Classifications

• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
  • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
  • E04B2/84—Walls made by casting, pouring, or tamping in situ
  • E04B2/842—Walls made by casting, pouring, or tamping in situ by projecting or otherwise applying hardenable masses to the exterior of a form leaf
  • E04B2/847—Walls made by casting, pouring, or tamping in situ by projecting or otherwise applying hardenable masses to the exterior of a form leaf the form leaf comprising an insulating foam panel
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
  • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
  • E04B2/84—Walls made by casting, pouring, or tamping in situ
  • E04B2/842—Walls made by casting, pouring, or tamping in situ by projecting or otherwise applying hardenable masses to the exterior of a form leaf
  • E04B2/845—Walls made by casting, pouring, or tamping in situ by projecting or otherwise applying hardenable masses to the exterior of a form leaf the form leaf comprising a wire netting, lattice or the like
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • 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
  • 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
  • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
  • E04C2/38—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels
  • E04C2/384—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels with a metal frame
• • 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
  • E04C2/44—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose
  • E04C2/52—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose with special adaptations for auxiliary purposes, e.g. serving for locating conduits
  • E04C2/521—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose with special adaptations for auxiliary purposes, e.g. serving for locating conduits serving for locating conduits; for ventilating, heating or cooling
• • 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
  • E04B1/16—Structures made from masses, e.g. of concrete, cast or similarly formed in situ with or without making use of additional elements, such as permanent forms, substructures to be coated with load-bearing material

Definitions

• present construction methods typically rely on steel stud frames having insulation sprayed or placed on the interior side of the stud wall.
• Such an arrangement is not as efficient as possible because heat can be conducted from wall surfaces directly to the frame elements, circumventing the surrounding insulation.
• Providing external insulation, i.e. insulation placed on the outside of the stud frame can be helpful, but to date there has not been a reliable means to applying such insulation.
• insulation placed only externally will not provide sufficient heat and cold protection and therefore spray or roll insulation will still have to be provided on the inside wall.
• the construction can be rendered expensive, cumbersome, and labor intensive.
• U.S. Patent 5,522,194 to Graulich describes a planar building panel core having two faces coated with a cementitious material whereby the core is a closed-cell foam insulation board. A metal grid or lath is laid over the foam before the cement is applied.
• the core panel includes a plurality of spaced metal furring vertical channel members which are fastened to a support structure and a steel reinforcing sheet spanning the face of each panel, thus comprising a frame surrounding the foam insulation board. Cement is applied over the metal grid and the foam board to result in a unitary construction panel. While providing a relatively sound system, this construction invention is flawed in that there is no means for prefabricating any aspect of the design and it requires extensive assembly of the frame elements around the foam board during construction of the system. Assembly cannot be complete using standard hand tools by unskilled labor. Further, the foam board is not disposed on the exteriors of the frame and therefore the structural rigidity and insulative properties are compromised.
• the complex framing structure is disposed around the foamboard and includes numerous interconnected parts which renders the system difficult to assemble and not amenable to affordable housing construction by unskilled workers.
• the construction method does not provide both internal and external insulation at the wall surface.
• the present invention provides an improved building construction system and method designed to addressed the problems outlined above and provides a systemized product that provides housing for residential or commercial use, can be economically constructed, does not need high level and expensive skilled labor, is extremely strong and weather resistant, has excellent internal and external thermal insulation capabilities, and requires low maintenance. It is, therefore, to the effective resolution of the aforementioned problems and shortcomings of the prior art that the present invention is directed.
• the present invention provides a composite building construction system, comprising: a frame, wallboard, and a concrete layer.
• the wallboard comprises an outer portion and inset portion wherein the wallboard is attached to the frame with the outer portion covering an exterior side of the frame and the inset portion is disposed within the frame.
• the wallboard thus provides exterior and interior insulation for the system.
• the wallboard may be attached to the frame by an adhesive or by common fasteners.
• the concrete layer is sprayed on to the outer portion of said wallboard, forming a strong durable composite construction system.
