Method of constructing an integrated concrete wall structure

• US 5,055,252 A
• Filed: 04/23/1990
• Issued: 10/08/1991
• Est. Priority Date: 01/12/1989
• Status: Expired due to Term

• Current Assignee: SWA HOLDING COMPANY INCORPORATED
• Original Assignee: SUPERIOR WALLS OF AMERICA, LIMITED
• Inventors: Zimmerman, Melvin M.
• Primary Examiner(s): Silbaugh, Jan H.
• Assistant Examiner(s): AFTERGUT, KAREN K
• Application Number:
  US07/512,968
• Time in Patent Office: 533 Days
• Field of Search: 264/256, 264/246, 264/333, 264/261, 264/251, 264/263, 264/250, 264/253, 264/DIG. 57, 264/275, 264/277, 264/278, 264/296, 52/583, 52/602, 52/704, 52/705, 52/707, 52/719, 52/125.5, 52/686, 52/309.12, 52/405, 52/601, 52/612, 52/809
• US Class Current: 264/263
• CPC Class Codes: E04C 2/06 reinforced
• CPC Class Codes: E04C 2/382 with a frame of concrete or other stone-like substance
• CPC Class Codes: E04C 2/526 with adaptations not otherwise provided for, for connecting, transport; for making impervious or hermetic, e.g. sealings
• CPC Class Codes: Y10S 264/57 Processes of forming layered products

Abstract

A method of constructing a wall by casting concrete within a horizontal frame which surrounds "U" shaped stud forms, which will determine vertical studs, and support members, which will determine top and bottom horizontal members. Before filling the frame with concrete the spaces between the stud forms and the support members are filled with insulating panels which are supported on the edges of the stud molds. Also before pouring the concrete, reinforcing rods may be placed in the stud molds and support members, and the reinforcing rods connected together to form an integrated reinforcing structure.

Claims

1. A method of constructing a prefabricated wall structure comprising:

orienting interspaced stud molds, with channel shape cross section configurations and edges defining an open portion of the channel shape, in a horizontal configuration within a framing means such that the edges of the stud molds form uppermost parts of the stud molds and are located within an essentially horizontal plane within the framing means;

orienting two parallel support members, with channel shape cross section configurations, edges defining an open portion of the channel shape, and channel shape cutouts in one wall of the channel configuration, at opposite ends of the stud molds so that the stud molds adjoin the support members at the channel shaped cutouts and the edges of the support members form uppermost parts of the support members and are located in the horizontal plane of the edges of the stud molds;

laying rigid insulation panels within the framing means, on top of the edges of the stud molds and the support members, but not covering the open portions of the channel shapes of the stud molds and the support members, to form a continuous surface within the framing means;

pouring concrete into an enclosure formed by the framing means, stud molds, support members and rigid insulation panels so as to cover the rigid insulation panels and to fill the stud molds and the support members thereby forming the prefabricated wall structure.

permitting the poured concrete to set; and

removing the wall structure from the framing means, stud molds and support members.

2. The method of constructing a prefabricated wall structure as in claim 1 further comprising placing a decorative layer upon the poured concrete before the concrete sets.

3. The method of constructing a prefabricated wall structure as in claim 1 further including locating reinforcing means within the stud molds and the support members and attaching together the reinforcing means in the stud molds and the support members before pouring the concrete.