Abstract:
A system and method for forming wall structures onsite without the need for prefabricated wall elements are provided. The wall structures can be constructed with the use of only a framing crew, without the need for other types of construction specialists. Further, the wall structures can be assembled very quickly. The wall structure includes a wood frame, with styrofoam interior, and concrete blown onto the outer surface thereof.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims priority to provisional application Ser. No. 60/940,772, filed May 30, 2007. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    The present invention relates to systems and methods for building construction, and, more particularly, to such systems and methods for erecting wall structures in place. 
         [0004]    2. Description of Related Art 
         [0005]    It is known to construct walls onsite with the use of prefabricated materials, such as concrete blocks and prefabricated concrete columns and other structures. However, both of these methods require the transport of heavy materials, and the employment of specialized work crews to assemble the concrete materials onsite. 
         [0006]    Therefore, it would be beneficial to provide a system and method for constructing wall structures onsite using concrete without the need for prefabrication off-site, or for pouring and lifting poured concrete elements. 
       SUMMARY OF THE INVENTION 
       [0007]    The present invention is directed to a system and method for forming wall structures onsite without the need for prefabricated wall elements. The wall structures can be constructed with the use of only a framing crew, without the need for other types of construction specialists. Further, the wall structures can be assembled very quickly. 
         [0008]    The features that characterize the invention, both as to organization and method of operation, together with further objects and advantages thereof, will be better understood from the following description used in conjunction with the accompanying drawing. It is to be expressly understood that the drawing is for the purpose of illustration and description and is not intended as a definition of the limits of the invention. These and other objects attained, and advantages offered, by the present invention will become more fully apparent as the description that now follows is read in conjunction with the accompanying drawing. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]      FIG. 1  is a front view of a wall structure of initial elements of the present invention, including plywood base and frame. 
           [0010]      FIG. 2  is a front view of a partially assembled wall structure of the present invention with styrofoam insulation laid in the frame. 
           [0011]      FIGS. 3 and 4  are front ( FIG. 3 ) and horizontal cross-sectional ( FIG. 4 ) views of the wall structure following an application of concrete. 
           [0012]      FIGS. 5 and 6  are vertical cross-sectional views of the wall structure before ( FIG. 5 ) and after ( FIG. 6 ) an application of concrete. 
           [0013]      FIG. 7  is a front cross-sectional view of a wall structure including a lintel. 
           [0014]      FIG. 8  is a horizontal cross-sectional view of a wall structure at a corner. 
           [0015]    FIGS.  9 A, 9 B is a flowchart for an exemplary embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0016]    A description of the preferred embodiments of the present invention will now be presented with reference to  FIGS. 1-9 . 
         [0017]    The front view of  FIG. 1  illustrates the initial structure of the wall assembly and process of the present invention. The system  10  ( FIGS. 1-8 ) and method  100  (FIGS.  9 A, 9 B) start with a concrete horizontal foundation slab  11  having been poured onsite. To form a solid wall unit  12 , 12 ′, a structural, substantially planar construction element, such as a base sheet  14  of plywood, has a moisture-barrier layer  15 , such as Visqueen, although this is not intended as a limitation, affixed to a rear face  16  thereof (block  101 ). The base sheet  14  has a frame  17  affixed to a front face  18  thereof (block  102 ). The frame  17  can comprise three substantially parallel elongated wooden elements  19 - 21  positioned in vertical spaced-apart relation from each other. The vertical frame elements  19 - 21  are bridged by a top elongated horizontal wooden element  22 , which is affixed to top ends  23  of the parallel elements  19 - 21 . Frame elements  19 - 21  all terminate in spaced relation from top  24 , bottom  25 , and side  26 , 27  edges of the base sheet  14 . Frame elements  19 , 20  comprise outer frame elements, and frame element  21  is positioned therebetween. Spaces  28 , 29  leading to the base sheet  14  that are not covered by the frame  17  are defined by the frame elements  19 - 22 . 
         [0018]    In order to form a door unit  30 , a moisture-barrier layer is also affixed to a rear face of a door sheet  33 , which can comprise substantially the same material as that used for the base sheet  14 . The door sheet  33  has a region wherein an aperture  34  is desired to be formed therein extending vertically from a bottom edge  31  to a height  36  below a top edge  37 , and extending to a width  38  horizontally in spaced relation from opposed side edges  39 , 39 ′. A three-piece door jamb  13  is affixed to a front face  41  of the door sheet  33  in surrounding relation to the door sheet aperture region  34  at side  35 , 35 ′ and top  32  edges thereof (block  103 ). 
