U.S. patent application number 13/540007 was filed with the patent office on 2014-01-02 for internally braced insulated wall and method of constructing same.
This patent application is currently assigned to INTEGRATED STRUCTURES, INC.. The applicant listed for this patent is Roy Gary Black. Invention is credited to Roy Gary Black.
Application Number | 20140000199 13/540007 |
Document ID | / |
Family ID | 49776703 |
Filed Date | 2014-01-02 |
United States Patent
Application |
20140000199 |
Kind Code |
A1 |
Black; Roy Gary |
January 2, 2014 |
Internally Braced Insulated Wall and Method of Constructing
Same
Abstract
A high thermal resistant vertical wall on a base foundation in
which stacked ICFs define an interior wall space that is filled
with foam and concrete membranes coat the exteriors of the
ICFs.
Inventors: |
Black; Roy Gary; (Berkeley,
CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Black; Roy Gary |
Berkeley |
CA |
US |
|
|
Assignee: |
INTEGRATED STRUCTURES, INC.
Berkeley
CA
|
Family ID: |
49776703 |
Appl. No.: |
13/540007 |
Filed: |
July 2, 2012 |
Current U.S.
Class: |
52/309.4 ;
52/741.4 |
Current CPC
Class: |
E04B 2/845 20130101;
E04B 2/8652 20130101; E04B 1/7604 20130101; E04B 2/847 20130101;
E04B 2/8647 20130101 |
Class at
Publication: |
52/309.4 ;
52/741.4 |
International
Class: |
E04B 1/78 20060101
E04B001/78; E04C 2/20 20060101 E04C002/20 |
Claims
1. A high thermal resistant vertical wall supported on a base
foundation having a length comprising: a plurality of ICFs on the
base foundation each comprising generally parallel spaced apart
panel members wherein each said panel member has an interior
surface and an exterior surface with the space between the said
interior surfaces defining an interior wall space; foam disposed in
said interior wall space and a concrete membrane adjacent to said
exterior surface of said panel members.
2. The high thermal resistant vertical wall of claim 1 further
comprising: a plurality of bracing ladders supported at spaced
apart locations on the base foundation within said interior wall
space and surrounded by said foam.
3. The high thermal resistant vertical wall of claim 1 further
comprising: a plurality of spar members spanning said interior wall
space and having ends that are disposed outside of said interior
wall space adjacent said exterior panel surfaces in a said concrete
membrane and surrounded by said foam.
4. The high thermal resistant vertical wall of claim 2 further
comprising: a plurality of spar members sets spanning said interior
wall space and having ends that are disposed outside of said
interior wall space adjacent said exterior panel surfaces in a said
concrete membrane and surrounded by said foam wherein a spar member
set comprises a plurality of spar members.
5. The high thermal resistant vertical wall of claim 3 wherein said
spar members are made of fiberglass.
6. The high thermal resistant vertical wall of claim 1 wherein said
foam is a rigid polyurethane closed cell foam.
7. The high thermal resistant vertical wall of claim 6 wherein said
foam is high density.
8. The high thermal resistant vertical wall of claim 6 wherein said
foam is low density.
9. The high thermal resistant vertical wall of claim 1 wherein said
foam is formed by a combination of liquids that expand when exposed
to the air.
10. The high thermal resistant vertical wall of claim 1 wherein
said ICFs are stacked on the foundation in a running bond.
11. The high thermal resistant vertical wall of claim 4 further
comprising vertical connecting rods disposed adjacent to the
exterior surfaces of said panel members and affixed to said spar
member ends and encapsulated in a said concrete membrane.
12. The high thermal resistant vertical wall of claim 4 wherein
said spar member sets are disposed at spaced apart locations along
the base foundation with only two spar sets at any given location
where said spar member sets are in vertical alignment.
13. The high thermal resistant vertical wall of claim 4 wherein
said spar member sets comprise two cross spar members each spanning
said interior wall space at an angle to the vertical and each
having end members generally that are vertical and parallel to said
panel surfaces and disposed adjacent to a said exterior surface and
two U-shaped spar members that span said interior wall space at
generally right angles to said panel member surfaces and have end
members that are generally horizontal and parallel to said panel
exterior surfaces wherein said cross spar member end member lie
between a said U-shaped spar member end members by which they are
restrained.