• one or more rebar supports are attached to the frame at the exterior side of said frame and are spaced apart from the wallboard.
• the rebar supports are secured to the frame by one or more key bolts which pass through the wallboard and into the frame and are lockingly engaged with the frame.
• the frame may include key holes with correspond to the lock ends of the key bolts, which bolts may be secured by inserting and rotating them within the frame.
• a wire grid may be attached to the one or more key bolts and is spaced apart from the wallboard and the rebar supports whereby the grid and the rebar provide a support structure for the concrete layer.
• the concrete layer is 3 inches thick.
• the frame includes a plurality of outer framing members and one or more cross members.
• the inset portion of the wallboard includes one or more channels configured to accommodate the one or more cross members of the frame and thus fit snugly inside the frame.
• the outer framing members and the one or more cross members include one or more apertures for the routing of electrical wires or plumbing and the apertures are adapted to receive conduits for protecting the electrical wires and the plumbing.
• the wallboard may also include channels to accommodate the conduits.
• One or more guide wires may be attached to the frame by key bolts at he exterior side of said frame, the guide wires spaced apart from said wallboard and adapted to indicate the depth of the concrete layer to be applied.
• the frame sections are manufactured using a computer system that prefabricates and codes the frame sections for easy assembly.
• the interior side of the frames is configured to receive drywall or other finishing material.
• the frame comprises high tensile steel and the wallboard comprises expanded polystyrene.
• the wallboard may be dimensioned such that the depth of the inset portion is greater than the depth outer portion of said wallboard. In any event, the wallboard provides significant external and internal insulation: a substantial advantage over the prior art.
• a housing unit or building may be constructed by providing one or more frame sections each prefabricated and coded according to a building plan.
• the frame sections are assembled together to form a housing structure.
• the wallboard is attached to the frame sections, the rebar supports and wire grid is attached to the wallboard, the guide wire is installed and then concrete is sprayed over the wire grid, rebar, and wallboard until the relatively thick concrete layer is formed.
• the guide wire may be used to indicate the depth of the concrete to be applied.
• the concrete Once the concrete has been cured, it can be finished with paint, stucco, or other known housing unit finish materials.
• the interior side of the frame can be finished with drywall.
• FIG. 1 is an exploded schematic of one embodiment of the building construction system of the present invention.
• FIG. 2 is a cross-sectional cutaway view of one embodiment of the building construction system of the present invention.
• FIG. 3 is a perspective view of one embodiment of the building construction system of the present invention.
• FIG. 4 is another perspective view of one embodiment of the system of the present invention.
• FIG. 5 is a perspective view of one aspects of the frame and wallboard configuration of the present invention.
• FIG. 6 is a perspective view of one embodiment of the wallboard of the present invention showing the inset portion, outer portion, and channels.
• FIGS. 7A-7C depict various embodiments of the key bolts and the key hold engagement used with the frame of the present invention.
• FIG. 8 is a perspective view of another embodiment of the present invention, utilizing support arches useful for concrete application.
• the present invention overcomes the disadvantages of the prior art by incorporating a combination of sprayed concrete onto an internal and external insulating board which is cladding a steel stud frame.
• FIG. 1 shown is an exploded schematic of one embodiment of the system of the present invention arranged and constructed in accordance with one embodiment of the method of the present invention. Shown is a section, or a portion of a composite construction system 1, comprising a frame 10, a wallboard 11, a support grid 12, and a concrete layer 13.
• the system 1 is provided as a wall structure for a building or housing unit and will typically be assembled in sections as described in detail below.
• the wallboard 11 is secured to and disposed on an exterior side 101 of the frame 10.
• wallboard 11 is secured to frame 10 by an adhesive such as an epoxy or clue.
• wallboard 11 is further fastened to frame 10 by one or more key bolts 30 received through wallboard 11 and terminating within a portion of frame 10.
• a plurality of bolts 30 may be provided through wallboard 11 and into frame 10 to provide a secure attachment of the two components.
• the bolts 30 may include eyelets that are configured to receive and secure rebar support 14 and/or guide wire 15 which provide additional support and guidance for the application of the concrete layer 13, as discussed in further detail below.