         [0019]    In order to form a window unit  42 , a moisture-barrier layer is also affixed to a rear face of a window sheet  45 , which can comprise substantially the same material as that used for the base sheet  14 . The window sheet  45  has a region wherein an aperture  46  is desired to be formed therein having opposed side edges  47 , 48 , a bottom edge  49 , and a top edge  50  in spaced relation from opposed side edges  51 , 52 , a bottom edge  53 , and a top edge  54  of the window sheet  45 . 
         [0020]    A frame  55  is affixed to a front face  56  of the window sheet  45 . Side  57 , 58  and top  59  elements of the frame  55  are in spaced relation from the respective side  51 , 52  and top  54  edges of the window sheet  45 . The frame  55  comprises a plurality of elongated frame elements that are affixed together. Two of the frame elements  57 , 58  positioned vertically closest to the respective side edges  51 , 52  of the window sheet  45  comprise outer frame elements. The top frame element  59  is adjacent and in spaced relation from the aperture region&#39;s top edge  50 , and a central frame element  63  extends vertically from adjacent the aperture region&#39;s bottom edge  49  downward to adjacent the window sheet&#39;s bottom edge  53 , leaving spaces  64 , 65  between the central frame element  63  and the outer frame elements  57 , 58 . 
         [0021]    A window jamb  66  is affixed to the window sheet&#39;s front face  56  in surrounding relation to the window sheet&#39;s aperture region  46  (block  104 ) at the side  47 , 48 , the top  50 , and the bottom  49  edges thereof, so that and a top jamb element  67  is positioned adjacent the top frame element  59 , two side jamb elements  68 , 69  are positioned adjacent the respective outer frame elements  57 , 58 , and a bottom jamb element  70  is positioned adjacent a top end  71  of the central frame element  63 . 
         [0022]    An elongated bottom support element  72  is affixed to the bottom edges  25 , 53  of the base  14  and window  45  sheets, respectively (block  105 ). An elongated top support element  73  is affixed to the top edges  24 , 37 , 54  of the base sheet  14 , door sheet  33 , and window sheet  45  (block  106 ). Preferably the top support element  73  extends horizontally farther than a horizontal extent of the frame elements relative to the base, door, and window sheets&#39; front faces (see  FIG. 5 ). 
         [0023]    Insulation material  74  is affixed to the base sheet&#39;s front face  18  and to the window sheet&#39;s front face  56  in filling relation to the spaces  28 , 29 ;  64 , 65  defined by the frame elements (block  107 ). Additional insulation material  95  can also be positioned between the top support element  73  and the sheet&#39;s top frame element  22 . 
         [0024]    Structural wall  12 , 12 ′, door  30 , and window  42  units can be positioned adjacent each other in substantially co-planar fashion as desired ( FIG. 2 ; block  108 ). In this case, adjacent outer frame elements  20 , 19  of the first  12  and the second  12 ′ wall unit define a columnar space  75  therebetween. Similarly columnar spaces  76 , 77  are defined by door and window units, or any combination thereof. This positioning creates a joint  78  between adjacent outer edges  27 , 26 , which is buttressed with a beam  79  placed and affixed therealong. 
         [0025]    The bottom support element  72  is affixed to the foundation slab  11  at the building site (block  109 ). A dowel  80 , for example, an “L”- or “J”-shaped bar, is inserted into the foundation slab  11  to extend substantially vertically within the columnar spaces  75 - 77  ( FIGS. 5 and 6 ; block  110 ). 
         [0026]    One or more horizontal top  81  and one or more horizontal bottom  82  reinforcing bars are positioned in front of and across the base sheet  14 , door sheet  33 , and window sheet  45  (block  111 ). The horizontal top reinforcing bar  81  is positioned beneath and adjacent the top support element  73 , and the horizontal bottom reinforcing bar  82  is positioned above and adjacent the bottom support element  72 . The horizontal top reinforcing bar  81  can be affixed to the top support element  73  with the use of a “J” bolt  83  ( FIG. 5 ; block  112 ), although this is not intended as a limitation. 
         [0027]    One or more additional reinforcing bars  84  can also be positioned in front of and across the door sheet  33  beneath the horizontal top reinforcing bar  81  and above the door aperture&#39;s top edge  37  (block  113 ). One or more additional reinforcing bars  85  can also be positioned in front of and across the window sheet  45  beneath the horizontal top reinforcing bar  81  and above the window aperture&#39;s top edge  50  (block  114 ). 
         [0028]    One or more vertical reinforcing bars  86  are also positioned within the columnar spaces  75 - 77  (block  115 ), and a reinforcing bar  94  can also be positioned horizontally approximately midway along the door  14  and window  45  sheets. 
         [0029]    During construction, in order to provide additional bracing for the structural units  12 , 12 ′, 30 , 42 , a top end  87  of an elongated brace member  88  can be affixed to the top support element  73 . A bottom end  89  of the elongated brace member  88  can be affixed to the foundation slab  11  behind the rear face  16  of and in spaced relation from the structural units  12 , 12 ′, 30 , 42  (block  116 ). This brace member  88  can comprise, for example, a wire, and should be sufficiently taut to retain the structural units  12 , 12 ′, 30 , 42  in an upright orientation. 