14. A method of constructing a high thermal resistance wall having
a top and a bottom onto a base foundation having a length
comprising: (a) stacking a base run of ICFs onto the base
foundation wherein said ICFs comprise spaced apart panel members
having interior and exterior surfaces with said interior surfaces
defining an interior wall space; (b) disposing a plurality of
bracing ladders supported at spaced apart locations on the base
foundation within said interior wall space extending to the top of
the wall; (c) disposing in said base run of ICFs at spaced apart
locations along the length of the base foundation a lower spar set
comprising a plurality of spar members spanning said interior wall
space and having spar ends that are disposed outside of said
interior wall space adjacent said exterior panel surfaces; and (d)
injecting close cell polyurethane foam forming liquids into said
interior wall space in which said foam forming liquids expand to
fill the space between said ICF panels and surround said bracing
ladders and portions of said spar sets within said interior wall
space with close cell polyurethane foam.
15. The method of claim 14 wherein said panels have a height and
further comprising: (e) stacking onto the base run of ICFs an
additional run of ICFs to a height of several said panels wherein
said additional run ICFs comprise spaced apart panel members having
interior and exterior surfaces with said interior surfaces defining
an interior wall space and; (f) injecting close cell polyurethane
foam forming liquids into said additional run interior wall space
in which said foam forming liquids expand to fill the space between
said additional run ICF panels and surround said bracing ladders
with close cell polyurethane foam before stacking another
additional run of said ICFs on to the previous said run of ICFs;
(g) stacking onto the previous additional run of ICFs additional
runs of ICFs each said additional run to a height of several said
panels wherein said additional run ICFs comprise spaced apart panel
members having interior and exterior surfaces with said interior
surfaces defining an interior wall space and; (h) repeating steps
(f) and (g) until an uppermost additional said run of ICFs reaches
within several panel heights of the top of said wall.
16. The method of claim 15 further comprising: (i) stacking onto
said uppermost said additional run of ICFs a top run of ICFs to a
height of several said panels wherein said top run of ICFs comprise
spaced apart panel members having interior and exterior surfaces
with said interior surfaces defining an interior wall space; (j)
disposing in said top run of ICFs at spaced apart locations along
the length of the base foundation an upper spar set comprising
spars having end sections wherein said spars span said interior
wall space and penetrate through said top run ICF panels locating
said spar end sections outside of said interior wall space and
adjacent a said panel exterior surface; (k) injecting close cell
polyurethane foam forming liquids into the interior wall space of
said top run of ICFs in which said foam forming liquids expand to
fill the space between said top run ICF panels and surrounds said
upper spar sets and said bracing ladders with close cell
polyurethane foam.
17. The method of claim 14 wherein the foundation includes embedded
spaced apart anchor dowels at spaced apart locations along the
foundation extending above the foundation to a height of several
said ICF panels further comprising: (l) disposing adjacent each
anchor dowel a connecting rod that extends vertically to a height
that places it adjacent said spar ends of said upper spar set and
adjacent said spar ends of said lower spar set; (m) securing said
end sections of said spars of said lower spar set and said end
sections of said spars of said upper spar set to a said connecting
rod; and (n) applying a concrete membrane to said exterior surfaces
of said ICF panels that comprise said base run, said additional
runs and said top run to a thickness that encapsulates said anchor
dowels, said connecting rods and said spar set end sections.
18. The method of claim 17 wherein said concrete membrane is
applied under pressure.
Description
BACKGROUND OF THE INVENTION
[0001] The present invention relates to wall structures and methods
of constructing same and, in particular, to wall structures having
internal bracing during construction and superior thermal
resistance.
[0002] Approximately 50% of the energy consumed in the operation of
a building is used to maintain the temperature of the interior
spaces. In the cold months, the energy is used for heating, while
in the hotter months, the energy is used for cooling. Walls with
exceptional thermal resistance, such as those of the present
invention, have the potential to significantly reduce the operating
energy of a building.
[0003] The present invention relates to systems and methods for
constructing very high thermal resistivity ("R value") building
walls having interior and exterior membrane surfaces typically of
concrete and applied under pressure.