• the key bolts 30 are configured to lockingly engage pre-fabricated key holes provided in the frame 10 to allow for ease of installation, as further described below.
• other fasteners may be used instead of bolts, such as screws, nails, staples, and the like.
• Grid 12 which is spaced apart from but attached to wallboard 11.
• Grid 12 may comprise a wire mesh grid, a rebar grid, or similar rigid grid that provides additional structural support for concrete layer 13.
• grid 12 is attached to either rebar support 14 or one or more bolts 30 by ties 35 which are received around both the grid 12 and either the rebar support 14 or a bolt 30.
• Other means of connecting the grid 12 may be employed, including brackets, screws, bolts, staples, and the like.
• the wire grid 12 is disposed between the wallboard 11 and the guide wire 15 such that the guide wire 15 is on the outside of the system 1.
• the rebar support 14 is disposed between the wallboard 11 and the grid 12. Further, it is appreciated that one or more rebar supports 14 may be provided, with corresponding bolts, and the rebar supports 14 may be disposed horizontally and/or vertically, or in a frame-like manner around the periphery of the frame 10.
• concrete layer 13 is sprayed over grid 12 such that the concrete adheres to wallboard 11 and has a thickness extending away from wallboard 11.
• Grid 12 and/or rebar 14 provide structural support for the adherence of concrete layer 13 to wallboard 11.
• concrete layer 13 is applied in multiple thin-layer applications in order to assure adherence and structural rigidity with respect to wallboard 11.
• the guide wire 15 is disposed across the wallboard and may provide guidance during the application of the concrete layer 13, i.e. to delimit the desired depth of concrete layer 13 application. As depicted in FIG.
• concrete layer 13 is applied such that grid 12 and rebar 14 is disposed within the concrete layer 13; or, said differently, concrete layer 13 is disposed on either side of grid 12 and/or rebar 14 and, in many cases, will be disposed through grid 12 wherein grid 12 includes interstitial gaps 121 (FIG. 1) by way of its grid configuration.
• grid 12 includes interstitial gaps 121 (FIG. 1) by way of its grid configuration.
• the grid 12 provides support for and catches the concrete layer 13 during application to prevent the concrete from sliding down the wall surface.
• the rebar supports 14 provide structural reinforcement once the concrete layer 13 has set. In FIG.
• the guide wire 15 provides a designation of the depth of concrete layer 13 to be applied. In some embodiments, the guide wire 15 will be flush with the outer edge of the concrete layer 13. However, for illustrative purposes in FIG. 2, the guide wire 15 is shown to be contained inside the concrete layer somewhat - such a configuration is not required nor should the depth of the concrete layer 13 and relationship to guide wire 15 be limited to that shown in FIG. 2.
• the stud frame 10 of the present invention is constructed through use of a fabricating machine which forms the studs from coiled metal (steel, aluminum, and the like) and marks the components with coding to allow for quick, easily assembled construction by workers who do not need high level construction skills, rather they need only to match the markings for assembly.
• FIG. 4 shows an example of one section of frame 10 shown having a generally square or rectangular shape. Shown is frame 10 from the perspective of interior side 102 with wallboard 11 attached to the exterior side of frame 10.
• Frame 10 may include outer framing members 103 and one or more cross members 104, which functions as studs, providing a riding structural support system for building construction.
• the inset portion 112 is deeper than the outer portion 111, for example the inset portion 112 may have a depth of 2 inches extending into the frame 10 whereas the outer portion 111 has a depth of 1 inch extending outward from the frame 10.
• the inset portion 112 includes one or more channels 113 which are configured to accommodate the cross members 104 of the frame 10. This allows the inset portion 112 wallboard 11 to fit snugly and securely within the internal cavities 140 of frame 10 with minimal movement, which eases construction and assembly and provides added rigidity and stability to the construction system 1.
• FIG. 5 demonstrates the configuration of the outer portion 111 and inset portion 112 of wallboard 11 as well as the fitment of same inside the internal cavities 140 of frame 10 by way of channels 113.