         [0030]    A substantially planar wire mesh  90  is positioned atop the structural units  12 , 12 ′, 30 , 42  wherever there is no aperture  34 , 46  (block  117 ). The mesh  90  is positioned in horizontal spaced relation from the frame elements and the insulation material  74 , and from a front edge  91  of the top support element  73  (see  FIG. 5 ). 
         [0031]    A sprayable concrete  93 , for example, Gunite, is applied to the front faces of the structural units  12 , 12 ′, 30 , 42  (block  118 ) so as cover the frames, the sheets&#39; front faces, the insulation material, the bottom support element, the top support element, the reinforcing bars, and the dowel, and to fill the columnar spaces to form vertical columns, avoiding the aperture regions. The aperture regions are subsequently cut out (block  119 ). 
         [0032]    When the concrete  93  has dried, the brace  88  and the door and window coverings  92  can be removed (block  120 ). 
         [0033]    Exemplary dimensions for the elements of the system  10  will now be presented, with the understanding that these dimensions are not intended as limitations, and that local building codes and other site considerations may alter the specific relative and absolute dimensions. 
         [0034]    The base sheet  14  can comprise 4 ft×8 ft×½-in. exterior plywood; the Visqueen  15  can be 2 mils thick. The base sheet frame  17  can be 85 in. high, 42 in. wide. The vertical frame elements  19 - 21  can comprise 2×4-in. pressure-treated wood, are 20.25 in. apart, 85 in. long, and are 1.5 in. above the base sheet&#39;s bottom edge  25 . The top frame element  22  can comprise a 2×4-in pressure-treated plate, be 42 in. long, and is 9.5 in. below the top support element  73 . The top support element  73  can comprise two 2×8-in. pressure-treated plates, fastened to the rebar  81  with a “J” bolt  83  and flat washer ( FIG. 5 ). 
         [0035]    The joint-protective beam  79  can comprise 1×4-in. pressure-treated board. The window  66  and door  13  jambs comprise 2×8-in. pressure-treated beams. The insulation material  74  can comprise, for example, 3½-in.-thick solid polyurethane, although this is not intended as a limitation. 
         [0036]    The reinforcing bars  81 , 82 , 84 , 85 , 86 , 94  can comprise a #4 steel rebar. The horizontal rebars  81 , 82 , 94  are preferably separated by a maximum of 4 ft. The wire mesh  90  can comprise 4×4-in.-W4/W4 welded wire fabric positioned at a mid-depth of the concrete  93 . The columns defined by the columnar spaces  75 - 77  are preferably a minimum of 6 in. wide and 6.25 in. deep, and encase two #4 steel rebars  86 . The bottom support element  72  is attached to a plate that is affixed to the slab  11  using ¼×4-in. tapcons. 
         [0037]    The exterior concrete  93  can comprise an air-injected shotcrete or Gunnite, such as used in the construction of swimming pools, is applied at 4500 psi, which cures much more rapidly than conventional concrete. 
         [0038]    A second storey  96  ( FIG. 7 ) can be added, wherein the vertical rebar  86  is extended upward, and the wire mesh  90  is extended 2 ft above the floor  96 . Here only two smaller top plates  73 , 2×4-in., are used. 
         [0039]    Corner construction ( FIG. 8 ) can include a 2×2-in. pressure-treated corner tie  97 . 
         [0040]    The environmentally friendly wall structure  10  of the present invention has an R factor of 15.03, and can stand up to a category 4-5 hurricane. In addition, the concrete can be made into a firewall by adding fire clay into the concrete mix. Outside plumbing can be encased in the wall, thereby preventing freezing. Drywall can be added directly to the interior atop the plywood  14 . Since the surface is solid concrete, there are no joints, thereby obviating air and moisture penetration. The columns and lintels are continuous and formed of concrete. The wall structure  10  can be assembled in a single day, using only a framing crew to assemble the framework. The interior walls are ready for drywall to be applied as desired for interior finishing. 
         [0041]    In the foregoing description, certain terms have been used for brevity, clarity, and understanding, but no unnecessary limitations are to be implied therefrom beyond the requirements of the prior art, because such words are used for description purposes herein and are intended to be broadly construed. Moreover, the embodiments of the system and method illustrated and described herein are by way of example, and the scope of the invention is not limited to the exact details of construction and use. 
         [0042]    Having now described the invention, the construction, the operation and use of preferred embodiments thereof, and the advantageous new and useful results obtained thereby, the new and useful constructions, and reasonable mechanical equivalents thereof obvious to those skilled in the art, are set forth in the appended claims.