[0004] One of the difficulties of constructing such walls is
keeping them in place and plumb while they are being erected and
while the membranes are being applied.
[0005] The prior art practice for keeping walls in place during
construction is to use external bracing, primarily using wood or
pipe members. The disadvantages of external bracing (regardless of
the materials used) is that the bracing makes the application of
the outer membrane difficult, requiring substantial effort and
time, which translates directly into added expense. External
bracing also consumes materials that are typically discarded. Even
if some of the bracing materials are reused or recycled, they add
nothing to the structural integrity of the wall after it is fully
constructed.
[0006] U.S. Pat. No. 7,461,488 teaches an internal bracing system
using straw bales. While that system has been successfully
implemented and is an advance over the prior art, straw bales are
inherently non-uniform in size, cumbersome to work with and at risk
of attracting and retaining moisture. The present invention
provides the advantages of internal bracing without the
disadvantages accompanying straw bales and provides a much higher
level of thermal resistivity and earthquake stability.
[0007] The present invention teaches a wall structure and method
for its construction that can provide exceptionally high thermal
resistivity and stability under earthquake conditions using
internal bracing during construction that permits walls of 30 feet
and more to be constructed with little or no external bracing. The
ability to construct a wall of the present invention using only
internal bracing eliminates the difficulties of applying the outer
wall membrane and incorporates members that provide that bracing as
internal structural elements of the finished wall.
BRIEF DESCRIPTION OF THE INVENTION
[0008] The high thermal resistance wall of the present invention
comprises a pair of generally parallel spaced apart concrete
membranes connected by spars with insulated concrete forms (ICFs)
having spaced apart ICF panels disposed adjacent to and between the
membranes defining an internal wall space and insulating foam
filling the internal wall space. In addition, internal bracing
structures disposed in the internal wall space during construction
remain as structural elements of the finished wall.
[0009] The method of constructing the wall comprises: stacking
spaced apart ICF panels onto the foundation base wherein each panel
has an interior surface and an exterior surface where the interior
surfaces define an internal wall space; securing a plurality of
bracing ladders at spaced apart locations on the base foundation in
the internal wall space adjacent the ICFs; disposing a plurality of
spar members across the internal wall space and through the ICF
panels; filling the internal wall space with insulating foam; and
applying a concrete membrane onto the exterior surfaces of the ICF
panels to a thickness that covers portions of the spar members. In
a preferred embodiment, the membranes are only applied after the
entire wall is otherwise constructed.
[0010] The invention achieves its outstanding results by the
strategic placement (both vertically and horizontally) and
interconnection of a plurality of ladder structures (truss-like
members) and various spar members. The ladder structures give the
walls sufficient out-of-plane strength to remain erect and plumb
during construction both before the outer membrane is applied and
while the outer membrane is applied.
[0011] The present invention permits the membranes to be applied
without the need to work around external bracing, greatly
simplifying that process.
[0012] It follows, of course, that erecting and dismantling
external bracing is eliminated, as are the substantial costs and
waste associated therewith.
[0013] One of the outstanding features of the present invention is
that a wall of any height (from 8 feet to 35 feet or more) can be
assembled from small parts that are easily transported to the site.
Spars and rebar members are tied or tack welded to form a stiff
truss-like system that stabilizes the wall during and after
construction.
[0014] Accordingly, it is an object of the present invention to
provide internal bracing systems and methods for constructing a
high R-value wall. It is another object of the present invention to
provide internal bracing and methods for constructing a high
R-value wall to a height of 35 feet or more without the need for
external bracing.
[0015] Yet another object of the present invention is to provide
systems and methods for constructing a high R-value wall in which
permanent internal structural elements act as bracing during
construction.
