure. Once the foundation wall is cured, soil is backfilled around the foundation wall to provide a desired grade away from the foundation.
- a typical wall includes a bottom plate or foundation sill that is attached to a foundation, typically a concrete slab or concrete wall. Bottom ends of spaced apart vertical studs are secured to the bottom plate and a top ends of the spaced apart vertical studs are secured to a top plate. A height of the wall is essentially defined by the length of the vertical studs.
- the wall provides the support for the outer wall material, such as wood panels and siding, and also the interior wall material, such as sheet rock. Insulation is typically placed between the studs when the stud wall is raised into place and the outer wall material is secured to the stud wall.
- Construction of the stud wall is very labor intensive and can take a considerable amount of time to construct.
- the studs must be cut to a precise length and secured to the bottom and top plates, typically with nails.
- the studs must be cut to accommodate the required space for the window and/or door and the space must be reinforced with a lintel, which also must be constructed by the construction workers.
- the stud wall is raised and secured to the foundation, typically with bolts that are set into the concrete foundation and through bores in the bottom plate.
- the bores in the bottom plate are positioned about the bolts.
- Washers are positioned on the bolts and nuts threadably engage each bolt to frictionally secure the bottom plate to the foundation.
- Electric wiring and plumbing are then installed which may including drilling through the studs to place the wiring and plumbing in the desired locations within the wall. Installation of the electric wiring and plumbing can be very labor intensive, time consuming and costly.
- the composite foam and concrete wall is formed by aligning slabs of foam side by side to form a foam layer where the seams between the foam panels are substantially parallel to the upper and lower edges of the composite wall.
- Spaced apart channels are formed into an upper surface of the aligned slabs of foam substantially perpendicular to the seams wherein the pilasters are a sufficient depth to aid in securing a concrete layer to the upper surface of the foam panels.
- a horizontal channel is formed into the foam layer at a top surface. Rebar is placed in the channels and is raised from the foam surface a selected distance with rebar chairs.
- An end plate utilized as a top wall of a form with spaced apart lifting mechanism is positioned proximate the top end of the foam layer and proximate a top edge of the horizontal channel.
- a remaining portion of the form is placed about a perimeter of the foam layer and extends upwardly above the foam layer a selected distance, where the distance defines a wythe of concrete of the composite wall. Concrete is then placed into the form and over the foam layer wherein the concrete is placed into the channels and creates pilasters that increase the structural strength of the wall and also increase the bond strength between the concrete layer and the foam layer.
- the lifting force is substantially perpendicular to the seams in the foam and, therefore, prevents cracking in the concrete during the lift.
- structural detail can be added to the surface, such as rocks, coloring or a stamping that resembles siding or a brick pattern. Because of the thickness of the concrete, the wall is structural, meaning it satisfies the requirements of a load bearing wall and the foam layer provides superior thermal and sound insulating qualities.
- the foundation includes a foam portion that can define the dimensions of the foundation, including the length, the width and the height of the foundation.
- An upper channel is formed into the foam portion substantially along a longitudinal axis extending along the length of the block from a top surface and into the block.
- the upper channel extends about one half the thickness of the block and can have a dovetailed construction such that a width of the bottom of the channel is greater than the opening in the top surface and wherein both left and right side surfaces extend inwardly at an acute angle from the bottom surface of the channel to the opening.
- the opposing ends of the foam block include left and right openings that extend from the top surface to the bottom surface where a top portion of the left and right openings is defined by the upper channel.
- Lower portions of the left and right openings can have a dovetail configuration where an opening at the bottom surface is lower than that of the transition from the upper surface to the lower surface.
- Rebar may optionally placed within the upper channel and/or the left and right opening and concrete is then placed into the upper channel and the left and right openings such that the concrete is substantially even with the outer surfaces of the foam portion. Because of the thickness of the concrete in the upper channel, the composite foam and concrete foundation meets the structural requirements of a standard foundation while being able to be produced off-site or prior to the construction of the structure. In some structures, piers or pilings may also be used to ensure the structural requirements are met.
- Another aspect of the present disclosure relates to a method of constructing a foundation of structure.
- the method includes positioning a number of pilings or piers into the soil at locations where foundations described above abut each other such that the concrete bottom surfaces of the foundation rest on the upper surface of the pier.
- the piers and foundations are positioned into the soil at a selected depth (which is dependent upon building codes) such that the concrete in the upper surface defines a perimeter of the structure.
- a structural wall as described above is positioned proximate the foundation and is raised to be positioned on the concrete surface of the foundations where the structural wall is disclosed herein and can be a composite foam and concrete wall. Upper edges of the walls are leveled with shims between the foundation and the wall.
- the structural wall is then secured to the foundation by a securing mechanism. Once the walls are secured to the foundations, the adjacent walls are secured together at the seams with adhesive and additional securing mechanisms can secure the adjacent walls together at the top surface.
- the method also includes positioning an insulating panel about a perimeter of the foundations and adjacent the outside edge of the foundation. The insulating panel extends a selected distance away from the foundation such that the foundation is protected from climatic factors such as frost. Soil is then back filled over the insulating panel, the foundation and is adjacent a lower portion of the structural wall.
- Bracket that is configured to be secured to a foam layer at least along a side edge and a top edge of the foam layer.
- the bracket includes a bottom portion configured to be positioned on an upper surface of the foam block and an angled tang forming an acute angle with the bottom portion.
- the angled tang is configured to be positioned in an angled slot within the foam layer to prevent the bracket from moving on the foam layer as the concrete is placed.
- a wall extends from a distal edge the bottom portion wherein a distance from a top edge of the wall to the bottom portion defines a thickness of a wythe of concrete, when placed.
- a screed portion extends from an upper end of the wall where the screed wall is substantially parallel to the bottom portion.
- the screed wall provides a surface for leveling the placed concrete.
- the bracket can optionally include angled spaced apart braces extending from the bottom portion to the wall wherein the braces can prevent the wall from flexing outwardly due to forces imparted onto the wall by the placed concrete.
- the bracket supports one or more lifting mechanism that are encased within the placed concrete where the lifting mechanisms can be utilized to lift the wall into place.
- An angle of the wall can be any desired angle relative to the bottom portion.
- FIG. 1 is a view of a typical gable roofed house.
- FIG. 2 is a perspective view of a foam layer and form for a solid wall and a wall with a window utilized to form a portion of the house.
- FIG. 3 is an end view of the wall.
- FIG. 4 is a view of a portion of the wall with a portion of the window frame with rebar placed within a pilaster.
- FIG. 5 is another view of a portion of the wall with a portion of the window frame with rebar placed within a pilaster.
- FIG. 6 is a view of a portion of the wall with the top, horizontal pilaster and the top plate.
- FIG. 7 is another view of the portion of the wall with the top, horizontal pilaster and the top plate.
- FIG. 8 is a view of a portion of the window frame and the foam wall.
- FIG. 9 is a perspective view of the window frame.
- FIG. 10 is a perspective of an installed window frame with the wall.
- FIG. 11 is a perspective view of the solid wall having a bottom surface treatment and a top surface treatment.
- FIG. 12 is another perspective view of the solid wall having a bottom surface treatment and a top surface treatment.
- FIG. 13 is a perspective view of the wall with the window having a bottom surface treatment and a top surface treatment.
- FIG. 14 is another perspective view of the wall with the window having a bottom surface treatment and a top surface treatment.
- FIG. 15 is another perspective view of the wall with the window having a bottom surface treatment and a top surface treatment.
- FIG. 16 is a perspective view of the wall with the window having the window being raised with a loader bucket on a tractor.
- FIG. 17 is a side view of the raised wall.
- FIG. 18 is a perspective view from the top surface of the raised wall.
- FIG. 19 is a perspective view of a foundation.
- FIG. 20 is a top view of the foundation
- FIG. 21 is an end view of the foundation.
- FIG. 22 is a bottom view of the foundation.
- FIG. 23 is a schematic view of the foundation positioned within the soil and a wall secured thereto.
- FIG. 24 is another schematic view of another foundation positioned within the soil and a wall secured thereto.
- FIG. 25 is a schematic view of foundation forms creating a perimeter of a structure with piers located where foundations are positioned adjacent each other.
- FIG. 26 is a schematic view of another embodiment of a wall having brackets defining edges of the concrete layer.
- FIG. 27 is a cross sectional view of the wall illustrated in FIG. 26 .
- FIG. 28 is an exploded view of a bracket with a lifting mechanism.
- FIG. 28A is a side view of the bracket illustrated in FIG. 28 .
- FIG. 29 is a perspective view of a bracket with a right angle.
- FIG. 29A is a side view of the bracket illustrated in FIG. 29 .
- FIG. 30 is a perspective view of a bracket with a 135 degree angle.
- FIG. 30A is a side view of the bracket illustrated in FIG. 30 .
- FIG. 31 is a schematic view of a wall joint with an exterior ninety degree angle.
- FIG. 32 is a partial schematic view of two wall secured together.
- FIG. 33 is a partial perspective view of a wall with channels in the foam layer configured to accept rafter or ceiling beams.
- FIG. 34 is a flow chart of an exemplary building method.
- FIG. 35 is a schematic view of batter boards defining a perimeter of a structure and holes for piers of a structure.
- FIG. 36 is a schematic view of holes for piers, foam portions of foundations defining a perimeter of the structure and a drainage grid for the structure.
- FIG. 37 is an enlarged view of a portion of FIG. 36 .
- FIG. 38 is a view of a foam portion of a wall constructed with two layers of foam.
- FIG. 39 is perspective view of another foundation with holes within the foam portion for drainage purposes.
- FIG. 40 is a schematic view of a foundation portion of a structure.
- FIG. 41 is a flow chart of another exemplary building method.
- FIG. 1 A gabled house is illustrated in FIG. 1 that is constructed using foundations, walls and methods of construction as disclosed herein.
- a form 10 for a wall 12 without any openings and a form 20 for a wall 22 with a window frame 23 are illustrated in FIG. 2 .
- the form 10 includes a bottom wall 14 and an opposing top wall 16 that are connected with a right sidewall 18 and a left sidewall 19 wherein the left side wall is at an angle which is about 45 degrees.
- the form 20 includes a bottom plate 24 and an opposing top plate 26 that are connected with left and right walls 28 and 29 .
- the form 20 does not include an angled wall, but one or both sidewalls 28 and 29 could be at any desired angle.
- the wall 12 and the wall 22 have a similar foam layer 46 where the layer 46 includes a plurality of foam panels 40 , 42 and 44 that are placed adjacent each other such that seams 48 and 50 are substantially parallel to a bottom surface 52 and a top surface 54 .
- the plurality of foam panels 40 , 42 and 44 form the foam layer 46 of a composite load bearing wall 12 and 22 . While three foam panels 40 , 42 , and 44 are illustrated to form the height of the wall, any number of panels and any width panels are within the scope of the present disclosure.
- a typical foam panel is constructed of modified expanded polystyrene because the foam has a high R value for insulation purposes.
- the foam layer is typically treated with a pesticide such as zinc borate to prevent insect and rodent infestations.
- the modified expanded polystyrene foam also is a fire preventative material, as the modified foam material will not promote a fire once the source of the fire is extinguished or removed from the foam.
- One non-limiting foam material is sold under the INSULFOAM® trademark by the Insulfoam division of the Carlisle Construction Materials headquartered in Puyallup, Wash. However, other materials of the foam panels are also contemplated.
- foam panels 40 , 42 and 44 are nominally about six inches in thickness. However, a nominal eight inch thickness foam panel is also contemplated.
- the foam panels can be any desired thickness provided the panels provide the necessary insulation and structure to secure a concrete layer thereto.
- the foam layer 46 includes left and right channels 56 and 58 that are cut into the panels 40 , 42 and 44 from the bottom surface 52 to the top surface 54 wherein the left and right channels 56 and 58 are substantially perpendicular to the seams 48 and 50 .
- a depth of the pilasters 56 and 58 is nominally about two inches. However, the depth of the channels 56 and 58 can be any depth that aids in securing a concrete layer to the foam layer 46 while not adversely affecting the structural integrity of the foam layer 46 . It is understood that the thickness of the foam layer 46 can dictate the depth of the channels 56 and 58 .
- a channel be formed around the entire perimeter of the formed wall which will sheer the entire panel to maintain the panel's shape and integrity.
- a bottom header or beam is also contemplated, while not illustrated in the figures.
- the foam layer 46 includes a channel 60 at the top surface 54 that extends into the foam layer 46 at a similar depth as that of the channels 56 and 58 .
- the channel 60 is substantially the same depth as that of the channels 56 and 58 .
- the channels 56 , 58 and 60 can be formed by any desired mechanism including a chain saw with a depth gauge or a hot melt type of cutting process. Whatever method is utilized, the channels 56 , 58 and 60 typically are formed with a dovetail construction where a width of the pilaster 56 , 58 and 60 is greater at the bottom surface relative to a top surface.
- the top plate 26 includes a dove tail cut 62 along the length to provide additional securing of the concrete layer to the top wall 26 .
- the window frame 23 includes a dado cut 25 about the outer perimeter to also allow concrete to flow therein and provide a more secure attachment of the concrete layer to the window frame 23 .
- dado cuts in the top plate 26 and the window frame 23 are optional.
- rebar chairs 66 and rebar 68 are placed into the channels 56 , 58 and 60 .
- the rebar 68 provides strength to the concrete within the channels 56 , 58 and 60 and prevents the concrete pilasters placed into the channels from cracking within the channels 56 , 58 and 60 .
- the window frame 23 is installed by utilizing boards 70 that include the dado cuts 25 and have flashing 72 and 74 at the top and bottom edges 76 and 78 .
- a gap between the window frame 23 and the foam panel 46 allows the concrete to be placed between the frame 23 and the foam layer 46 .
- the concrete between the frame 23 and the foam panel 46 forms a tight seal which prevents air infiltration and other external pressures, such as sound, wind, moisture and heat (or cold) from entering into the interior of a build from the exterior and vise versa.
- the flashing 76 and 78 extends around the perimeter of the window frame 23 about the outer edges 76 and 78 and aids, in preventing water and moisture from entering into the seam between the boards 70 and the foam panel 46 and maintaining a flat interior surface which can be very beneficial when securing dry wall to the interior surface.
- the flashing 76 and 78 is optional.
- a typical pre-manufactured window frame 23 is manufactured by Prebuck LLC located in Grand Rapids, Mich.
