Method of building

• US 7,073,306 B1
• Filed: 03/12/2004
• Issued: 07/11/2006
• Est. Priority Date: 05/29/2003
• Status: Active Grant

• Current Assignee: Harry Edward Hagaman
• Original Assignee: Harry Edward Hagaman
• Inventors: Hagaman, Harry Edward
• Primary Examiner(s): SLACK, NAOKO N
• Application Number:
  US10/799,219
• Time in Patent Office: 851 Days
• Field of Search: 527/451, 527/471, 52/799, 52/791.3, 522/237, 52D/IG.9, 527/451.9, 527/461, 527/450.9, 527/421, 249/20, 249/33, 249/34
• US Class Current: 52/745.09
• CPC Class Codes: E04B 1/35 Extraordinary methods of construction, e.g. lift-slab, jack-block E04B1/34 takes precedence; falsework, shuttering for shaping walls, floors, ceilings or roofs in situ E04G11/04; conveying or assembling of building materials E04G21/00; working measures on existing buildings E04G23/00
• CPC Class Codes: E04B 1/3555 Constructions using straw bales
• CPC Class Codes: E04B 2/84 Walls made by casting, pouring, or tamping in situ E04B2/02, E04B2/56 take precedence; forms therefor E04G11/06; working of concrete or similar masses able to be cast or poured in situ E04G21/02
• CPC Class Codes: E04B 2/8635 with ties attached to the inner faces of the forms E04B2/8611 and E04B2/8623 take precedence
• CPC Class Codes: E04B 2/8652 with ties located in the joints of the forms
• CPC Class Codes: E04B 2002/867 Corner details
• CPC Class Codes: Y10S 52/09 Structure including reclaimed component, e.g. trash

Abstract

This is an improved method of building with fibrous material though other materials can be substituted. A binding secures fibrous material to form a wall assembly (10). Wall surfacing (20) can be included in the binding and forming process, reducing the labor required to apply it. Other building features and components can also be included in the binding and forming process such as electrical wiring, furring strips, windows, doors and structural reinforcing. This method vastly reduces the difficulties encountered when installing these components. The versatility of the method also allows for attributes such as flat wall surfaces and variable wall thicknesses, which are difficult to achieve using baled fiber.

Claims

1. A method of constructing a wall for a building, the method comprising the steps of:

A. providing a layer of loose fibers over a foundation for the wall;

B. applying an amount of pressure to the layer of loose fibers so as to compress the fibers;

C. binding the layer of fibers while the pressure is being applied;

D. applying an additional layer of loose fibers over the previous layer of fibers;

applying an amount of pressure to the additional layer of loose fibers so as to compress the fibers;

E. binding the layer of fibers while the pressure is being applied so as to increase the surface of the wall; and

F. repeating step D and step E until the wall is completed;

wherein the binding step for each of the additional layers of fibers includes binding the additional layer of fibers to the previous layer of fibers.

2. The method of claim 1 wherein the binding step comprises providing a wire mesh for the front side of the wall and a wire mesh for the back side of the wall and using wire to connect the wire mesh for the front side of the wall to the wire mesh for the back side of the wall so as to hold the compression on the fibers.

3. The method of claim 1 wherein step C and step E comprise using glue or cement for binding the layer of fibers.

4. The method of claim 1 further comprising the step of applying a layer of plaster to at least one of the sides of the wall.

5. The method of claim 1 further comprising the step of providing a bottom plate between the loose fibers and the foundation recited in step A.

6. The method of claim 1 further comprising the step of providing a top plate on the last layer of loose fibers.

7. The method of claim 1 further comprising the step of:

providing a bottom plate between the loose fibers and the foundation recited in step A and providing an anchor so as to connect the bottom plate to the foundation; and

providing a top plate at the top edge of the wall.

8. The method of claim 1 further comprising the step of applying a layer of plaster to at least one of the side surfaces formed by the layers of compressed fibers and inserting a plaster spacer between the plaster and the at least one of the side surfaces formed by the layers of compressed fibers.