• FIG. 6 shows the wallboard 11 along, with outer portion 111, inset portion 112, and channels 113. It is appreciated that the relative thickness of outer portion 111 and inset portion 112 can vary depending on the desired application and desire structural and insulative properties. Further, the configuration, size, and shape of the channels 113 can vary depending on the configuration of frame 10. Accordingly, the present invention is not limited to the configurations shown in the figures.
• the framing members 103 and 104 include one or more apertures 105 punched there-through.
• the apertures 105 are configured to receive and channel electrical wiring, plumbing, and the like.
• conduits 106 are provided through apertures 105 and provide protection for wiring or plumbing passed there-through.
• the inset portion 112 of wallboard 11 has a depth that accommodate and does not block apertures 105 and conduits 106, which conduits are adjacent to the inside surface of the wallboard 11. In other embodiments, it may be desired for the depth of inset portion 112 to be somewhat deeper where it would otherwise cover up or block the apertures 105.
• additional channels 113 can be provided which align with apertures 105 and therefore accommodate conduits 106 similar to how the channels 113 accommodate the cross members 104 of frame 10.
• the inside of the frame 10 at interior side 102 of frame 10 may receive and contain insulation material 107 which may be poured, sprayed, or applied in sheets or rolls thereto.
• insulation material 107 may not be necessary in situations and climates where the wallboard 11 with inset portion 112 provides sufficient insulation. Accordingly, the material selected for wallboard 11 may vary depending on desired insulative characteristics as further discussed below. Additionally, the depth of inset portion 112 of wallboard 11 can be increased in order to increase its ability to insulate, depending on the desired application and installation.
• interior side 102 of frame 10 is typically the side facing the inside of the particular building or home and the exterior side 101 (which receives wallboard 11, grid 12, and cement layer 13) is the exterior of the building or home.
• the interior side 102 may be finished with typical interior wall material such as drywall, plasterboard, sheet rock, and the like.
• the result of the present invention is a combined building or housing frame 10 structure covered with an insulating exterior wallboard 11 to which a sprayed concrete layer 13 has been applied.
• Each frame 10 as described above comprises at least a portion of a wall of a building or housing structure.
• This configuration provides substantial strength and durability and exceeds typical hurricane, earthquake and other weather strength rating requirements presently used throughout the world.
• This enhanced strength is achieved primarily due to the relatively thick concrete layer 13 combined with the rigid frame 10 and further combined with the extended-depth wallboard 11 which provide internal insulation at the frame.
• a housing unit can be assembled in a matter of three or four days rather than months by utilizing the building construction system and method of the present invention; minimal skill is needed by the assembly crews and fabrication can be customized to meet local codes, plumbing and electrical requirements.
• Most single family units are anticipated to be in the twelve hundred to fifteen hundred square feet of living space.
• the units can be built as independent units or in multiple family configurations and, in that sense, the particular size and configuration of a given housing unit built in accordance with the present invention is not limiting.
• the frame 10 is configured to lockingly receive a plurality of bolts 30 having various configurations.
• the bolts 30 are received in flanges of the frame 10 at various points along the frame 10 as desired for the particular application.
• FIG. 7A depicts one embodiment of a key bolt 30 configured as a stud screed bolt.
• the proximal end of the bolt 30 includes a bow-tie or bubble-like male connector 31 and the distal end includes a receiving eyelet 32.
• a bolt flange 33 may be provided proximal to the male connector 31.
• the receiving eyelet 32 is relatively small and is configured to receive guide wire 15.
• FIG. 7B depicts another embodiment of a key bolt 30 configured as a support bolt.
• the proximal end includes a bow-tie or bubble-like male connector 31 and the distal end includes a receiving eyelet 32.
• a bolt flange 33 may be provided proximal to the male connector 31.
• the eyelet 32 is somewhat larger and is configured to receive and engage a rebar support 14.
• frame 10 may include one or more flanges 301 which may comprise stamped or bent portions of the frame 10.
• One or more key holes 302 are provided through flanges 301 and provide a point of entry for the male connector 31 of key bolts 30.