- the boards 73 are engineered laminated strand lumber (LSL) and are treated to prevent decay and insect infestation and have a minimal moisture content of about 4-6 weight percent.
- the Prebuck engineered boards are made from saplings that are treated and then processed into the engineered board. As such, the treatment extends through the entire board and not just penetrating a portion of the board. Therefore, when the board is cut, the end remains treated and will not decay or be susceptible to insects.
- the treatment utilized in the Prebuck engineered board is zinc borate, which is a preservative and prevents insect infestation. Zinc borate is not as toxic to human beings as other wood preservatives.
- LSL can also be used for any structural and/or framing members within a building. Suitable LSL structural and/or framing members include those sold under the StrandGuard® trade designation and the TimberStrand® trade designation by Weyerhaeuser Company located in Federal Way, Wash. and the SolidGuard® trade designation by Louisiana Pacific Corporation headquartered in Nashville, Tenn. While an engineered wood window frame treated throughout its thickness with zinc borate is disclosed, any type of material that can be formed into the window frame is within the scope of the present invention. It is also contemplated that a similar manufacturing process be utilized with door frames. It is also contemplated that the windows and door frames be constructed of any suitable building material, including but not limited to metal and composite materials.
- a typical window would be a vinyl window wherein the perimeter of the window casing is secured to the window frame 23 with a bead of sealant such as, but not limited to, a caulk. Utilizing a vinyl window frame and caulk removes the need for flashing as there is no means of penetration of water or air between the window casing and window frame 23 .
- the finished wall 12 with the foam layer 46 and a concrete layer 80 is illustrated with the framing removed.
- the concrete layer 80 is at least nominally two inches in thickness which provides sufficient structural integrity such that the wall 12 can be an exterior load bearing wall.
- the concrete layer 80 fills the channels 56 , 58 and 60 to form pilasters in the foam layer and placed until even with a top of the framing. While the concrete layer 80 is not cured, a surface treatment 82 can be applied to the concrete layer 80 .
- field stones 84 are set into the concrete layer 80 in a lower portion 86 .
- the concrete layer 80 in the lower portion 86 is colored a different color than the concrete 80 in an upper portion 88 .
- field stones 84 and utilizing different colors in the concrete layer 80 are illustrated, these are but a couple of non-limiting examples of surface treatments that can be utilized.
- Other non-limiting surface treatments include stamping the concrete to have the appearance of siding or brick.
- paint, dye or other colorant could be applied or integral to the concrete mix to provide different surface treatment.
- the finished wall 22 is illustrated with the concrete layer 80 secured to the foam layer 46 .
- field stone 84 are positioned into the concrete layer at the lower portion 86 as the surface treatment 82 .
- the concrete layer 80 in the lower portion 86 is not colored, and an upper portion 88 has a contrasting color.
- the window frame 78 has been covered by the concrete layer 80 and is not visible.
- the concrete layer 80 can have similar treatments as described with respect to the wall 12 .
- the wall 22 is illustrated being lifted utilizing a loader bucket on a tractor where chains 90 are secured to bolts 92 in the top plate 26 .
- the pilaster within the channel 60 along the top plate 26 provides additional structural integrity to lift the wall 22 relative to a nominal two inch thickness of the concrete layer 80 .
- a gravitational force is placed upon the wall 22 that is substantially perpendicular to the seams 48 and 50 .
- the panels 40 , 42 and 44 do not move relative to each other as the wall 22 is lifted, which prevents cracking, bowing or bending of the concrete layer 80 which may not be apparent at the time of the lift but will become noticeable over time.
- the wall 12 is constructed similarly to the wall 22 and will also not cause a crack in the concrete layer 80 when lifted.
- siding fastening strips such as furring strip or nailing strip
- the fastening strips can be constructed of wood or metal and are spaced apart to support siding such, for instance, lap siding.
- Applicant can customize the look of an exterior surface to meet any needs of the owner including having a stone or brick treatment on the bottom portion with lap siding on the upper portion of the wall.
- the walls 12 and 22 can be manufactured at a plant or manufacturing facility remote from the site of the construction and therefore can eliminate much of the labor required to build a stud framed structure.
- the walls 12 and 22 can be prefabricated to any reasonable desired length, width and height and can be lifted and installed on a previously formed foundation at the site. Because of the thickness of the concrete layer 80 the wall 12 can be installed below ground and can be secured to a foundation for the foundation, such that a foundation wall is not required, which can also save time and money compared to a stud frame structure.
- the wall 12 and 22 can have beveled side edges such as the side wall 19 , two walls can be easily joined together using connectors that are positioned into the adjacent concrete layers 80 . Since the connectors would not penetrate though the inner surface of the foam, there would be no thermal bridge from the outside which would affect the insulating properties of the foam layer 46 .
- a typical angle of the beveled edge is 45 degrees so that any wall edge can be mated with any other wall edge. However, other angles of the edges besides 45 degrees are also contemplated.
- the walls 12 and 22 can include interlocking joints which aid in secure the walls 12 and/or 22 together, typically with a securing mechanism.
- the foam layer 46 is of a thickness such as for example eight inches, the utilities that are required in the wall can be easily installed by cutting channels into the foam layer 46 . It is contemplated that a chain saw with a depth guard or a hot knife designed to cut foam can be utilized to quickly and efficiently form the channels. Once the channels are formed into the foam layer the utilities including plumbing and electric wiring can be easily installed.
- sheet rock can be glued or adhered to the inner surface of the foam layer 46 so that the building can be quickly finished relative to a structure that utilizes stud walls.
- the adhesive forms a vapor barrier that meets code and does not require a plastic wrap. This allows for the elimination of mechanical fastening of the sheet rock by for instance nails or screws, which in turn minimizes the labor required to mount the sheet rock and the finishing of the sheet rock, such as with a mud to evening the seams and cover the nail or screw indentions.
- no additional insulation in the walls is necessary because the foam layer 46 provides the necessary insulation. As such, the step of installing insulation which is required in a standard stud wall is not required.
- a layer of plaster can be applied to the foam to provide a finished look to the interior walls instead of the sheet rock.
- the application of plaster is less expensive and less labor intensive than securing sheet rock to the foam layer and then mudding the seams prior to painting the sheet rock.
- a colorant can be mixed into the plaster such that a coat of paint may not be required.
- the walls of the structure can be formed off-site and shipped to the location.
- the bolts 92 or lifting hardware in the top plate 26 are designed to easily raise the walls 12 and 22 such that the walls of the building can be quickly and efficiently installed relative to the stud wall structure.
- the walls can be quickly secured together, with prefabricated window and door frames such that the structure can be efficiently constructed in a short amount of time.
- the foundation 100 includes a foam block 102 (typically EPS) of a desired length L, width W and height H.
- the foam block 102 typically has a height of about twelve (12) inches and a width of twenty four (24) inches and any desired length.
- the present disclosure is not limited a block of having a twelve (12) inch height and a twenty four (24) inch width. Rather any foam block having a sufficient size can be used provided the block of foam provides the necessary structural integrity.
- a dovetail channel 104 (as illustrated in FIGS. 23 and 24 ) is cut into the block from the top surface 105 and into the block approximately a distance one half of the height where the dovetail channel 104 extends from a left end 106 to a right end 108 .
- a typical depth of the dovetail channel 104 is about 12 inches. However, other depths are contemplated.
- the dovetail channel 104 defines a top portion 108 of a left and right end channel 110 and 111 .
- the left and right end channels 110 and 111 have a dovetail configuration and extend from the top surface 105 to a bottom surface 112 .
- a form is positioned about the foam block 102 and concrete is placed to fill the dovetail channel 104 and the left and right end channels 110 .
- the left and right channels 110 extend into the block 104 a selected distance such that a concrete surface 114 and 116 large enough to engage an earth anchor or pier after the concrete is placed and cured.
- the end channels 110 are filled with concrete and form concrete vertical pilasters 124 and 126 that include the surfaces 114 and 116 that are capable of being placed upon a platform of an earth anchor, piling, pier or other support, if necessary.
- a top surface 123 of the pilaster 122 forms a portion of a perimeter of the foundation of the structure that supports the walls 12 and/or 22 of the structure
- the foundation 100 is illustrated positioned within the soil a selected depth below ground level 120 .
- the foundation 100 includes the foam block 102 and a concrete pilaster 122 having a dovetail cross section and a height that this approximately half of the height H of the block 104 .
- the dovetail configuration of the pilaster 122 within the block aids in retaining the pilaster 122 within the foam block 104 . While dovetail configured channels and pilasters are discussed and illustrated, any suitable configuration of the channels and pilasters for the foundation is also contemplated.
- insulation panels 130 are then place adjacent an outer vertical surface 132 of the foam block 104 about the entire perimeter of the structure.
- the insulation panels 130 are typically about 2 inches thick and about 48 inches in width (however other dimensions of the insulating panels are contemplated).
- the insulation panels typically EPS foam, prevent frost and other climate factors from engaging the foundation and extend the life of the structure.
- the foundation 100 can be used at a depth that would not require the insulation panels 130 .
- the fastening mechanism 140 includes metal strips 142 secured to the top surface 123 of the pilaster 122 and to the sides of the wall 12 and/or 22 .
- An angle iron 144 is secured to the metal strips 122 , typically with a weld. Utilizing the metal strips 142 and the angle iron 144 secures the wall 12 and/or 22 to the foundation 100 .
- the wall 12 and/or 22 is secured to the foundation 100 with a securing mechanism that includes a channel 150 within the upper surface 123 of the pilaster 122 that is sized to a width and depth to accept a bottom portion of the wall 12 and/or 22 .
- a concrete or adhesive can be used to secure the wall 12 and/or 22 with the channel 150 and thereby secure the wall 12 and/or 22 to the foundation 100 in a vertical position.
- the use of the disclosed foundation 100 and the walls 12 and/or 14 eliminates the need to dig and place footings and to build a foundation wall, typically out of cinder blocks. Therefore, a significant amount of time and expense can be eliminated from the construction of a structure utilizing the disclosed foundation 100 and walls 12 and/or 14 .
- FIG. 25 schematically illustrates adjacent foundations 100 forming a footprint or perimeter of a structure wherein piers 101 are located under the adjacent ends of the foundations 100 .
- a non-limiting example of a pier includes a bell shaped pier.
- a insulating layer 103 abuts the foundations and extends outwardly therefore to protect the foundations 100 from climatic factor such as frost.
- a wall 200 includes a foam layer 201 formed using foam panels 202 , 204 and 206 oriented such that seams between the panels 202 , 204 and 206 are substantially parallel to upper and lower edges 208 and 210 .
- the foam layer 201 is typically a nominal six or eight inches thick. However, other thicknesses of the foam layer 201 are also contemplated.
- a plurality of spaced apart channels 212 are cut into the foam layer 201 in a manner similar as described with respect to the channels 58 and 60 .
- the plurality of spaced apart channels 212 have a dovetail cross-section and extend from the upper edge 208 to the lower edge 210 and rebar is positioned, as required by engineering specification, in the channels 212 as previously described.
- concrete fibers can be utilized instead of rebar.
- the channels 212 are spaced a distance D1 approximately thirty six inches to forty eight inches apart on center. However, any distance D1 is within the scope of the present disclosure. While a dovetail cross-section is illustrated, the channel can have other cross-sectional configurations.
- Rebar is positioned within the channels 212 as described for walls 12 and 22 .
- the foam layer 201 includes spaced apart grooves 214 that are substantially square or rectangular in configuration.
- the spaced apart grooves 214 extend into the foam layer 201 a distance less than the distance the channels 212 extend into the foam panel 201 .
- the grooves 214 interrupt a bonding surface 203 of the foam panel 201 which results in better bonding between the foam panel 201 and a concrete layer or wythe when placed.
- the grooves 214 are spaced apart a distance D2 between about twelve inches and about 24 inches. However, any distance D2 is within the scope of the present disclosure.
- the grooves 214 are disclosed and illustrated herein, the grooves 214 are optional.
- a left bracket 220 is secured to the foam layer 201 proximate a left edge 205 and along a length of the left edge 205 and a right bracket 222 is attached to the foam layer 201 proximate a right edge 207 and along a length of the right edge 207 .
- the brackets 220 and 222 are configured to withstand forces imparted by placed concrete, provide a screed surface for leveling the placed concrete and provide a finished surface for securing adjacent walls together.
- the bracket 220 provides a finished surface or edge to the panel or wall surface.
- a bottom bracket 224 is secured to the foam layer 210 proximate the bottom edge 210 and a top bracket 226 is secured to the foam layer 201 proximate the top edge 208 where both brackets 224 and 226 extend along a length of the respective edge.
- the brackets 224 and 226 are configured to withstand forces imparted by placed concrete, provide a screed surface for leveling the placed concrete and provide a finished surface for securing adjacent walls together.
- Each bracket 220 , 222 , 224 and 226 includes a top edge that is substantially even where a distance from the top edge of the bracket 220 , 222 , 224 and 226 to the bonding surface 203 of the foam layer 201 defines a thickness of a wythe 230 of concrete that forms the wall 200 .
- each bracket 220 , 222 , 224 and 226 has a flat member that extends in a direction substantially parallel to the bonding surface 203 of the foam layer 201 which provides as surface to screed the wythe 203 .
- the use of the brackets 220 , 222 , 224 and 226 allows the wall to be formed with a finished outer surface of the wythe 230 and finished edges and therefore the wall 200 will require minimal, if any finishing work prior to installation.
- each bracket 220 , 222 , 224 and 226 are utilized to different purposes.
- the bracket 226 is utilized to form the upper edge of the wall 200 while retaining lifting mechanisms 240 thereto such that when the concrete wythe 230 is placed the lifting mechanisms 240 are securely encased in the wythe 230 and provide sufficient support to enable a cable or chain to be attached thereto for a lift from a horizontal portion to a substantially vertical position and onto foundation 100 .
- the bracket 226 includes a bottom portion 242 that is substantially flat and is configured to abut the bonding surface 203 of the foam layer.
- An angled tang 244 extends from one edge of the bottom portion 242 .
- the angled tang 244 is configured to be positioned within a slot foam layer 201 where the slot has substantially the same angle.
- the angle is acute and is in the range of 20 degrees and about 60 degrees.
- a typical angle is about 30 degrees.
- the engagement of the tang 244 with the slot prevents movement toward the upper end 208 of the foam layer when the concrete is placed.
