Patent ID: 11536019

Abstract:
A method for constructing a three-dimensional (3D) printer-printable wall system includes forming a concrete foundation on a substrate, where the concrete foundation embeds horizontal and vertical reinforcements. A first inner wythe horizontal layer and a first outer wythe horizontal layer are printed using a concrete mixture from a 3D printer. The first inner wythe horizontal layer and the first outer wythe horizontal layer are separated by an interstitial space. A first wall dam is placed between the first inner wythe horizontal layer and the first outer wythe horizontal layer in the interstitial space. Additional inner wythe horizontal layers are printed on top of the first inner wythe horizontal layer to form a composite inner wythe. Additional outer wythe horizontal layers are printed on top of the first outer wythe horizontal layer to form a composite outer wythe. At least one additional wall dam is placed on every horizontal layer, while a wall tie and an attachment bracket for utility lines are placed only on pre-defined intervals of horizontal layers of the composite inner wythe and the composite outer wythe, which are separated by the interstitial space. A sill cap is installed on top of the composite inner wythe and the composite outer wythe, where the sill cap comprises a first curb to encapsulate a top portion of the composite inner wythe, a second curb to encapsulate a top portion of the composite outer wythe, and a central trough positioned between the first curb and the second curb. An anchor mechanism is inserted into the sill cap.