• a key bolt 30 passes through wallboard 11 and into the key hole 31 of frame 10 and is then rotated 90 degrees such that the male connector is lockingly engaged with the flange 301 of frame 10.
• the key hole 302 - key bolt 30 arrangement provides a simple and easy to operate means of attaching rebar and guide wire to the frame 10, which provides added support and concrete application guidance for the construction system 1.
• the key holes 302 could be provided anywhere on the frame 10 and do not necessarily have to be on the flange 301. Further, with reference back to FIGS. 1-4, it is appreciated that two or more key bolts can be used in conjunction to support a rebar support 14 and/or a guide wire 15. In some embodiments, the key holes 302 are provided at equidistant points along the frame 10 and the key bolts 30 are provided therein such that the weight of the rebar 14 and/or guide wire 15 can be equally supported along the frame. It is further appreciated that, in some embodiments, the length of the key bolts 30 utilized for the guide wire 15 are substantially longer than the length of the key bolts 30 used support the rebar 14.
• This configuration allows the guide wire 15 to extend well beyond the wallboard 11 surface in order to delineate the maximum depth or thickness of concrete layer 13 to be applied. Accordingly, a variety of varying length key bolt 30 for guide wire 15 can be utilized to provide a guide for various desired depths of the concrete layer 13.
• the wall configuration, square footages, windows, doors, electrical, plumbing, ventilation and other requirements are placed into a take off for analyses by a computer software program for calculation of number of feet needed for frames 10, frame 10 dimensions and placement, cut outs for placement of plumbing and electrical wires, placement of windows, doors and ventilation needs, as well as sizing to meet local and national codes and best practices for the location where the homes are going to be built.
• the result of the multistage analyses is a computerized output of frame 10 requirements that can be fed into a frame fabricating machine.
• the frame fabricating machine then can produce the frames 10 in sections, including the cross-members and outer members needed for the construction of the unit.
• the frames are typically fabricated from rolled coils of sheet metal material such as steel or aluminum but may also comprise wood or other materials as suitable for the particular application.
• a steel frame section having a 3-inch concrete layer applied thereto is capable of withstanding at least 50,000 psi of pressure and therefore is preferred as a weather-rated material in certain applications.
• the frame sections are marked at each end with a coding number. Headers and sills are likewise marked with numbers at all locations where they will interact with the frame sections or any bracing pieces, cross-members, and the like.
• the frame 10 sections are produced in the order of assembly, so that the pieces are assembled in the order of fabrication.
• the unit's foundation and base is prepared, which may be concrete slab or a framed structural deck that can be covered with wooden boards, insulated boards or other decking materials, which optionally can be covered with concrete spray material and troweled.
• the walls of the building or housing structure are provided as frame 10 sections in accordance with the present system and method are typically assembled flat on the ground using screw drill guns that fasten the frames to headers, sills or other reinforcing pieces.
• screw drill guns that fasten the frames to headers, sills or other reinforcing pieces.
• the exterior sides 101 of frames 10 are then covered with the wallboard 11, therefore providing internal and external insulating properties, which inset portion 112 of the wallboard 11 is received in the cavities 140 of the frame 10.
• the wallboard 11 may be secured to the frame 10 by an adhesive, epoxy, or the like.
• the wallboard may be further affixed to the frame 10 sections with fasteners and/or, in some embodiments, key bolts 30 may be provided through the wallboard therefore providing two purposes (1) provide additional fastening of the wallboard 11 to the frame and (2) provide a means to attach rebar 14 and/or guide wire 15 to the assembly. If rebar supports 14 are desired, the supports are provided into the eyelets of the one or more key bolts 30.
• Grid 12 may be then fastened to the bolts 30 or the rebar 14 by wire ties 35, whereby the grid 12 helps with the application of concrete layer 13 and adds tensile strength to the concrete layer 13. If a guide wire 15 is desired, it is secured through the eyelets of one or more key bolts and thus the guide wire 15 may define the depth of concrete layer 13 to be applied over the wallboard 11. It is appreciated the wallboard 11 is configured with channels 113 that match the configuration of the frame 10, including any cross members 104 and conduits 106 as desired.