- the bottom portion 242 can be secured to the bonding surface 203 with a layer of adhesive.
- the bracket 226 includes a wall 246 that extends from another edge of the bottom portion 242 .
- the wall 246 has a height H from the bottom portion 242 that defines the thickness of the wythe 230 .
- a screed portion 248 extends from the wall 246 wherein the screed portion 248 is substantially parallel to the bottom portion 242 such that the placed concrete can be screeded using the brackets 220 , 222 , 224 and 226 .
- the wall 246 includes spaced apart apertures 250 that are configured to allow access to the lifting mechanism 240 when encased within the wythe 230 .
- an end cap 252 Prior to placing the concrete, an end cap 252 having a similar perimeter to that of the aperture is positioned through the aperture.
- the end cap 252 has a slot 254 that separates end cap halves 256 , 258 that are secured together with a living hinge 260 .
- the slot 254 is spread apart and a top portion 262 of the lifting mechanism 240 having at least one aperture 264 therein is positioned within the slot 254 .
- the end cap halves 256 , 258 are forced together to frictionally secure the end cap 252 about the top portion 262 of the lifting mechanism 240 .
- the end cap 252 is then secured within the aperture 250 in the wall 246 such that the lifting mechanism 240 is retained in a selected position.
- the lifting mechanism 240 includes a main portion 266 between the top portion 262 and the bottom portion 268 .
- the bottom portion includes arcuate members 270 , 272 that function as an anchor to prevent the lifting mechanism 240 from being pulled through the top portion of the wall 200 as the wall 200 is lifted. While arcuate anchor members 270 , 272 are illustrated, other types of anchor configurations can be utilized.
- the end cap 252 can also be utilized in different applications such as, but not limited to, providing access to a tightening mechanism secured to cables within the concrete wythe such that the concrete can be post tensioned. Post tensioning the concrete allows the structure to be utilized in different applications, such as, but not limited to a floor panel.
- the lifting mechanism 240 is typically of a monolithic construction where a material of construction is steel. However, other material of construction besides steel is contemplated for the lifting mechanism 240 .
- the end cap 240 having a low surface energy, is removed to provide access to a void in the wythe 230 which provides access to the aperture 264 . Cables or chains can then be secured to spaced apart lifting mechanism 240 to lift the wall 200 .
- braces 281 Prior to placing the concrete, spaced apart braces 281 are secured in spaced apart slots 282 in the bottom portion 242 and spaced apart slots 284 in the wall 246 . An area of the slots 282 and 284 are minimized to prevent concrete from flowing therethrough.
- the braces 281 include a “T” shaped end 286 that is wider than the slot 284 wherein one portion of the “T” shaped end 286 is position through the slot 284 followed by the other portion.
- a typical slot 284 is a coin slot opening, which prevents concrete from flowing through the slot.
- the portions of the “T” shaped end 286 prevent the end 286 from sliding through the slot 284 .
- the brace 281 includes a hook shaped end 288 that is configured to engage the slot 282 in the bottom portion 242 .
- the brace 281 includes a tab 283 that extends outwardly therefrom.
- the tab 283 allows rebar or other materials to be secured to the brace.
- the rebar can be utilized to retain the lifting mechanisms 240 in the selected portion.
- the bracket 300 includes a bottom portion 302 , angled tang 304 , substantially vertical wall 306 and a screed portion 308 that is substantially parallel to the bottom portion 302 .
- the bottom portion 302 includes slot 310 , similar to slot 280 in the bracket 240 , and slot 312 , similar to slot 282 in the wall 246 , such that the same brace 281 can be utilized.
- the slot 312 is located within a channel 313 , that is angled from the wall 313 .
- the channel 313 defines corners into which an adhesive placed when walls are secured together. The corners in the adhesive created by the channel 313 prevent air and moisture penetration.
- a similar process is used to install and secure the bracket 300 to the foam layer 201 relative to the bracket 240 .
- the bracket 240 is typically used on the bottom portion of the wall 202 , but can be used on any edge of the wall 200 .
- the left and right edges 205 and 207 are typically at an angle such that when adjacent walls are secured together, a single seam is formed.
- the angle of the structure is determined and bisected such that the walls 200 have abutting surfaces having the same lengths and dimensions.
- a bracket 310 having a wall 314 having a 135 degree angle relative to the bottom portion 312 is utilized as illustrated in FIGS. 30 and 30A .
- the bracket includes an angled tang 316 and a screed portion 318 , as previously described.
- the bracket 310 includes spaced apart slots 320 in the bottom portion 312 and spaced apart slots 322 in the wall 314 .
- Braces 324 having a similar configuration to the brace 281 are utilized wherein the ends of the brace 324 are installed in the slots 320 and 322 .
- FIG. 31 is a schematic of two walls 330 and 332 joined at a 45 degree angle using the bracket 310 .
- Each wall 330 , 332 is constructed as describe with respect to wall 200 and includes the foam layer 334 and the concrete wythe 336 .
- Each wall 330 , 332 includes the bracket 310 and the foam layer 334 is at the same angle as that of the wall 314 .
- brackets While a 90 corner and a 135 degree angled corners are illustrated, other common angles for the walls of the wall relative to the bottom portion of the brackets include an angle of 22.5 degrees for a bay treatment, 90 degrees for butted walls and 135 degrees for outer bay treatments. Further, a bracket with a forty five degree angled wall can be used for inside corners.
- the wall 314 of the bracket 310 is located between about one eighth to one quarter of an inch form the foam surface 334 on the wall 330 and the wall 314 of the bracket 310 is positioned between about one eighth of an inch to about one half of an inch from the angled foam surface 334 on the wall 332 to provide a gap between the brackets 310 .
- a typical gap is between about one quarter of an inch and about one half of an inch.
- An adhesive layer is positioned in the void between the angled foam surface 334 and the wall 314 to substantially fill the void.
- a typical adhesive is a pre-compressed joint sealant.
- One such pre-compressed joint sealant is sold under the WillSeal® trade designation by WillSeal located in Hudson, N.H. However any suitable adhesive or sealant is within the scope of the present application.
- the adhesive securely joins the two edges to secure the walls 330 , 332 together.
- the walls 360 , 362 include foam layers 364 , 366 and concrete wythes 368 , 370 along with brackets 340 .
- the bracket 340 is secured flush with the surface of the foam layer 366 of the wall 362 while the bracket 340 is secured a distance from the surface of the foam layer 362 of the wall 360 where the distance is typically between about one eighth of an inch and about one half of an inch.
- An adhesive layer 372 is positioned in the void between the walls 344 and when the walls 360 , 362 are positioned next to each other, the adhesive layer 372 secures the walls 360 , 362 together.
- FIG. 33 another embodiment of a wall 380 is illustrated and is constructed as described with respect to the wall 200 .
- the wall 380 has a modified foam layer 382 relative to the foam layer 201 of the wall 200 .
- the wythe 384 is similar that of the wythe 230 .
- the foam layer 382 includes an upper portion 386 that extends above a surface 388 that is substantially flush or even with the wall 246 of the bracket.
- the upper portion 386 extends a length of the foam layer 283 and has spaced apart channels 390 having a bottom surface 392 located above the surface 388 .
- the channels are configured to accept a rafter beam or ceiling beam and are spaced apart to accept the rafter beam or ceiling beam per the building specification.
- An insert 390 typically metal with a “U” shaped channel, can be installed to provide additional strength to the foam layer 382 , although the insert is not required.
- Preforming the foam layer 382 with the channels 390 decreases the amount of time and labor required to build a structure as the rafter beams or ceiling beams can be adhered within the channels. 390 .
- a complementary piece of foam (not shown) with similarly spaced apart channels can be installed on the surface 388 once the wall 380 is in the raised position to extend a length of the channels 390 and provide more stability to the rafter beam or ceiling beam secured within the channel 390 .
- a method 400 of constructing a building is illustrated in FIG. 34 .
- the method includes step 402 of clearing a location for the building, excavating the necessary soil to the proper finished grade, digging in the pier in selected locations about a footprint or perimeter of the building and to locate foundations and insulation.
- piers are positioned into the ground at selected elevations and locations where foundation about such that ends of adjacent foundations are supported by the pier. It is contemplated that each pier having an upper surface that is at substantially the same level such that the foundation will be level.
- An exemplary pier is a bell shaped pier however other styles of piers are also contemplated. After the piers are created in the soil, the interior can be vacuumed to remove loose soil and the concrete is placed into the interior of the foundation.
- the foundations as previously described herein are positioned on the soil such that the soil supports the foundation along its length and end portions are supported by the piers. Once installed, the foundations provide a perimeter or footprint of the building.
- the preformed composite foam and concrete walls 12 , 22 , 200 or 380 are raised and set onto the respective foundation and secured together at the respective side edges with adhesive.
- the walls 12 , 22 , 200 or 380 are shimmed at the interface with the foundation when necessary to cause the upper surfaces of joined walls to be substantially even.
- a bottom portion of the wall is then secured to the foundation.
- a top surface of the adjacent walls can be joined together with any suitable bracket.
- insulating layers are posited about the foundation and outwardly from the foundation.
- the insulating layer prevents frost and other environmental factors from affecting the foundation.
- soil is back filled over the foundation, insulating layer and the bottom portion of the wall.
- rafters and or ceiling beams are installed.
- the rafter or ceiling beams are typically installed with walls 380 having the channels 390 for accepting the beams or rafters.
- the ceiling beams and/or rafters can be secured to a top beam as illustrated with walls 12 and 22 .
- the ceiling beams and rafters can optionally be constructed from LSL.
- a preferred roofing system is a metal roof manufactured by Gerard Roofing Technologies located in Brea, Calif.
- foam is positioned between the rafters or ceiling joints and a ceiling material is installed.
- an insulation layer is installed within the footprint of the building.
- a typical thickness of insulation is between about 4 and 10 inches, depending upon local building codes.
- rebar is positioned above the insulating layer and ends of the rebar are tied to the wythe in the exterior wall.
- a radiant heating system can be installed and then a slab concrete is placed within the foot print of the building.
- step 424 interior walls and utilities are installed.
- step 426 the interior of the building is finished.
- an area of land is leveled in preparation for a building to be constructed.
- Underground services including, but not limited to, sewer and water and optionally electrical are installed and the associated trenches are then compacted to a required density.
- batter boards 500 are set for a perimeter 502 of the building and a nominal one inch to a nominal two inches of sand is placed on the leveled soil within the space defined by the batter boards and compacted to a building code for the area.
- the soil is excavated and graded for a selected distance beyond the perimeter.
- the soil is excavated and graded to support a foam layer that provides frost protection to the foundation.
- Holes 504 for piers are then drilled in locations where two foundations meet. Loose soil is removed from the holes 504 and the base of the hole is compacted. Once the holes 504 are drilled and the soil is removed, foam portions of the foundations are positioned about a perimeter of the structure.
- abutting ends 512 , 514 of the foundations 508 , 510 are configured to have an angled surface that abut each other. For instance in FIG. 36 a right angled corner is illustrated where the abutting ends have forty five degree surfaces. Depending upon the angle of the corner, the angle is bisected to determine the angle of the abutting edges of the foundations.
- rebar 516 is positioned in a top channel 518 of the foundations 508 , 510 .
- Rebar also bridges the two abutting 512 , 514 surfaces and from the top channel 518 and into the holes 502 for the piers.
- the foundations 508 , 510 form a continuous top channel 518 and end slots 520 in the foam provide an opening to the drilled holes 502 .
- Concrete is then placed into the top channel 518 and fills the holes 502 to form the piers for the foundations 508 , 510 . Because the concrete is placed into the foundations 508 , 510 and into the holes 502 to form the piers when cured, the concrete is of a monolithic construction that provides additional strength to the structure.
- the walls can be raised and secured to the foundations as previously described.
- the walls can be formed using an alternative construction.
- a wall 530 can be formed by providing a first panel 532 having a desired thickness, typically between two inches and six inches in thickness.
- the first panel 532 is constructed as previously described where the seams between the first panels is substantially perpendicular or normal to stresses incurred during a lift, such as a tilt lift.
- the first panel 532 has substantially flat top and bottom surfaces 531 and 532 and optionally holes are cut through the thickness of the panel for window and doors as previously described.
- Brackets 540 , 542 , 544 and 546 are secured about the perimeter of the first panel 532 with an adhesive.
- the brackets 540 , 542 , 544 and 546 are similar to the brackets 220 , 222 , 224 and 226 previously disclosed. However because an adhesive is utilized, the tang is not required to retain the brackets 540 , 542 , 544 and 546 to the first panel 532 .
- a groove is cut into the top surface 531 to provide sufficient space to secure the brace to the bottom member as previously discussed. Because a minimal amount of material is removed, the first panel has improved structural strength relative to the panel having the angled slots for accepting the angled tang.
- Channels 535 that define the pilasters are formed by securing a second layer 534 having spaced apart portions to the first layer 532 with an adhesive.
- the second portions form dovetailed channels for forming the concrete pilasters.
- the portions of the second layer can provide any desired configurations.
- the concrete is placed onto the exposed surfaces of the first and second layers.
- the braces are utilized as a screed surface as previously disclosed.
- the bottom surface 533 of the first layer 532 includes a fire resistant layer of material.
- a typical material of construction is Sold under the DENSILITE trade designation. However, the present disclosure is not limited to this material.
- the walls 530 are secured together as previously described. Once the exterior walls are in place on the concrete in the foundation, ceiling beams, trusses and/or rafters are secured within spaced apart slots 552 in the top edge of the first panel 532 . Inserts may optionally be secured within the slots between the first panel 532 and the ceiling beams and/or rafters to provide increased structural integrity.
- a foam layer is positioned between the ceiling beams and/or rafters.
- the foam layers provide insulation and can also reduce the transmission of sound between stories of the structure.
- a sheeting can be installed above the ceiling beams, trusses and/or rafters.
- electric wiring is placed on an upper surface of the ceiling beams and or stringers of the rafters.
- One or more through bores is cut into the foam layer for lighting and a wireless light is installed.
- One or more wireless switches are installed into a wall wherein the one or more switches are typically battery powered which reduces the installation costs associated with the installation of wiring.
- the wireless system is more energy efficient relative to typical installations.
- foam portions 560 of the foundations 508 , 510 include through bores 562 that allow drainage tubing 564 to be installed in a pattern, typically a grid pattern.