9. The method of claim 1 further comprising the step of applying a layer of plaster to at least one of the side surfaces formed by the layers of compressed fibers and inserting a plaster spacer between the plaster and the at least one of the side surfaces formed by the layers of compressed fibers, and urging the plaster, plaster spacer, and the fiber together.

10. The method of claim 1 wherein the fibers comprise straw.

11. The method of claim 1 wherein the fibers comprise hay.

12. The method of claim 1 wherein the fibers comprise paper.

13. The method of claim 1 wherein the fibers comprise plastic.

14. The method of claim 1 wherein the fibers comprise cornstalks.

15. The method of claim 1 wherein the fibers comprise foam type insulators.

16. The method of claim 1 further comprising the step of applying a wall surfacing material to at least one of the sides of the wall.

17. The method of claim 1 further comprising the step of applying a wall surfacing material to at least one of the sides of the wall so that the pressure applied in step B and step D is applied to the wall surfacing material.

18. The method of claim 1 further comprising gauging the fiber density after step B and step D so as to vary the fiber compression.

19. The method of claim 1 further comprising the step of applying a layer of adobe or a layer of plaster over the compressed fiber formed in step E.

20. The method of claim 1 wherein step A comprises providing earth mixed with the layer of fibers.

21. The method of claim 1 further comprising the step of providing an additive to the fiber so as to increase the fire resistance and reduce mold for the fibers.

22. A method of constructing a wall for a building, the method comprising the steps of:

A. providing a layer of loose straw over a wood bottom plate and providing plaster at the side edges of the layer of loose straw;

B. applying an amount of pressure to the layer of loose straw and the plaster so as to compress the straw;

C. binding the layer of straw while the pressure is being applied and binding the fibers to the bottom plate;

D. applying an additional layer of loose straw over the previous layer of straw;

providing additional plaster at the side edges of the layer of loose straw;

applying an amount of pressure to the additional layer of loose straw and the additional plaster so as to compress the straw;

E. binding the layer of straw while the pressure is being applied so as to increase the surface of the wall;

F. repeating step D and step E until the wall is completed; and

G. providing a top plate over the last layer of straw and binding the top plate to the last layer of straw;

wherein the binding step for each of the additional layers of straw includes binding the additional layer of straw to the underlying layer of straw.

23. A method of constructing a panel for a building, the method comprising the steps of:

A. providing a first mesh for defining a first side of the panel;

B. providing a second mesh for defining a second side of the panel, opposite the first side;

C. providing a layer of loose fibers between the first mesh and the second mesh;

D. applying an amount of pressure to the layer of loose fibers so as to compress the fibers; and

E. binding the first mesh to the second mesh while the pressure is applied so as to substantially keep the fibers compressed.

24. The method of claim 23 further comprising providing a mesh grid so as to lock the first mesh to the second mesh.

25. The method of claim 23 wherein the first mesh and the second mesh comprise a locking mesh.

26. The method of claim 23 wherein the first mesh and the second mesh comprise a self locking mesh.

27. The method of claim 23 further comprising providing a self locking mechanism wherein the first mesh is locked to the second mesh so as to provide the binding of step E.

28. The method of claim 23 further comprising the step of applying a wall surfacing material to at least one of the sides of the panel so that the pressure applied in step D is applied to the wall surfacing material.

29. The method of claim 23 further comprising the step of applying a layer of plaster to at least one of the sides of the panel so that the pressure applied in step D is applied to the plaster.

30. The method of claim 23 further comprising the step of applying a layer of plaster to each of the sides of the panel so that the pressure applied in step D is applied to the plaster.

31. The method of claim 23 further comprising providing a mesh grid comprising shafts and tubes with interlocking teeth configured so as to lock the first mesh to the second mesh.

32. The method of claim 23 wherein the fibers comprise straw.

33. The method of claim 23 wherein the fibers comprise hay.

34. The method of claim 23 wherein the fibers comprise paper.

35. The method of claim 23 wherein the fibers comprise plastic.

36. The method of claim 23 wherein the fibers comprise cornstalks.

37. The method of claim 23 wherein the fibers comprise foam type insulators.

38. The method of claim 23 further comprising the step of providing an additive to the fiber so as to increase the fire resistance and reduce mold for the fibers.