[0016] The foregoing and other objectives, features and advantages
of the invention will be more readily understood upon consideration
of the following detailed description of the invention taken in
conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a perspective view of a partial wall according to
the present invention with portions broken away to expose certain
parts of the internal structure of the wall in relation to its
foundation;
[0018] FIG. 2; is a sectional view of the lower part of a wall of
the present invention showing internal elements as well as the
outer membrane;
[0019] FIG. 3 is a section view of the lower part of a wall of the
present invention showing a bracing ladder in relation to some of
the other internal elements;
[0020] FIG. 4 is perspective view of stacked ICFs in relation to
spacers and spar sets as employed in the present invention;
[0021] FIG. 5 is a perspective view (with a portion enlarged)
showing a spar set and connecting rods with which it forms a wall
truss element of the present invention; and
[0022] FIG. 6 is a section view of a wall of the present invention
showing the positions of two spar sets relative to the wall top and
bottom.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0023] The following description includes some specific
measurements for purposes of illustration only and, except where
otherwise indicated, such specific measurements are not to be taken
as limitations of the invention. While these dimensions will change
for walls of different thicknesses and heights, what does not
change is the functional relationship of the various structural
members to one another.
[0024] Referring to FIGS. 1 and 2, a wall 11 (only a portion of
which is shown), according to the present invention, is constructed
on a base foundation 12 and comprises as main structural and
insulating elements: a plurality of insulated concrete forms (ICFs)
13 comprised of spaced apart ICF panels 14 stacked onto the base
foundation 12 and defining an interior wall space 18; a plurality
of bracing ladders 23 spaced along the length 12L of base
foundation 12; a plurality of spar members 28, 37 and 38 that
comprise spar member sets 33 that span the interior wall space 18
and extend through the ICFs 13 placing their respective end
sections 30, 31, 37b and 38b outside of the exterior surface 14a of
ICF panels 14; a plurality of anchor dowels 17 anchored in and
spaced along the base foundation 12 outside of the exterior surface
14b of ICF panels 14 and extending vertically a distance beyond one
or two stacked ICFs 13; connecting rods 22 in overlapping adjacent
relation to anchor dowels 17 and extending vertically to or near
the top (not shown) of the wall 11 and secured to end sections 30,
31, 37b and 38b of spar sets 33; an interior concrete membrane 44;
an exterior concrete membrane 48; and insulating foam 53 (FIG. 1)
filling the interior wall space 18 surrounding the bracing ladders
23 and the portions of the spar member sets 33 within the interior
wall space 18.
[0025] Referring to FIGS. 1, 2 and 3, a pair of spaced apart
channel tracks 56 are secured to the base foundation 12 along its
length 12L as guides for positioning and aligning the panels 14 of
ICFs 13 on the base foundation 12 and setting the width 13W of the
interior wall space 18. Bracing ladders 23 are disposed at spaced
apart locations along the length 12L of foundation 12 and sized to
fit within the interior wall space 18 abutting the interior walls
14a of the ICF panels 14. Once positioned, the ladders 23 are
secured to the foundation 12 in any one of several known ways of
securing a metal structure to concrete, such as by purlin anchors
24 cast into the foundation 12. In one embodiment, the ladders 23
are located along the foundation 12 at intervals of about every 12
feet; however, that distance can vary depending on the size of the
wall. The ladders 23 are oriented on the base foundation 12 such
that the plane of the ladders 23 (the plane containing the ladder
cross-members 23b) is transverse to the length 12L of the
foundation 12. The height of ladders 21 is approximately equal to
the height (11H) of the wall 11 (FIG. 6), which can be 35 feet or
more.
[0026] Referring to FIGS. 1 and 3, bracing ladders 23 are comprised
of a pair of spaced apart parallel rails 23a rigidly held together
by attached cross members 23b that unify the ladder 23 into a
single Pratt truss. The ladders 23 can be constructed from a
variety of materials including wood as well as metal. In a
preferred embodiment, the ladders 23 are constructed from recycled
sheet metal.
[0027] Referring to FIGS. 1, 2 and 4, insulated concrete forms
(ICFs) 13 are well known in the construction industry and widely
used as forming systems for concrete foundations and the like. Each
ICF comprises spaced apart panel members 14, each panel having an
interior surface 14a and an exterior surface 14b. Typically and
according to the prior art, ICFs are interlocking modular units
that are dry-stacked (without mortar) and filled with concrete. One
popular ICF structure includes interlocking pegs 19 and pockets 20
(FIG. 2) that lock together somewhat like Lego.RTM. bricks and are
used in the prior art to create concrete forms for structural walls
of a building. ICFs are currently manufactured from any of the
following materials: Polystyrene foam (expanded or extruded--most
common), Polyurethane foam (including soy-based), cement-bonded
polystyrene beads and other foam materials.