- a material 566 is placed over the drainage tubing wherein the material allows moisture and gases such as radon to travel therethrough and into the drainage tubing such that the moisture is removed from the structure.
- a typical material of construction is 3 ⁇ 4 minus or 1 inch minus aggregate. The material is compacted to a required code and protects the drainage tubing or tile.
- a layer of insulating foam 568 is positioned on the material 566 and radiant heat heating tubes 570 are installed and secured to the layer of foam 568 .
- Rebar chairs 572 are installed on the foam layer 570 and at least one grid of rebar 574 is installed on the chairs 572 .
- Rebar 574 is also positioned into the foam portions 560 of the foundations 508 , 510 around the perimeter of the structure.
- Concrete 578 is then placed on the foam layer 568 and covers the radiant heating tubes 570 and the rebar 574 , 576 wherein the rebar 576 extending into the foam portions 568 of the foundations 508 , 510 ties the concrete slab 578 to the foundations 508 , 510 .
- a typical thickness of the concrete slab 578 is between four and ten inches and more typically between six and eight inches, however the thickness will be controlled by engineering specifications for the structure.
- a channel is cut into the inner surface of some walls.
- the channels provide a conduit to place electrical wiring into the structure.
- the channels are cut proximate a bottom surface such that a floor board can be installed to cover the channel, which decreases construction costs.
- the channels for the wiring can be located anywhere within the inner surface of the walls.
- additional interior walls or hung cabinets are desired for a structure.
- a channel can be cut into the inner surface of the foam of a size sufficient to secure a board therein with an adhesive.
- the board can then be utilized as a mounting material for the wall or the cabinetry.
- the board does not extend to the concrete, there is no thermal bridge from the outdoor environment to the inside environment.
- the board can be anchored to the exterior concrete wythe.
- a foam layer is installed about the perimeter of the foundations to protect the foundations from frost. Soil is then backfilled to a desired grade and covers the foam layer.
- the method 600 includes cleaning, excavating and fine grading the building site at step 602 .
- piers are located and dug and foam forms are placed in position to define a perimeter of the structure.
- concrete is placed in the foam forms and piers to create a monolithic foundation. Once the foundation is set, the method includes steps 608 - 626 that are similar or the same as disclosed with respect to steps 408 - 426 to complete the construction.
- a simulation of the energy performance of the disclosed walls 12 , 22 , 200 and 380 along with a roof with the Gerard metal roof was conducted by DAREnergy Consulting located in Sacramento, Calif. using the CBECC-Res energy compliance software to determine the thermal efficiency of the disclosed structure.
- the fixed assumptions for the simulation included a structure 48 feet by 24 feet with an assumption that quality insulation installation (QII) was used to account for the lack of air gaps in the windows, doors and between the joints of the walls and because the disclosed structure has substantially no thermal bridging. An assumption was made that there were 4.4 changes of air per hour.
- the construction of the walls was assumed to have a three inch wythe of concrete and variable thickness foam (EPS with an R value of 4.8/inch).
- the outer walls were covered with a layer of stucco and the inner layers were covered with gypsum board.
- the floor was a slab of concrete covered with tile.
- An insulating layer of R-10 insulation was installed outside of the structure a maximum distance of four feet.
- the roof was a metal roof with cool roof properties for zones 12 and 14, and was assigned a 0.27 reflectance and 0.90 emittance.
- An R-5 above deck insulation was assumed and variable amounts of EPS foam was inserted between the rafter beams located on a 24′′ spacing.
- the roof assumed a 1 inch continuous layer of insulation and optionally a radiant barrier (such as foil) installed at the top of the attic to block solar gains from the roof.
- the space conditioning assumed a combined hydronic and 90% boiler with no cooling.
- the wall thickness and insulating variables were simulated in different climate zones and include the following results for California climate Zone 16 with and without a radiant barrier on the roof in Tables 1, California climate Zone 14 with and without a radiant barrier on the roof, California climate Zone 12 with and without a radiant barrier on the roof. Wall insulation thickness, and roof insulation was varied in the simulations. The results are as follows.
- the Energy Design Rating reflects the annual energy consumption including lighting, domestic appliances, and electronics not included in the California Title 24 performance.
- the Performance is a percentage of the level above a building that complies with California's Energy Efficiency Standards (Title 24, Part 6) for space conditioning and water heating.
- the lower range of performance is an East/West front orientation of the building and the higher range is for a North/South front orientation of the building.
- the results of the simulation indicate a significant increase in energy efficiency relative to California Energy Efficiency Standards.
- the simulations surprisingly indicated at least a forty percent increase in performance independent of the climate zone and whether or not a radiant barrier was considered. Also, comparing the simulations with the radiant barrier to simulations without the radiant barrier resulted in a slight increase in simulated energy efficiency.
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Abstract
A composite foam and concrete wall includes a foam layer having a top surface, a bottom surface, a left wall surface and a right wall surface wherein the foam layer comprises at least two foam panels that define a seam that is substantially parallel to the top surface and the bottom surface. A concrete layer is secured to a surface of the foam layer.
Description
- The present application claims the benefit of U.S. Provisional Patent Application Ser. No. 62/050,471 entitled COMPOSITE FOAM AND CEMENT WALL AND METHOD OF MAKING SAME that was filed on Sep. 15, 2014, the contents of which are incorporated by reference in its entirety.
- The present disclosure relates to a composite foam and concrete foundation and a composite foam and concrete wall and a method of mounting the wall to the foundation.
- Construction of a typical footing is very labor intensive and can take a considerable amount of time to construct. The typical structure requires a hole to be excavated to a desired depth such that a footing can be constructed that will not be affected by frost or other conditions created by the climate. However, in some construction projects excavation of the soil is not required. The footing is then typically placed concrete. Once cured, a foundation wall, typically cinder blocks secured with mortar, a cementious wall or a masonary wall is then constructed with the footings providing the necessary support for the structure. Once the foundation wall is cured, soil is backfilled around the foundation wall to provide a desired grade away from the foundation.
- However, excavation of the soil, placing the footing, waiting for the footing to cure, constructing the foundation wall and waiting a sufficient time for curing takes a significant amount of time and effort that increases the cost of construction. It may be beneficial and cost effective to utilize a foam foundation that can be utilized to support a foundation wall, which may or may not be preformed.
- A typical wall includes a bottom plate or foundation sill that is attached to a foundation, typically a concrete slab or concrete wall. Bottom ends of spaced apart vertical studs are secured to the bottom plate and a top ends of the spaced apart vertical studs are secured to a top plate. A height of the wall is essentially defined by the length of the vertical studs. The wall provides the support for the outer wall material, such as wood panels and siding, and also the interior wall material, such as sheet rock. Insulation is typically placed between the studs when the stud wall is raised into place and the outer wall material is secured to the stud wall.
- Construction of the stud wall is very labor intensive and can take a considerable amount of time to construct. The studs must be cut to a precise length and secured to the bottom and top plates, typically with nails. In the event windows and/or doors are to be placed into the wall, then the studs must be cut to accommodate the required space for the window and/or door and the space must be reinforced with a lintel, which also must be constructed by the construction workers.
- Once the stud wall is formed, it is raised and secured to the foundation, typically with bolts that are set into the concrete foundation and through bores in the bottom plate. The bores in the bottom plate are positioned about the bolts. Washers are positioned on the bolts and nuts threadably engage each bolt to frictionally secure the bottom plate to the foundation. Once the stud wall is raised, the outer wall is secured to the studs typically with nails and then siding is secured to the outer wall.
- Electric wiring and plumbing are then installed which may including drilling through the studs to place the wiring and plumbing in the desired locations within the wall. Installation of the electric wiring and plumbing can be very labor intensive, time consuming and costly.
- In many developing locations, such as the oil fields of North Dakota, the lack of adequate housing is an issue. While people are willing to pay for the construction of a residence, the labor force is not available to meet the housing construction needs. The use of a standard wood stud frame for the residence is one of the impediments to having the required housing built due to the time required to properly build a structure with stud walls.
- Also, while quality lumber is currently available, it is foreseeable that in the future that the wood required for the stud wall may not be available. As such, there is a need for a wall, that does not require wood, or other renewable materials, which can be quickly constructed while having good energy and sound efficiency.
- One aspect of the present disclosure relates to a composite foam and concrete wall. The composite foam and concrete wall is formed by aligning slabs of foam side by side to form a foam layer where the seams between the foam panels are substantially parallel to the upper and lower edges of the composite wall. Spaced apart channels are formed into an upper surface of the aligned slabs of foam substantially perpendicular to the seams wherein the pilasters are a sufficient depth to aid in securing a concrete layer to the upper surface of the foam panels. A horizontal channel is formed into the foam layer at a top surface. Rebar is placed in the channels and is raised from the foam surface a selected distance with rebar chairs. An end plate utilized as a top wall of a form with spaced apart lifting mechanism is positioned proximate the top end of the foam layer and proximate a top edge of the horizontal channel. A remaining portion of the form is placed about a perimeter of the foam layer and extends upwardly above the foam layer a selected distance, where the distance defines a wythe of concrete of the composite wall. Concrete is then placed into the form and over the foam layer wherein the concrete is placed into the channels and creates pilasters that increase the structural strength of the wall and also increase the bond strength between the concrete layer and the foam layer. When the wall is raised, utilizing the lifting mechanisms within an upper horizontal pilaster proximate the top portion of the form, the lifting force is substantially perpendicular to the seams in the foam and, therefore, prevents cracking in the concrete during the lift. While the concrete is not set, structural detail can be added to the surface, such as rocks, coloring or a stamping that resembles siding or a brick pattern. Because of the thickness of the concrete, the wall is structural, meaning it satisfies the requirements of a load bearing wall and the foam layer provides superior thermal and sound insulating qualities.
- Another aspect of the present disclosure relates to a composite foam and concrete foundation. The foundation includes a foam portion that can define the dimensions of the foundation, including the length, the width and the height of the foundation. An upper channel is formed into the foam portion substantially along a longitudinal axis extending along the length of the block from a top surface and into the block. The upper channel extends about one half the thickness of the block and can have a dovetailed construction such that a width of the bottom of the channel is greater than the opening in the top surface and wherein both left and right side surfaces extend inwardly at an acute angle from the bottom surface of the channel to the opening. The opposing ends of the foam block include left and right openings that extend from the top surface to the bottom surface where a top portion of the left and right openings is defined by the upper channel. Lower portions of the left and right openings can have a dovetail configuration where an opening at the bottom surface is lower than that of the transition from the upper surface to the lower surface. Rebar may optionally placed within the upper channel and/or the left and right opening and concrete is then placed into the upper channel and the left and right openings such that the concrete is substantially even with the outer surfaces of the foam portion. Because of the thickness of the concrete in the upper channel, the composite foam and concrete foundation meets the structural requirements of a standard foundation while being able to be produced off-site or prior to the construction of the structure. In some structures, piers or pilings may also be used to ensure the structural requirements are met.
- Another aspect of the present disclosure relates to a method of constructing a foundation of structure. The method includes positioning a number of pilings or piers into the soil at locations where foundations described above abut each other such that the concrete bottom surfaces of the foundation rest on the upper surface of the pier. The piers and foundations are positioned into the soil at a selected depth (which is dependent upon building codes) such that the concrete in the upper surface defines a perimeter of the structure. A structural wall as described above is positioned proximate the foundation and is raised to be positioned on the concrete surface of the foundations where the structural wall is disclosed herein and can be a composite foam and concrete wall. Upper edges of the walls are leveled with shims between the foundation and the wall. Once positioned on the concrete surface of the foundation and leveled, the structural wall is then secured to the foundation by a securing mechanism. Once the walls are secured to the foundations, the adjacent walls are secured together at the seams with adhesive and additional securing mechanisms can secure the adjacent walls together at the top surface. The method also includes positioning an insulating panel about a perimeter of the foundations and adjacent the outside edge of the foundation. The insulating panel extends a selected distance away from the foundation such that the foundation is protected from climatic factors such as frost. Soil is then back filled over the insulating panel, the foundation and is adjacent a lower portion of the structural wall.
- Another aspect of the present disclosure includes a bracket that is configured to be secured to a foam layer at least along a side edge and a top edge of the foam layer. The bracket includes a bottom portion configured to be positioned on an upper surface of the foam block and an angled tang forming an acute angle with the bottom portion. The angled tang is configured to be positioned in an angled slot within the foam layer to prevent the bracket from moving on the foam layer as the concrete is placed. A wall extends from a distal edge the bottom portion wherein a distance from a top edge of the wall to the bottom portion defines a thickness of a wythe of concrete, when placed. A screed portion extends from an upper end of the wall where the screed wall is substantially parallel to the bottom portion. The screed wall provides a surface for leveling the placed concrete. The bracket can optionally include angled spaced apart braces extending from the bottom portion to the wall wherein the braces can prevent the wall from flexing outwardly due to forces imparted onto the wall by the placed concrete. In some instances, the bracket supports one or more lifting mechanism that are encased within the placed concrete where the lifting mechanisms can be utilized to lift the wall into place. An angle of the wall can be any desired angle relative to the bottom portion.