• the guide wire 15 designates the depth of the concrete application. It is desirable for the grid 12 and the rebar 14 to be located substantially in the middle of the concrete layer and thus the grid 12 and rebar 14 are spaced apart from the wallboard 11 and the final outer wall surface of the concrete layer 13. Once the concrete layer 13 has cured, the housing structure is formed and finishing can take place. Roof frame 10 sections may be constructed in a similar manner but would typically be covered with a roofing material of choice as wallboard 11, preferably a material that provides good water resistance and good insulation.
• one or more support arches 70 may be secured to one or more bolts 30.
• the arches 70 may comprise strips of metal or other rigid material and have a width that extends outwardly from the surface of the wallboard 11.
• the arches 70 may be disposed between the wallboard 11 and the wire grid 12 and are provided in order to catch the concrete layer 13 during the spraying application.
• the geometry and location of the arches 70 is not limited, and other similar strips may be provided on the wallboard 11 to effectuate this purpose.
• the wallboard 11 may comprise a variety of building construction materials known in the art and is particularly useful because it provides both external and internal insulation in a single, easy to install piece.
• the wallboard 11 comprises a suitable expanded polystyrene material providing insulative properties.
• the wallboard 11 comprises what is known in the art as "blueboard” which is configured to accept and react with the cement layer 13 for optimal adhesion and durability.
• Other foam- like materials may be utilized as wallboard 11 and such materials may be chemically treated to accept adherence of cement.
• "blueboard” is typically a foam-board insulation material comprising polyisocyanurate, extruded polystyrene, expanded polystyrene foam, and combinations thereof.
• the wallboard 11 material may be selected according to its "R-value" or thermal resistance value and may preferably have an R-value between 4.5 and 5.0, which is typical of blueboard known in the art.
• the wallboard 11 comprises primarily expanded polystyrene which may have an R value of 12 or greater, depending on the overall thickness.
• Such an R- value provides a significant improvement over typical construction methods. It is appreciated, that other materials including composite styrofoam, foam and foam-like boards known in the art are contemplated, provided they have improved insulation, strength, and plaster/cement adherence characteristics.
• the present invention provides a significant advantage over the prior art because the wallboard 11 provides both internal and external insulation as well as providing a surface for the concrete layer 13 to adhere to.
• interior walls can be covered with typical drywall materials and if additional insulation is desired it can accomplished by using blown in insulation, batting, or board type, installed on the interior side 102 of the frame 10.
• additional insulation is not necessary in most instances because of the substantial external and internal insulative properties of the extended wallboard 11.
• the exterior concrete, after curing, can be painted or finished with a finishing material such as stucco to provide the desired appearance.
• the product can be quickly assembled and made ready for use.
• the method of construction of the units consists of fabricating the frames, marking the frames, assembling the frames in the walls, trusses and assemblies, covering the exterior walls with the wall board, adding the grid to the exterior surface of the wall board; spraying the exterior with wall board with the desired amount of cement; allowing the concrete to cure.

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• Engineering & Computer Science (AREA)
• Architecture (AREA)
• Civil Engineering (AREA)
• Structural Engineering (AREA)
• Physics & Mathematics (AREA)
• Electromagnetism (AREA)
• Building Environments (AREA)
• Laminated Bodies (AREA)

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• 2013
  • 2013-08-27 WO PCT/US2013/056730 patent/WO2014035926A2/en active Application Filing
  • 2013-08-27 EP EP13833444.6A patent/EP2909391B1/de active Active
  • 2013-08-27 CA CA2886517A patent/CA2886517C/en active Active
  • 2013-08-27 ES ES13833444T patent/ES2762852T3/es active Active
  • 2013-08-27 AU AU2013309041A patent/AU2013309041A1/en not_active Abandoned
• 2017
  • 2017-11-07 AU AU2017258845A patent/AU2017258845B2/en not_active Ceased
• 2019
  • 2019-12-23 CY CY20191101353T patent/CY1122743T1/el unknown

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