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Method of forming structural walls and roofs

  • US 4,288,962 A
  • Filed: 02/27/1979
  • Issued: 09/15/1981
  • Est. Priority Date: 02/27/1979
  • Status: Expired due to Term
First Claim
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1. The method of forming a structural wall in place comprising the following steps:

  • (a) erecting vertically in spaced relation a plurality of support studs;

    (b) placing a section of plasterboard on the side of the support studs facing the interior side of the structural wall;

    (c) spraying a layer of high density expanded cellular foam to the plasterboard from the side exterior to the structural wall to substantially fill the space between the studs;

    (d) allowing the foam layer to cure to form a solid insulating layer;

    (e) spraying a layer of bonding agent over the exterior exposed surface of said insulating layer so that the inner surface of the bonding agent and stud are coplanar;

    (f) spraying a layer of cementitious material to said bonding agent and inner surface of the stud in a continuous thickness of at least one-half inch without including reinforcements; and

    (g) allowing said cementitious layer to cure to form a smooth, hard, durable exterior wall layer, said support stud being a metal I-beam having substantially parallel flanges in the plane of said structural wall, the flanges being joined by a web, the I-shaped beam being of unitary construction, said cementitious material being a mixture of Portland cement, hydrated lime, calcium chloride, calcium stearate, and alkali-resistant fiber glass filaments approximately one-half inch in length, and said expanded cellular foam is a polyurethane synthetic resin, said metal stud being aluminum and the outer flange having a width less than the width of the interior flange, the interior flange being perforated to facilitate bonding of the plasterboard with the foam layer, said inner perforated flange having a plurality of perforations in staggered configuration along the I-shaped beam, and the web of said beam is perforated to allow passage therethrough of electrical conduit, plumbing and the like.

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