-
FIG. 1 is a view of a typical gable roofed house. -
FIG. 2 is a perspective view of a foam layer and form for a solid wall and a wall with a window utilized to form a portion of the house. -
FIG. 3 is an end view of the wall. -
FIG. 4 is a view of a portion of the wall with a portion of the window frame with rebar placed within a pilaster. -
FIG. 5 is another view of a portion of the wall with a portion of the window frame with rebar placed within a pilaster. -
FIG. 6 is a view of a portion of the wall with the top, horizontal pilaster and the top plate. -
FIG. 7 is another view of the portion of the wall with the top, horizontal pilaster and the top plate. -
FIG. 8 is a view of a portion of the window frame and the foam wall. -
FIG. 9 is a perspective view of the window frame. -
FIG. 10 is a perspective of an installed window frame with the wall. -
FIG. 11 is a perspective view of the solid wall having a bottom surface treatment and a top surface treatment. -
FIG. 12 is another perspective view of the solid wall having a bottom surface treatment and a top surface treatment. -
FIG. 13 is a perspective view of the wall with the window having a bottom surface treatment and a top surface treatment. -
FIG. 14 is another perspective view of the wall with the window having a bottom surface treatment and a top surface treatment. -
FIG. 15 is another perspective view of the wall with the window having a bottom surface treatment and a top surface treatment. -
FIG. 16 is a perspective view of the wall with the window having the window being raised with a loader bucket on a tractor. -
FIG. 17 is a side view of the raised wall. -
FIG. 18 is a perspective view from the top surface of the raised wall. -
FIG. 19 is a perspective view of a foundation. -
FIG. 20 is a top view of the foundation -
FIG. 21 is an end view of the foundation. -
FIG. 22 is a bottom view of the foundation. -
FIG. 23 is a schematic view of the foundation positioned within the soil and a wall secured thereto. -
FIG. 24 is another schematic view of another foundation positioned within the soil and a wall secured thereto. -
FIG. 25 is a schematic view of foundation forms creating a perimeter of a structure with piers located where foundations are positioned adjacent each other. -
FIG. 26 is a schematic view of another embodiment of a wall having brackets defining edges of the concrete layer. -
FIG. 27 is a cross sectional view of the wall illustrated inFIG. 26 . -
FIG. 28 is an exploded view of a bracket with a lifting mechanism. -
FIG. 28A is a side view of the bracket illustrated inFIG. 28 . -
FIG. 29 is a perspective view of a bracket with a right angle. -
FIG. 29A is a side view of the bracket illustrated inFIG. 29 . -
FIG. 30 is a perspective view of a bracket with a 135 degree angle. -
FIG. 30A is a side view of the bracket illustrated inFIG. 30 . -
FIG. 31 is a schematic view of a wall joint with an exterior ninety degree angle. -
FIG. 32 is a partial schematic view of two wall secured together. -
FIG. 33 is a partial perspective view of a wall with channels in the foam layer configured to accept rafter or ceiling beams. -
FIG. 34 is a flow chart of an exemplary building method. -
FIG. 35 is a schematic view of batter boards defining a perimeter of a structure and holes for piers of a structure. -
FIG. 36 is a schematic view of holes for piers, foam portions of foundations defining a perimeter of the structure and a drainage grid for the structure. -
FIG. 37 is an enlarged view of a portion ofFIG. 36 . -
FIG. 38 is a view of a foam portion of a wall constructed with two layers of foam. -
FIG. 39 is perspective view of another foundation with holes within the foam portion for drainage purposes. -
FIG. 40 is a schematic view of a foundation portion of a structure. -
FIG. 41 is a flow chart of another exemplary building method. - A gabled house is illustrated in
FIG. 1 that is constructed using foundations, walls and methods of construction as disclosed herein. Aform 10 for awall 12 without any openings and aform 20 for awall 22 with awindow frame 23 are illustrated inFIG. 2 . Theform 10 includes abottom wall 14 and an opposingtop wall 16 that are connected with aright sidewall 18 and aleft sidewall 19 wherein the left side wall is at an angle which is about 45 degrees. Theform 20 includes abottom plate 24 and an opposingtop plate 26 that are connected with left andright walls form 20 does not include an angled wall, but one or bothsidewalls - Referring to
FIGS. 2-7 , thewall 12 and thewall 22 have asimilar foam layer 46 where thelayer 46 includes a plurality offoam panels bottom surface 52 and atop surface 54. The plurality offoam panels foam layer 46 of a compositeload bearing wall foam panels - A typical foam panel is constructed of modified expanded polystyrene because the foam has a high R value for insulation purposes. The foam layer is typically treated with a pesticide such as zinc borate to prevent insect and rodent infestations. The modified expanded polystyrene foam also is a fire preventative material, as the modified foam material will not promote a fire once the source of the fire is extinguished or removed from the foam. One non-limiting foam material is sold under the INSULFOAM® trademark by the Insulfoam division of the Carlisle Construction Materials headquartered in Puyallup, Wash. However, other materials of the foam panels are also contemplated.
- As illustrated the
foam panels - The
foam layer 46 includes left andright channels panels bottom surface 52 to thetop surface 54 wherein the left andright channels seams pilasters channels foam layer 46 while not adversely affecting the structural integrity of thefoam layer 46. It is understood that the thickness of thefoam layer 46 can dictate the depth of thechannels - It is also contemplated that a channel be formed around the entire perimeter of the formed wall which will sheer the entire panel to maintain the panel's shape and integrity. Also, a bottom header or beam is also contemplated, while not illustrated in the figures.
- The
foam layer 46 includes achannel 60 at thetop surface 54 that extends into thefoam layer 46 at a similar depth as that of thechannels channel 60 is substantially the same depth as that of thechannels - The
channels channels pilaster - The
top plate 26 includes a dove tail cut 62 along the length to provide additional securing of the concrete layer to thetop wall 26. Thewindow frame 23 includes a dado cut 25 about the outer perimeter to also allow concrete to flow therein and provide a more secure attachment of the concrete layer to thewindow frame 23. However, dado cuts in thetop plate 26 and thewindow frame 23 are optional. - Once the
channels foam panel 46, rebar chairs 66 andrebar 68 are placed into thechannels rebar 68 provides strength to the concrete within thechannels channels - Referring to
FIGS. 8-10 , thewindow frame 23 is installed by utilizing boards 70 that include the dado cuts 25 and have flashing 72 and 74 at the top andbottom edges window frame 23 and thefoam panel 46 allows the concrete to be placed between theframe 23 and thefoam layer 46. The concrete between theframe 23 and thefoam panel 46 forms a tight seal which prevents air infiltration and other external pressures, such as sound, wind, moisture and heat (or cold) from entering into the interior of a build from the exterior and vise versa. The flashing 76 and 78 extends around the perimeter of thewindow frame 23 about theouter edges foam panel 46 and maintaining a flat interior surface which can be very beneficial when securing dry wall to the interior surface. However, the flashing 76 and 78 is optional. - While any type of
board 73 for thewindow frame 23 can be utilized, a typicalpre-manufactured window frame 23 is manufactured by Prebuck LLC located in Grand Rapids, Mich. Theboards 73 are engineered laminated strand lumber (LSL) and are treated to prevent decay and insect infestation and have a minimal moisture content of about 4-6 weight percent. The Prebuck engineered boards are made from saplings that are treated and then processed into the engineered board. As such, the treatment extends through the entire board and not just penetrating a portion of the board. Therefore, when the board is cut, the end remains treated and will not decay or be susceptible to insects. The treatment utilized in the Prebuck engineered board is zinc borate, which is a preservative and prevents insect infestation. Zinc borate is not as toxic to human beings as other wood preservatives. - While the use of LSL is disclosed for window and door frames, it is also contemplated that the LSL can also be used for any structural and/or framing members within a building. Suitable LSL structural and/or framing members include those sold under the StrandGuard® trade designation and the TimberStrand® trade designation by Weyerhaeuser Company located in Federal Way, Wash. and the SolidGuard® trade designation by Louisiana Pacific Corporation headquartered in Nashville, Tenn. While an engineered wood window frame treated throughout its thickness with zinc borate is disclosed, any type of material that can be formed into the window frame is within the scope of the present invention. It is also contemplated that a similar manufacturing process be utilized with door frames. It is also contemplated that the windows and door frames be constructed of any suitable building material, including but not limited to metal and composite materials.
- A typical window would be a vinyl window wherein the perimeter of the window casing is secured to the
window frame 23 with a bead of sealant such as, but not limited to, a caulk. Utilizing a vinyl window frame and caulk removes the need for flashing as there is no means of penetration of water or air between the window casing andwindow frame 23. - Referring to
FIGS. 11 and 12 thefinished wall 12 with thefoam layer 46 and aconcrete layer 80 is illustrated with the framing removed. Theconcrete layer 80 is at least nominally two inches in thickness which provides sufficient structural integrity such that thewall 12 can be an exterior load bearing wall. Theconcrete layer 80 fills thechannels concrete layer 80 is not cured, asurface treatment 82 can be applied to theconcrete layer 80. As illustrated,field stones 84 are set into theconcrete layer 80 in alower portion 86. Theconcrete layer 80 in thelower portion 86 is colored a different color than the concrete 80 in anupper portion 88. - While
field stones 84 and utilizing different colors in theconcrete layer 80 are illustrated, these are but a couple of non-limiting examples of surface treatments that can be utilized. Other non-limiting surface treatments include stamping the concrete to have the appearance of siding or brick. Also, paint, dye or other colorant could be applied or integral to the concrete mix to provide different surface treatment. - Referring to
FIGS. 13-15 thefinished wall 22 is illustrated with theconcrete layer 80 secured to thefoam layer 46. As illustratedfield stone 84 are positioned into the concrete layer at thelower portion 86 as thesurface treatment 82. Theconcrete layer 80 in thelower portion 86 is not colored, and anupper portion 88 has a contrasting color. Thewindow frame 78 has been covered by theconcrete layer 80 and is not visible. Theconcrete layer 80 can have similar treatments as described with respect to thewall 12. - Referring to
FIGS. 16-18 , thewall 22 is illustrated being lifted utilizing a loader bucket on a tractor wherechains 90 are secured tobolts 92 in thetop plate 26. It should be understood that the pilaster within thechannel 60 along thetop plate 26 provides additional structural integrity to lift thewall 22 relative to a nominal two inch thickness of theconcrete layer 80. As thewall 22 is lifted from a horizontal position to a vertical position, a gravitational force is placed upon thewall 22 that is substantially perpendicular to theseams panels wall 22 is lifted, which prevents cracking, bowing or bending of theconcrete layer 80 which may not be apparent at the time of the lift but will become noticeable over time. It should be understood that thewall 12 is constructed similarly to thewall 22 and will also not cause a crack in theconcrete layer 80 when lifted. - It is also contemplated that siding fastening strips, such as furring strip or nailing strip, can be embedded into the
concrete layer 80 or have a portion of the siding fastening strips extend from an exterior surface of the concrete layer. The fastening strips can be constructed of wood or metal and are spaced apart to support siding such, for instance, lap siding. As such, Applicant can customize the look of an exterior surface to meet any needs of the owner including having a stone or brick treatment on the bottom portion with lap siding on the upper portion of the wall. - The
walls walls concrete layer 80 thewall 12 can be installed below ground and can be secured to a foundation for the foundation, such that a foundation wall is not required, which can also save time and money compared to a stud frame structure. - Also because the
wall side wall 19, two walls can be easily joined together using connectors that are positioned into the adjacent concrete layers 80. Since the connectors would not penetrate though the inner surface of the foam, there would be no thermal bridge from the outside which would affect the insulating properties of thefoam layer 46. A typical angle of the beveled edge is 45 degrees so that any wall edge can be mated with any other wall edge. However, other angles of the edges besides 45 degrees are also contemplated. It is also contemplated that thewalls walls 12 and/or 22 together, typically with a securing mechanism. - Because the
foam layer 46 is of a thickness such as for example eight inches, the utilities that are required in the wall can be easily installed by cutting channels into thefoam layer 46. It is contemplated that a chain saw with a depth guard or a hot knife designed to cut foam can be utilized to quickly and efficiently form the channels. Once the channels are formed into the foam layer the utilities including plumbing and electric wiring can be easily installed. - Also, sheet rock can be glued or adhered to the inner surface of the
foam layer 46 so that the building can be quickly finished relative to a structure that utilizes stud walls. When the adhesive is properly applied to the foam or sheet rock, the adhesive forms a vapor barrier that meets code and does not require a plastic wrap. This allows for the elimination of mechanical fastening of the sheet rock by for instance nails or screws, which in turn minimizes the labor required to mount the sheet rock and the finishing of the sheet rock, such as with a mud to evening the seams and cover the nail or screw indentions. Further, no additional insulation in the walls is necessary because thefoam layer 46 provides the necessary insulation. As such, the step of installing insulation which is required in a standard stud wall is not required. - It is also contemplated that a layer of plaster can be applied to the foam to provide a finished look to the interior walls instead of the sheet rock. The application of plaster is less expensive and less labor intensive than securing sheet rock to the foam layer and then mudding the seams prior to painting the sheet rock. It is also noted that a colorant can be mixed into the plaster such that a coat of paint may not be required.
