Patent ID: 6557256
Filing Date: 2003-05-06
Classification: B28B,E04C,Y10T

Abstract:
A process of constructing a cast wall panel, comprising the steps of:assembling a meshwork grid having first and second spaced apart gridwork panels arranged substantially parallel to one another, each gridwork panel including a plurality of interconnected crossing wires; embedding at least one edge of said grid in a detachable spacer; inserting said grid into a mold having detachable mold sections; applying to the mold one surface layer which is applied to the mold as a formulation of gypsum, cement and a catalyst in fluid form to a thickness covering said first gridwork panel in the mold, said one surface layer hardening after being allowed to set; adding to the mold an insulating layer which is applied to the mold as a formulation of gypsum, cement, perlite and a catalyst in fluid form to a thickness below a level at which said second gridwork panel is located in the mold, said insulating layer hardening after being allowed to set; applying to the mold a second surface layer which is applied to the mold as a formulation of gypsum, cement and a catalyst in fluid form to a selected thickness substantially equal to the thickness of said one surface layer, said second layer hardening after being allowed to set; detaching said mold sections after all of said layers have set; and detaching said spacer from said one edge of the grid to expose said one edge.