- As such, the walls of the structure can be formed off-site and shipped to the location. The
bolts 92 or lifting hardware in thetop plate 26 are designed to easily raise thewalls - A
foundation 100 that can be utilized with thewalls FIGS. 19-22 . Thefoundation 100 includes a foam block 102 (typically EPS) of a desired length L, width W and height H. Thefoam block 102 typically has a height of about twelve (12) inches and a width of twenty four (24) inches and any desired length. However, the present disclosure is not limited a block of having a twelve (12) inch height and a twenty four (24) inch width. Rather any foam block having a sufficient size can be used provided the block of foam provides the necessary structural integrity. - A dovetail channel 104 (as illustrated in
FIGS. 23 and 24 ) is cut into the block from thetop surface 105 and into the block approximately a distance one half of the height where thedovetail channel 104 extends from aleft end 106 to aright end 108. A typical depth of thedovetail channel 104 is about 12 inches. However, other depths are contemplated. - The
dovetail channel 104 defines atop portion 108 of a left andright end channel 110 and 111. The left andright end channels 110 and 111 have a dovetail configuration and extend from thetop surface 105 to abottom surface 112. - A form is positioned about the
foam block 102 and concrete is placed to fill thedovetail channel 104 and the left andright end channels 110. The left andright channels 110 extend into the block 104 a selected distance such that a concrete surface 114 and 116 large enough to engage an earth anchor or pier after the concrete is placed and cured. - The
end channels 110 are filled with concrete and form concretevertical pilasters 124 and 126 that include the surfaces 114 and 116 that are capable of being placed upon a platform of an earth anchor, piling, pier or other support, if necessary. Atop surface 123 of thepilaster 122 forms a portion of a perimeter of the foundation of the structure that supports thewalls 12 and/or 22 of the structure - Referring to
FIG. 23 , thefoundation 100 is illustrated positioned within the soil a selected depth belowground level 120. Thefoundation 100 includes thefoam block 102 and aconcrete pilaster 122 having a dovetail cross section and a height that this approximately half of the height H of theblock 104. The dovetail configuration of thepilaster 122 within the block aids in retaining thepilaster 122 within thefoam block 104. While dovetail configured channels and pilasters are discussed and illustrated, any suitable configuration of the channels and pilasters for the foundation is also contemplated. - Once the
foundations 104 are placed in position,insulation panels 130 are then place adjacent an outervertical surface 132 of thefoam block 104 about the entire perimeter of the structure. Theinsulation panels 130 are typically about 2 inches thick and about 48 inches in width (however other dimensions of the insulating panels are contemplated). The insulation panels, typically EPS foam, prevent frost and other climate factors from engaging the foundation and extend the life of the structure. However, thefoundation 100 can be used at a depth that would not require theinsulation panels 130. - The
wall top surface 123 of thepilaster 122 and secured thereto with a fastening mechanism. Referring toFIG. 23 , the fastening mechanism 140 includesmetal strips 142 secured to thetop surface 123 of thepilaster 122 and to the sides of thewall 12 and/or 22. Anangle iron 144 is secured to the metal strips 122, typically with a weld. Utilizing the metal strips 142 and theangle iron 144 secures thewall 12 and/or 22 to thefoundation 100. - Referring to
FIG. 24 , thewall 12 and/or 22 is secured to thefoundation 100 with a securing mechanism that includes achannel 150 within theupper surface 123 of thepilaster 122 that is sized to a width and depth to accept a bottom portion of thewall 12 and/or 22. A concrete or adhesive can be used to secure thewall 12 and/or 22 with thechannel 150 and thereby secure thewall 12 and/or 22 to thefoundation 100 in a vertical position. - While a channel and concrete attaching mechanism and a weld between
metal strips 142 with anangle iron 144 are illustrated, other securing mechanisms are also within the scope of the present disclosure. - The use of the disclosed
foundation 100 and thewalls 12 and/or 14 eliminates the need to dig and place footings and to build a foundation wall, typically out of cinder blocks. Therefore, a significant amount of time and expense can be eliminated from the construction of a structure utilizing the disclosedfoundation 100 andwalls 12 and/or 14. -
FIG. 25 schematically illustratesadjacent foundations 100 forming a footprint or perimeter of a structure whereinpiers 101 are located under the adjacent ends of thefoundations 100. A non-limiting example of a pier includes a bell shaped pier. A insulating layer 103 abuts the foundations and extends outwardly therefore to protect thefoundations 100 from climatic factor such as frost. - Referring to
FIGS. 26 and 27 in another embodiment, awall 200 includes afoam layer 201 formed usingfoam panels panels lower edges panels foam layer 201 is typically a nominal six or eight inches thick. However, other thicknesses of thefoam layer 201 are also contemplated. - A plurality of spaced apart
channels 212 are cut into thefoam layer 201 in a manner similar as described with respect to thechannels channels 212 have a dovetail cross-section and extend from theupper edge 208 to thelower edge 210 and rebar is positioned, as required by engineering specification, in thechannels 212 as previously described. Alternatively, concrete fibers can be utilized instead of rebar. As illustrated, thechannels 212 are spaced a distance D1 approximately thirty six inches to forty eight inches apart on center. However, any distance D1 is within the scope of the present disclosure. While a dovetail cross-section is illustrated, the channel can have other cross-sectional configurations. Rebar is positioned within thechannels 212 as described forwalls - The
foam layer 201 includes spaced apartgrooves 214 that are substantially square or rectangular in configuration. The spaced apartgrooves 214 extend into the foam layer 201 a distance less than the distance thechannels 212 extend into thefoam panel 201. Thegrooves 214 interrupt abonding surface 203 of thefoam panel 201 which results in better bonding between thefoam panel 201 and a concrete layer or wythe when placed. As illustrated, thegrooves 214 are spaced apart a distance D2 between about twelve inches and about 24 inches. However, any distance D2 is within the scope of the present disclosure. Also, while thegrooves 214 are disclosed and illustrated herein, thegrooves 214 are optional. - A
left bracket 220 is secured to thefoam layer 201 proximate aleft edge 205 and along a length of theleft edge 205 and aright bracket 222 is attached to thefoam layer 201 proximate aright edge 207 and along a length of theright edge 207. Thebrackets bracket 220 provides a finished surface or edge to the panel or wall surface. - A bottom bracket 224 is secured to the
foam layer 210 proximate thebottom edge 210 and a top bracket 226 is secured to thefoam layer 201 proximate thetop edge 208 where both brackets 224 and 226 extend along a length of the respective edge. The brackets 224 and 226 are configured to withstand forces imparted by placed concrete, provide a screed surface for leveling the placed concrete and provide a finished surface for securing adjacent walls together. - Each
bracket bracket bonding surface 203 of thefoam layer 201 defines a thickness of awythe 230 of concrete that forms thewall 200. - When placed, the concrete fills the
channels 212 andgrooves 214 to formpilasters dovetailed pilasters 232 are utilized for structural integrity and thesmaller pilasters 234 are provide additional bonding between thewythe 230 and thefoam layer 201. As described in more detail below eachbracket bonding surface 203 of thefoam layer 201 which provides as surface to screed thewythe 203. The use of thebrackets wythe 230 and finished edges and therefore thewall 200 will require minimal, if any finishing work prior to installation. - Each
bracket FIGS. 28 and 28A , the bracket 226 is utilized to form the upper edge of thewall 200 while retaininglifting mechanisms 240 thereto such that when theconcrete wythe 230 is placed the liftingmechanisms 240 are securely encased in thewythe 230 and provide sufficient support to enable a cable or chain to be attached thereto for a lift from a horizontal portion to a substantially vertical position and ontofoundation 100. - The bracket 226 includes a
bottom portion 242 that is substantially flat and is configured to abut thebonding surface 203 of the foam layer. Anangled tang 244 extends from one edge of thebottom portion 242. Theangled tang 244 is configured to be positioned within aslot foam layer 201 where the slot has substantially the same angle. The angle is acute and is in the range of 20 degrees and about 60 degrees. A typical angle is about 30 degrees. The engagement of thetang 244 with the slot prevents movement toward theupper end 208 of the foam layer when the concrete is placed. Thebottom portion 242 can be secured to thebonding surface 203 with a layer of adhesive. - The bracket 226 includes a
wall 246 that extends from another edge of thebottom portion 242. Thewall 246 has a height H from thebottom portion 242 that defines the thickness of thewythe 230. Ascreed portion 248 extends from thewall 246 wherein thescreed portion 248 is substantially parallel to thebottom portion 242 such that the placed concrete can be screeded using thebrackets - The
wall 246 includes spaced apartapertures 250 that are configured to allow access to thelifting mechanism 240 when encased within thewythe 230. Prior to placing the concrete, anend cap 252 having a similar perimeter to that of the aperture is positioned through the aperture. Theend cap 252 has aslot 254 that separates end cap halves 256, 258 that are secured together with aliving hinge 260. Theslot 254 is spread apart and atop portion 262 of thelifting mechanism 240 having at least oneaperture 264 therein is positioned within theslot 254. The end cap halves 256, 258 are forced together to frictionally secure theend cap 252 about thetop portion 262 of thelifting mechanism 240. - The
end cap 252 is then secured within theaperture 250 in thewall 246 such that thelifting mechanism 240 is retained in a selected position. Thelifting mechanism 240 includes a main portion 266 between thetop portion 262 and thebottom portion 268. The bottom portion includesarcuate members lifting mechanism 240 from being pulled through the top portion of thewall 200 as thewall 200 is lifted. Whilearcuate anchor members - The
end cap 252 can also be utilized in different applications such as, but not limited to, providing access to a tightening mechanism secured to cables within the concrete wythe such that the concrete can be post tensioned. Post tensioning the concrete allows the structure to be utilized in different applications, such as, but not limited to a floor panel. - The
lifting mechanism 240 is typically of a monolithic construction where a material of construction is steel. However, other material of construction besides steel is contemplated for thelifting mechanism 240. - Once the concrete is placed and cured, the
end cap 240, having a low surface energy, is removed to provide access to a void in thewythe 230 which provides access to theaperture 264. Cables or chains can then be secured to spaced apart liftingmechanism 240 to lift thewall 200. - Prior to placing the concrete, spaced apart braces 281 are secured in spaced apart slots 282 in the
bottom portion 242 and spaced apartslots 284 in thewall 246. An area of theslots 282 and 284 are minimized to prevent concrete from flowing therethrough. Thebraces 281 include a “T” shapedend 286 that is wider than theslot 284 wherein one portion of the “T” shapedend 286 is position through theslot 284 followed by the other portion. Atypical slot 284 is a coin slot opening, which prevents concrete from flowing through the slot. The portions of the “T” shapedend 286 prevent theend 286 from sliding through theslot 284. Thebrace 281 includes a hook shaped end 288 that is configured to engage the slot 282 in thebottom portion 242. - With the “T” shaped
end 286 positioned through theslot 284, manual force is placed onto thebrace 281 which causes thebracket 240 to flex and cause thewall 246 towards thebottom portion 242. The hook shaped end 288 is then positioned the slot 228 and when the force is released thebrace 281 is in tension, which provides a counteracting force to the force of the placed concrete on thewall 246. As such, thewall 246 is retained in the selected position when theconcrete wythe 230 is placed. - The
brace 281 includes atab 283 that extends outwardly therefrom. Thetab 283 allows rebar or other materials to be secured to the brace. The rebar can be utilized to retain the liftingmechanisms 240 in the selected portion. - Referring to
FIGS. 29 and 29A , asimilar bracket 300 to that ofbracket 240 is illustrated. Thebracket 300 includes abottom portion 302,angled tang 304, substantiallyvertical wall 306 and ascreed portion 308 that is substantially parallel to thebottom portion 302. Thebottom portion 302 includesslot 310, similar toslot 280 in thebracket 240, andslot 312, similar to slot 282 in thewall 246, such that thesame brace 281 can be utilized. Theslot 312 is located within a channel 313, that is angled from the wall 313. The channel 313 defines corners into which an adhesive placed when walls are secured together. The corners in the adhesive created by the channel 313 prevent air and moisture penetration. A similar process is used to install and secure thebracket 300 to thefoam layer 201 relative to thebracket 240. Thebracket 240 is typically used on the bottom portion of thewall 202, but can be used on any edge of thewall 200. - The left and
right edges walls 200 have abutting surfaces having the same lengths and dimensions. For instance when two walls are joined to form a 90 degree corner, abracket 310 having awall 314 having a 135 degree angle relative to thebottom portion 312 is utilized as illustrated inFIGS. 30 and 30A . The bracket includes anangled tang 316 and ascreed portion 318, as previously described. - The
bracket 310 includes spaced apart slots 320 in thebottom portion 312 and spaced apartslots 322 in thewall 314.Braces 324 having a similar configuration to thebrace 281 are utilized wherein the ends of thebrace 324 are installed in theslots 320 and 322. -
FIG. 31 is a schematic of twowalls bracket 310. Eachwall wall 200 and includes thefoam layer 334 and theconcrete wythe 336. Eachwall bracket 310 and thefoam layer 334 is at the same angle as that of thewall 314. - While a 90 corner and a 135 degree angled corners are illustrated, other common angles for the walls of the wall relative to the bottom portion of the brackets include an angle of 22.5 degrees for a bay treatment, 90 degrees for butted walls and 135 degrees for outer bay treatments. Further, a bracket with a forty five degree angled wall can be used for inside corners.
- The
wall 314 of thebracket 310 is located between about one eighth to one quarter of an inch form thefoam surface 334 on thewall 330 and thewall 314 of thebracket 310 is positioned between about one eighth of an inch to about one half of an inch from the angledfoam surface 334 on thewall 332 to provide a gap between thebrackets 310. A typical gap is between about one quarter of an inch and about one half of an inch. - An adhesive layer is positioned in the void between the
angled foam surface 334 and thewall 314 to substantially fill the void. A typical adhesive is a pre-compressed joint sealant. One such pre-compressed joint sealant is sold under the WillSeal® trade designation by WillSeal located in Hudson, N.H. However any suitable adhesive or sealant is within the scope of the present application. As thewalls walls - Referring to
FIG. 32 , twowalls brackets 340. Thewalls foam layers concrete wythes brackets 340. Thebracket 340 is secured flush with the surface of thefoam layer 366 of thewall 362 while thebracket 340 is secured a distance from the surface of thefoam layer 362 of thewall 360 where the distance is typically between about one eighth of an inch and about one half of an inch. Anadhesive layer 372 is positioned in the void between the walls 344 and when thewalls adhesive layer 372 secures thewalls - Referring to
FIG. 33 , another embodiment of awall 380 is illustrated and is constructed as described with respect to thewall 200. For purposes of clarity, only top bracket is illustrated whereaperture 264 withinlifting mechanism 240 is illustrated. Thewall 380 has a modifiedfoam layer 382 relative to thefoam layer 201 of thewall 200. Thewythe 384 is similar that of thewythe 230. - The
foam layer 382 includes anupper portion 386 that extends above asurface 388 that is substantially flush or even with thewall 246 of the bracket. Theupper portion 386 extends a length of thefoam layer 283 and has spaced apartchannels 390 having abottom surface 392 located above thesurface 388. The channels are configured to accept a rafter beam or ceiling beam and are spaced apart to accept the rafter beam or ceiling beam per the building specification. Aninsert 390, typically metal with a “U” shaped channel, can be installed to provide additional strength to thefoam layer 382, although the insert is not required. Preforming thefoam layer 382 with thechannels 390 decreases the amount of time and labor required to build a structure as the rafter beams or ceiling beams can be adhered within the channels. 390. Optionally, a complementary piece of foam (not shown) with similarly spaced apart channels can be installed on thesurface 388 once thewall 380 is in the raised position to extend a length of thechannels 390 and provide more stability to the rafter beam or ceiling beam secured within thechannel 390. - A
method 400 of constructing a building is illustrated inFIG. 34 . The method includesstep 402 of clearing a location for the building, excavating the necessary soil to the proper finished grade, digging in the pier in selected locations about a footprint or perimeter of the building and to locate foundations and insulation. Instep 404 piers are positioned into the ground at selected elevations and locations where foundation about such that ends of adjacent foundations are supported by the pier. It is contemplated that each pier having an upper surface that is at substantially the same level such that the foundation will be level. An exemplary pier is a bell shaped pier however other styles of piers are also contemplated. After the piers are created in the soil, the interior can be vacuumed to remove loose soil and the concrete is placed into the interior of the foundation. - At
step 406 the foundations as previously described herein are positioned on the soil such that the soil supports the foundation along its length and end portions are supported by the piers. Once installed, the foundations provide a perimeter or footprint of the building. - At
step 408, the preformed composite foam andconcrete walls walls - At
step 410, insulating layers are posited about the foundation and outwardly from the foundation. The insulating layer prevents frost and other environmental factors from affecting the foundation. Atstep 412, soil is back filled over the foundation, insulating layer and the bottom portion of the wall. - At
step 414, rafters and or ceiling beams are installed. The rafter or ceiling beams are typically installed withwalls 380 having thechannels 390 for accepting the beams or rafters. However, the ceiling beams and/or rafters can be secured to a top beam as illustrated withwalls - At
step 416, another story or the roof is installed and shingled. A preferred roofing system is a metal roof manufactured by Gerard Roofing Technologies located in Brea, Calif. Atstep 418, foam is positioned between the rafters or ceiling joints and a ceiling material is installed. - At
step 419, an insulation layer is installed within the footprint of the building. A typical thickness of insulation is between about 4 and 10 inches, depending upon local building codes. - At
step 420, rebar is positioned above the insulating layer and ends of the rebar are tied to the wythe in the exterior wall. Optionally, a radiant heating system can be installed and then a slab concrete is placed within the foot print of the building. - At
step 424, interior walls and utilities are installed. Atstep 426, the interior of the building is finished. - In another embodiment, an area of land is leveled in preparation for a building to be constructed. Underground services including, but not limited to, sewer and water and optionally electrical are installed and the associated trenches are then compacted to a required density. Referring to
FIG. 35 ,batter boards 500 are set for aperimeter 502 of the building and a nominal one inch to a nominal two inches of sand is placed on the leveled soil within the space defined by the batter boards and compacted to a building code for the area. - The soil is excavated and graded for a selected distance beyond the perimeter. The soil is excavated and graded to support a foam layer that provides frost protection to the foundation.
-
Holes 504 for piers are then drilled in locations where two foundations meet. Loose soil is removed from theholes 504 and the base of the hole is compacted. Once theholes 504 are drilled and the soil is removed, foam portions of the foundations are positioned about a perimeter of the structure. - Referring to
FIG. 36 , abutting ends 512, 514 of thefoundations FIG. 36 a right angled corner is illustrated where the abutting ends have forty five degree surfaces. Depending upon the angle of the corner, the angle is bisected to determine the angle of the abutting edges of the foundations. - Referring to
FIGS. 36 and 37 ,rebar 516 is positioned in a top channel 518 of thefoundations holes 502 for the piers. Once the entire perimeter is completed, thefoundations - Concrete is then placed into the top channel 518 and fills the
holes 502 to form the piers for thefoundations foundations holes 502 to form the piers when cured, the concrete is of a monolithic construction that provides additional strength to the structure. - Once the concrete has cured, the walls can be raised and secured to the foundations as previously described. Alternatively, the walls can be formed using an alternative construction.
- Referring to
FIG. 38 , in the alternative construction, awall 530 can be formed by providing afirst panel 532 having a desired thickness, typically between two inches and six inches in thickness. Thefirst panel 532 is constructed as previously described where the seams between the first panels is substantially perpendicular or normal to stresses incurred during a lift, such as a tilt lift. Thefirst panel 532 has substantially flat top andbottom surfaces -
Brackets first panel 532 with an adhesive. Thebrackets brackets brackets first panel 532. To install the braces of thebrackets top surface 531 to provide sufficient space to secure the brace to the bottom member as previously discussed. Because a minimal amount of material is removed, the first panel has improved structural strength relative to the panel having the angled slots for accepting the angled tang. -
Channels 535 that define the pilasters are formed by securing asecond layer 534 having spaced apart portions to thefirst layer 532 with an adhesive. As previously disclosed, the second portions form dovetailed channels for forming the concrete pilasters. However, the portions of the second layer can provide any desired configurations. - With the braces and the portions of the second layer secured to the first layer, the concrete is placed onto the exposed surfaces of the first and second layers. The braces are utilized as a screed surface as previously disclosed.
- The bottom surface 533 of the
first layer 532 includes a fire resistant layer of material. A typical material of construction is Sold under the DENSILITE trade designation. However, the present disclosure is not limited to this material. - The
walls 530 are secured together as previously described. Once the exterior walls are in place on the concrete in the foundation, ceiling beams, trusses and/or rafters are secured within spaced apartslots 552 in the top edge of thefirst panel 532. Inserts may optionally be secured within the slots between thefirst panel 532 and the ceiling beams and/or rafters to provide increased structural integrity. - Once the ceiling beams, trusses and/or rafters are installed, a foam layer is positioned between the ceiling beams and/or rafters. The foam layers provide insulation and can also reduce the transmission of sound between stories of the structure. If required, a sheeting can be installed above the ceiling beams, trusses and/or rafters.
- In some instances, electric wiring is placed on an upper surface of the ceiling beams and or stringers of the rafters. One or more through bores is cut into the foam layer for lighting and a wireless light is installed. One or more wireless switches are installed into a wall wherein the one or more switches are typically battery powered which reduces the installation costs associated with the installation of wiring. The wireless system is more energy efficient relative to typical installations.
- Referring to
FIGS. 36 and 39 ,foam portions 560 of thefoundations bores 562 that allowdrainage tubing 564 to be installed in a pattern, typically a grid pattern. Referring toFIG. 40 , a material 566 is placed over the drainage tubing wherein the material allows moisture and gases such as radon to travel therethrough and into the drainage tubing such that the moisture is removed from the structure. A typical material of construction is ¾ minus or 1 inch minus aggregate. The material is compacted to a required code and protects the drainage tubing or tile. - With the
drainage tubes 564 installed, a layer of insulatingfoam 568 is positioned on the material 566 and radiantheat heating tubes 570 are installed and secured to the layer offoam 568. Rebar chairs 572 are installed on thefoam layer 570 and at least one grid ofrebar 574 is installed on thechairs 572.Rebar 574 is also positioned into thefoam portions 560 of thefoundations Concrete 578 is then placed on thefoam layer 568 and covers theradiant heating tubes 570 and therebar rebar 576 extending into thefoam portions 568 of thefoundations concrete slab 578 to thefoundations concrete slab 578 is between four and ten inches and more typically between six and eight inches, however the thickness will be controlled by engineering specifications for the structure. - In some embodiments, a channel is cut into the inner surface of some walls. The channels provide a conduit to place electrical wiring into the structure. In some embodiments, the channels are cut proximate a bottom surface such that a floor board can be installed to cover the channel, which decreases construction costs. However, the channels for the wiring can be located anywhere within the inner surface of the walls.
- In some instances, additional interior walls or hung cabinets are desired for a structure. To provide sufficient structural integrity for the interior walls or hung cabinetry, a channel can be cut into the inner surface of the foam of a size sufficient to secure a board therein with an adhesive. The board can then be utilized as a mounting material for the wall or the cabinetry. However, because the board does not extend to the concrete, there is no thermal bridge from the outdoor environment to the inside environment. Alternatively, the board can be anchored to the exterior concrete wythe.
- A foam layer is installed about the perimeter of the foundations to protect the foundations from frost. Soil is then backfilled to a desired grade and covers the foam layer.
- Referring to
FIG. 41 , another building method is illustrated that is similar to that as disclosed with respect toFIG. 34 . Themethod 600 includes cleaning, excavating and fine grading the building site atstep 602. Atstep 604 piers are located and dug and foam forms are placed in position to define a perimeter of the structure. Atstep 606, concrete is placed in the foam forms and piers to create a monolithic foundation. Once the foundation is set, the method includes steps 608-626 that are similar or the same as disclosed with respect to steps 408-426 to complete the construction. - The present disclosure is more particularly described in the following examples that are intended as illustrations only, since numerous modifications and variations within the scope of the present disclosure will be apparent to those skilled in the art.
- A simulation of the energy performance of the disclosed
walls structure 48 feet by 24 feet with an assumption that quality insulation installation (QII) was used to account for the lack of air gaps in the windows, doors and between the joints of the walls and because the disclosed structure has substantially no thermal bridging. An assumption was made that there were 4.4 changes of air per hour. - The construction of the walls was assumed to have a three inch wythe of concrete and variable thickness foam (EPS with an R value of 4.8/inch). The outer walls were covered with a layer of stucco and the inner layers were covered with gypsum board.
- An assumption was made that the structure had 10% glass coverage with the long walls having 44.8 square feet of windows and the short walls having 22.4 square feet of windows. The windows were assumed to have a U-factor of 0.32 and a solar heat gain coefficient of 0.34.
- The floor was a slab of concrete covered with tile. An insulating layer of R-10 insulation was installed outside of the structure a maximum distance of four feet.
- As previously discussed the roof was a metal roof with cool roof properties for
zones - The space conditioning assumed a combined hydronic and 90% boiler with no cooling. The wall thickness and insulating variables were simulated in different climate zones and include the following results for
California Climate Zone 16 with and without a radiant barrier on the roof in Tables 1,California Climate Zone 14 with and without a radiant barrier on the roof,California Climate Zone 12 with and without a radiant barrier on the roof. Wall insulation thickness, and roof insulation was varied in the simulations. The results are as follows. -
TABLE 1 Cold (California Climate Zone 16) Wall Insulation Roof Insulation Energy Design Variable Roofing Variable Variable Rating Performance 8 inches (R38) Gerard Metal Roof, 10 inches EPS (R48) 88.39 56.6-58.8% no radiant barrier 6 inches (R31) Gerard Metal Roof, R48 + R5 89.47 55.1-57.5% no radiant barrier 5.5 inches (R26) Gerard Metal Roof, R48 + RS 90.58 53.6-56.1% no radiant barrier 4.5 inches (R22) Gerard Metal Roof, R48 + R5 91.80 51.9-54.5% no radiant barrier 3.5 inches (R17) Gerard Metal Roof, R48 + R5 94.04 48.9-51.7% no radiant barrier 2 inches (R10) Gerard Metal Roof, R48 + RS 100.21 40.5-43.9% no radiant barrier 8 inches (R38) Gerard Metal Roof, 8 inches EPS (R38) 89.24 55.4-58.0% no radiant barrier 6 inches (R31) Gerard Metal Roof, R38 + R5 90.33 53.9-56.6% no radiant barrier 5.5 inches (R26) Gerard Metal Roof, R38 + R5 71.42 52.5-55.2% no radiant barrier 4.5 inches (R22) Gerard Metal Roof, R38 + RS 92.63 50.8-53.7% no radiant barrier 3.5 inches (R17) Gerard Metal Roof, R38 + R5 94.85 47.8-50.9% no radiant barrier 2 inches (R10) Gerard Metal Roof, R38 + R5 101.00 39.5-42.9% no radiant barrier 8 inches (R38) Gerard Metal Roof, 6 inches EPS (R29) 90.40 53.8-56.8% no radiant barrier 6 inches (R31) Gerard Metal Roof, R29 + R5 91.47 52.4-55.5% no radiant barrier 5.5 inches (R26) Gerard Metal Roof, R29 + R5 92.57 50.9-54.1% no radiant barrier 4.5 inches (R22) Gerard Metal Roof, R29 + RS 93.75 49.3-52.5% no radiant barrier 3.5 inches (R17) Gerard Metal Roof, R29 + R5 95.94 46.3-49.6% no radiant barrier 2 inches (R10) Gerard Metal Roof, R29 + R5 102.07 38.0-41.5% no radiant barrier -
TABLE 2 High Desert (continued) Wall Insulation Roof Insulation Energy Design Variable Roofing Variable Variable Rating Performance 8 inches (R38) GerardCool Roof, 10 inches EPS (R48) 97.79 43.6-49.2% w/radiant barrier 6 inches (R31) GerardCool Roof, R48 + R5 98.68 42.3-48.1% w/radiant barrier 5.5 inches (R26) GerardCool Roof, R48 + R5 99.70 40.9-46.9% w/radiant barrier 4.5 inches (R22) GerardCool Roof, R48 + R5 100.83 39.3-45.3% w/radiant barrier 3.5 inches (R17) GerardCool Roof, R48 + R5 102.94 36.4-42.6% w/radiant barrier 2 inches (R10) GerardCool Roof, R48 + R5 108.93 28.2-35.2% w/radiant barrier 8 inches (R38) GerardCool Roof, 8 inches EPS (R38) 98.32 42.8-48.5% w/radiant barrier 6 inches (R31) GerardCool Roof, R38 + R5 99.30 41.4-47.3% w/radiant barrier 5.5 inches (R26) GerardCool Roof, R38 + R5 100.33 40.0-45.9% w/radiant barrier 4.5 inches (R22) GerardCool Roof, R38 + R5 101.46 38.5-44.3% w/radiant barrier 3.5 inches (R17) GerardCool Roof, R38 + R5 103.57 35.6-41.8% w/radiant barrier 2 inches (R10) GerardCool Roof, R38 + R5 109.59 27.3-34.3% w/radiant barrier 8 inches (R38) GerardCool Roof, 6 inches EPS (R29) 99.17 41.6-47.3% w/radiant barrier 6 inches (R31) GerardCool Roof, R29 + R5 100.16 40.2-46.0% w/radiant barrier 5.5 inches (R26) GerardCool Roof, R29 + R5 101.19 38.8-44.6% w/radiant barrier 4.5 inches (R22) GerardCool Roof, R29 + R5 102.33 37.3-43.3% w/radiant barrier 3.5 inches (R17) GerardCool Roof, R29 + R5 104.44 34.4-40.7% w/radiant barrier 2 inches (R10) GerardCool Roof, R29 + R5 110.47 26.1-33.1% w/radiant barrier -
TABLE 3 High Desert (California Climate Zone 14) Wall Insulation Roof Insulation Energy Design Variable Roofing Variable Variable Rating Performance 8 inches (R38) Gerard Cool Roof, 10 inches EPS (R48) 98.36 42.7-48.6% no radiant barrier 6 inches (R31) Gerard Cool Roof, R48 + R5 99.26 41.5-47.4% no radiant barrier 5.5 inches (R26) Gerard Cool Roof, R48 + R5 100.29 40.1-45.9% no radiant barrier 4.5 inches (R22) Gerard Cool Roof, R48 + R5 101.40 38.5-44.6% no radiant barrier 3.5 inches (R17) Gerard Cool Roof, R48 + R5 103.53 35.6-41.9% no radiant barrier 2 inches (R10) Gerard Cool Roof, R48 + R5 109.54 27.4-34.4% no radiant barrier 8 inches (R38) Gerard Cool Roof, 8 inches EPS (R38) 98.99 41.8-47.6% no radiant barrier 6 inches (R31) Gerard Cool Roof, R38 + R5 99.98 40.5-46.3% no radiant barrier 5.5 inches (R26) Gerard Cool Roof, R38 + R5 101.00 39.1-45.1% no radiant barrier 4.5 inches (R22) Gerard Cool Roof, R38 + R5 102.14 37.5-43.4% no radiant barrier 3.5 inches (R17) Gerard Cool Roof, R38 + R5 104.26 34.6-41.0% no radiant barrier 2 inches (R10) Gerard Cool Roof, R38 + R5 110.27 26.4-33.4% no radiant barrier 8 inches (R38) Gerard Cool Roof, 6 inches EPS (R29) 99.96 40.5-46.1% no radiant barrier 6 inches (R31) Gerard Cool Roof, R29 + R5 100.96 39.1-45.0% no radiant barrier 5.5 inches (R26) Gerard Cool Roof, R29 + R5 101.99 37.7-43.5% no radiant barrier 4.5 inches (R22) Gerard Cool Roof, R29 + R5 103.13 36.2-42.2% no radiant barrier 3.5 inches (R17) Gerard Cool Roof, R29 + R5 105.25 33.3-39.6% no radiant barrier 2 inches (R10) Gerard Cool Roof, R29 + R5 111.27 25.0-32.0% no radiant barrier -
TABLE 4 Hot & Cold (California Climate Zone 12) Wall Insolation Roof Insulation Energy Design Variable Roofing Variable Variable Rating Performance 8 inches (R38) Gerard Cool Roof, 10 inches EPS (R48) 89.77 42.9-49.4% no radiant barrier 6 inches (R31) Gerard Cool Roof, R48 + R5 90.51 41.5-48.2% no radiant barrier 5.5 inches (R26) Gerard Cool Roof, R48 + R5 91.31 40.0-46.9% no radiant barrier 4.5 inches (R22) Gerard Cool Roof, R48 + R5 92.12 38.5-45.5% no radiant barrier 3.5 inches (R17) Gerard Cool Roof, R48 + RS 93.68 35.6-42.9% no radiant barrier 2 inches (R10) Gerard Cool Roof, R48 + R5 98.22 27.2-35.2% no radiant barrier 8 inches (R38) Gerard Cool Roof, 8 inches EPS (R38) 90.40 41.7-48.3% no radiant barrier 6 inches (R31) Gerard Cool Roof, R38 + R5 91.11 40.4-47.0% no radiant barrier 5.5 inches (R26) Gerard Cool Roof, R38 + R5 91.89 38.9-45.8% no radiant barrier 4.5 inches (R22) Gerard Cool Roof, R38 + R5 92.71 37.4-44.4% no radiant barrier 3.5 inches (R17) Gerard Cool Roof, R38 + R5 94.32 34.4-41.7% no radiant barrier 2 inches (R10) Gerard Cool Roof, R38 + R5 98.84 26.0-34.0% no radiant barrier 8 inches (R38) Gerard Cool Roof, 6 inches EPS (R29) 91.19 40.2-46.8% no radiant barrier 6 inches (R31) Gerard Cool Roof, R29 + R5 91.96 38.8-45.5% no radiant barrier 5.5 inches (R26) Gerard Cool Roof, R29 + R5 92.69 37.4-44.3% no radiant barrier 4.5 inches (R22) Gerard Cool Roof, R29 + R5 93.54 35.9-42.9% no radiant barrier 3.5 inches (R17) Gerard Cool Roof, R29 + R5 95.15 32.9-40.1% no radiant barrier 2 inches (R10) Gerard Cool Roof, R29 + R5 99.69 24.5-32.4% no radiant barrier -
TABLE 5 Hot & Cold (continued) Wall Insulation Roof Insulation Energy Design Variable Roofing Variable Variable Rating Performance 8 inches (R38) Gerard Cool Roof, 10 inches EPS (R48) 89.28 43.8-50.2% w/radiant barrier 6 inches (R31) Gerard Cool Roof, R48 + R5 90.03 42.4-49.0% w/radiant barrier 5.5 inches (R26) Gerard Cool Roof, R48 + R5 90.82 40.9-47.7% w/radiant barrier 4.5 inches (R22) Gerard Cool Roof, R48 + R5 91.63 39.4-46.3% w/radiant barrier 3.5 inches (R17) Gerard Cool Roof, R48 + R5 93.19 36.5-43.7% w/radiant barrier 2 inches (R10) Gerard Cool Roof, R48 + R5 97.73 28.1-36.0% w/radiant barrier 8 inches (R38) Gerard Cool Roof, 8 inches EPS (R38) 89.81 42.8-49.2% w/radiant barrier 6 inches (R31) Gerard Cool Roof, R38 + R5 90.57 41.4-48.0% w/radiant barrier 5.5 inches (R26) Gerard Cool Roof, R38 + R5 91.33 40.0-46.7% w/radiant barrier 4.5 inches (R22) Gerard Cool Roof, R38 + R5 92.20 38.3-45.3% w/radiant barrier 3.5 inches (R17) Gerard Cool Roof, R38 + R5 93.73 35.5-42.7% w/radiant barrier 2 inches (R10) Gerard Cool Roof, R38 + R5 98.27 27.1-35.0% w/radiant barrier 8 inches (R38) Gerard Cool Roof, 6 inches EPS (R29) 90.53 41.4-47.8% w/radiant barrier 6 inches (R31) Gerard Cool Roof, R29 + R5 91.31 40.0-46.6% w/radiant barrier 5.5 inches (R26) Gerard Cool Roof, R29 + R5 92.05 38.6-45.4% w/radiant barrier 4.5 inches (R22) Gerard Cool Roof, R29 + R5 92.89 25.7-33.6% w/radiant barrier 3.5 inches (R17) Gerard Cool Roof, R29 + R5 94.48 34.1-41.3% w/radiant barrier 2 inches (R10) Gerard Cool Roof, R29 + R5 99.02 37.1-44.0% w/radiant barrier - The Energy Design Rating reflects the annual energy consumption including lighting, domestic appliances, and electronics not included in the
California Title 24 performance. The Performance is a percentage of the level above a building that complies with California's Energy Efficiency Standards (Title 24, Part 6) for space conditioning and water heating. The lower range of performance is an East/West front orientation of the building and the higher range is for a North/South front orientation of the building. - The results of the simulation indicate a significant increase in energy efficiency relative to California Energy Efficiency Standards. The simulations surprisingly indicated at least a forty percent increase in performance independent of the climate zone and whether or not a radiant barrier was considered. Also, comparing the simulations with the radiant barrier to simulations without the radiant barrier resulted in a slight increase in simulated energy efficiency.
- Although the subject matter has been described in language specific to structural features and/or methodological acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described above as has been determined by the courts. Rather, the specific features and acts described above are disclosed as example forms of implementing the claims.
Claims (20)
1. A composite foam and concrete wall comprising;
a foam layer having a top surface, a bottom surface, a left wall surface and a right wall surface wherein the foam layer comprises at least two foam panels that define a seam that is substantially parallel to the top surface and the bottom surface; and
a concrete layer secured to a surface of the foam layer.
2. The composite foam and concrete wall of claim 1 and wherein the foam layer comprises:
a plurality of spaced apart channels extending from proximate the bottom surface to proximate the top surface; and
a plurality of pilasters within the channels and extending from the concrete layer.
3. The composite foam and concrete wall of claim 2 and wherein the plurality of spaced apart channels and the plurality of pilasters comprise a dovetail cross-section.
4. The composite foam and concrete wall of claim 1 and further comprising:
a left channel extending into the foam layer along the left wall surface;
a right channel extending into the foam along the right wall surface; and
a top channel extending into the foam along the top surface.
5. The composite foam and concrete wall of claim 4 and further comprising:
a left concrete pilaster extending from the concrete layer and positioned within the left channel;
a right concrete pilaster extending from the concrete layer and positioned within the right channel; and
a top concrete pilaster extending from the concrete layer and positioned within the top channel.
6. The composite foam and concrete wall of claim 1 and further comprising a top plate secured to a top surface of the concrete layer from the left surface to the right surface.
7. The composite foam and concrete wall of claim 1 and further comprising:
spaced apart lifting mechanisms positioned through the top plate wherein the spaced apart lifting mechanism are configured to engage a lifting mechanism such that the wall can be raised to a substantially vertical or standing position.
8. The composite foam and concrete wall of claim 1 and wherein the foam layer has a nominal thickness in the range of about 3 inches to about 10 inches.
9. The composite foam and concrete wall of claim 1 and wherein the concrete layer has a nominal thickness in the range of about 2 inches to about 6 inches such that the wall is a structural, load bearing wall.
10. A method of constructing a composite foam and concrete wall, the method comprising:
positioning a plurality of foam panels proximate each other to form a foam layer of a selected height and width;
forming a plurality of spaced apart channels in the foam layer extending from proximate a bottom end to proximate a top end;
positioning rebar within the spaced apart channels;
positioning a form about a perimeter of the foam layer wherein the form extends above an upper edge of the foam layer a selected distance; and
placing concrete on the foam panel and within the form to form a concrete layer with a plurality of pilasters extending into the foam layer and within the plurality of spaced apart channels.
11. The method of claim 10 and wherein forming the plurality of spaced apart channels comprises forming dovetail cross-sectional channels and wherein the placed concrete forms dovetail cross-sectional pilasters.
12. The method of claim 10 and wherein positioning a form about a perimeter of the foam layer comprises:
cutting an angled slot about the perimeter of the foam layer; and
positioning brackets about the perimeter wherein each bracket comprises:
a bottom portion positioned on the foam layer;
a angled tang extending from the bottom portion and positioned within the angled slot;
a wall extend from the bottom portion wherein a thickness the concrete layer is defined by a height of the wall; and
a screed portion substantially parallel to the bottom portion wherein the brackets are retained to the concrete layer and forms a finished surface.
13. The method of claim 10 and wherein positioning a form about a perimeter of the foam layer comprises:
positioning boards about the perimeter of the foam layer wherein the board at the top end comprises a top plate;
securing the boards together; and
after the concrete layer has cured, removing the form from the wall wherein the top plate is retained to the wall.
14. The method of claim 10 and further comprising:
cutting an area for a window from the foam layer; and
positioning a window frame within the cut out area wherein the cut out area is larger than the window frame such that when the concrete is placed the concrete encases the window frame.
15. The method of claim 10 and further comprising:
cutting an area for a door from the foam layer; and
positioning a door frame within the cut out area wherein the cut out area is larger than the door frame such that when the concrete is placed the concrete encases the door frame.
16. The method of claim 10 and further comprising:
forming a plurality of spaced apart grooves within the foam layer and between the spaced apart channels wherein the spaced apart grooves have a smaller cross-sectional area and depth relative to the cross-sectional area of the spaced apart channels wherein when the concrete is placed the grooves are filled with concrete.
17. A composite foam and concrete wall comprising;
a foam layer having a top surface, a bottom surface, a left wall surface and a right wall surface wherein the foam layer comprises at least two foam panels that define a seam that is substantially parallel to the top surface and the bottom surface;
a form secured to a top surface of the foam layer and extending from a perimeter of the foam layer; and
a concrete layer placed onto a surface of the foam layer wherein the form is retained to the foam layer and provides a finished surface to the concrete layer.
18. The composite foam and concrete wall of claim 17 and wherein the foam layer comprises:
a plurality of spaced apart channels extending from proximate the bottom surface to proximate the top surface; and
a plurality of pilasters within the channels and extending from the concrete layer.
19. The composite foam and concrete wall of claim 18 and wherein the plurality of spaced apart channels and the plurality of pilasters comprise a dovetail cross-section.
20. The composite foam and concrete wall of claim 17 and wherein the foam layer has a nominal thickness in the range of about 3 inches to about 10 inches.
Priority Applications (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US16/749,403 US20200157814A1 (en) | 2014-09-15 | 2020-01-22 | Composite foam and concrete wall and method constructing the same |
US16/935,860 US11536027B2 (en) | 2014-09-15 | 2020-07-22 | Composite foam and concrete foundation, composite foam and concrete wall and method of mounting composite foam and cement wall to the foundation |
US18/080,600 US20230114879A1 (en) | 2014-09-15 | 2022-12-13 | Composite foam and concrete foundation, composite foam and concrete wall and method of mounting composite foam and cement wall to the foundation |
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US16/749,403 US20200157814A1 (en) | 2014-09-15 | 2020-01-22 | Composite foam and concrete wall and method constructing the same |
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US16/935,860 Active US11536027B2 (en) | 2014-09-15 | 2020-07-22 | Composite foam and concrete foundation, composite foam and concrete wall and method of mounting composite foam and cement wall to the foundation |
US18/080,600 Pending US20230114879A1 (en) | 2014-09-15 | 2022-12-13 | Composite foam and concrete foundation, composite foam and concrete wall and method of mounting composite foam and cement wall to the foundation |
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US18/080,600 Pending US20230114879A1 (en) | 2014-09-15 | 2022-12-13 | Composite foam and concrete foundation, composite foam and concrete wall and method of mounting composite foam and cement wall to the foundation |
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Cited By (1)
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US11536027B2 (en) * | 2014-09-15 | 2022-12-27 | James Hodgson | Composite foam and concrete foundation, composite foam and concrete wall and method of mounting composite foam and cement wall to the foundation |
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CA3177044A1 (en) * | 2020-03-27 | 2021-09-30 | Nexii Building Solutions Inc. | Systems and methods for constructing a single-storey building |
US11572697B2 (en) | 2020-09-24 | 2023-02-07 | Saudi Arabian Oil Company | Composite insulated wall panel |
US11549633B1 (en) | 2021-09-01 | 2023-01-10 | Saudi Arabian Oil Company | Protecting a portion of a pipeline from an impact |
CN115467353A (en) * | 2022-11-14 | 2022-12-13 | 中建八局第二建设有限公司 | A precast concrete basis for assembled container board house |
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Cited By (1)
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US11536027B2 (en) * | 2014-09-15 | 2022-12-27 | James Hodgson | Composite foam and concrete foundation, composite foam and concrete wall and method of mounting composite foam and cement wall to the foundation |
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US20230114879A1 (en) | 2023-04-13 |
US10577798B1 (en) | 2020-03-03 |
US20200347597A1 (en) | 2020-11-05 |
US11536027B2 (en) | 2022-12-27 |
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