[0028] ICFs are used in prior art systems to form a cavity into
which concrete is pumped to form the core structural element of a
foundation or wall, with reinforcing steel (rebar) disposed between
the panel members 14 before concrete placement to give the concrete
flexural strength, similar to bridges and high-rise buildings made
of concrete.
[0029] While there are a number of different brands and
configurations of ICFs, those used in the present invention are
those available brands that are stackable, constructed from a
lightweight foam material and can be adjusted to vary the distance
between panel members 14 to create interior wall spaces 18 of
different widths 13W. As will be seen by what follows, ICFs 13 are
not used in the present invention as concrete forms at all, but
rather in a way and for a purpose that enables a novel wall
structure to be built having the same or better load-bearing
capabilities as a concrete core wall and superior thermal
resistance and earthquake stability, as well as other
advantages.
[0030] As best seen by reference FIGS. 2, 3 and 4, in one
embodiment, ICF panels 14 are stacked on foundation 12 in channels
56 (see also FIG. 1) in a running bond (the ends 14c of each panel
member 14 is located approximately midway between the panel ends
14c of the panel 14 immediately above and below) stacked to the
height of the wall. The bracing ladders 23 abut the internal
surface 14a of panel members 14 that are held apart at a fixed
spacing by spacers 16 that are typically made of plastic but can
also be made of other materials, as is known in the art. The
spacers 16 maintain the spacing 13W against internal forces that
would push panel members 14 apart.
[0031] Referring to FIGS. 1, 2, and 5, spar member sets 33 are
comprised of cross spar members 28 and 32 and U-shaped spars member
37 and 38 which are disposed to span the interior wall space 18 and
pass through ICF panels 14. Spar cross members 28 and 32 are
identical but disposed in mirror opposing relationship to each
other. Spar members 28 and 32 are each in their preferred
embodiment a contiguous structure having a generally straight
midsection 29 terminating at ends 29a and 29b. A first end section
30 is generally straight and extends from end 29a and forms an
obtuse angle 25 with the spar midsection 29. A second end section
31 extends from end 29b and curves back on itself, forming a
U-shape with the adjacent portion 29c of the midsection 29. The
spars 28 and 32 span the interior wall space 18 and extend through
the ICF panels 14 locating the first end sections 30 and second end
section 31 outside of the ICFs 13 (and outside of interior wall
space 18).
[0032] U-shaped spar member 37 has a generally straight midsection
37a and end sections 37b at approximate right angles to midsection
37a. In its preferred embodiment, the spar 37 is a contiguous
structure that spans the interior wall space at a location that
disposes its end sections 37b outside of the ICFs 14 (outside of
interior wall space 18) and around end sections 30 of cross spar
members 28 and 32 (see FIG. 5). U-shaped spar member 38, which is
identical to member 37, has a generally straight midsection 38a and
end sections 38b at approximate right angles to midsection 38a. In
its preferred embodiment, the spar 38 is a contiguous structure
that spans the interior wall space at a location that disposes its
end sections 38b outside of the ICFs 14 (outside of interior wall
space 18) and around end sections 31 of cross spar members 28 and
32 (see FIG. 5). The spars 37 and 38 restrain the end sections 30
and 31 of cross spar members 28 and 32 from flexing outwardly (away
from the ICF panels 14) when the cross member midsections 29 are
put under load.
[0033] Because the spar members 28, 32, 37 and 38 span the interior
wall space 18, they create a thermal conductivity path. Even when
only two spar sets 33 are used in each location (see below), the
amount of heat that can travel through these spar members is
surprisingly high when the spars sets 33 are made of a high thermal
conductance material such as steel rebar. The use of such high
thermal conductivity materials can result in a significant amount
of heat transfer and a concomitant reduction in the overall R-value
of the wall. In order to prevent this degradation in the R-value,
in a preferred embodiment of the invention, all of the spars that
comprise spar sets 33 are formed from fiberglass, which is a low
heat conductance material compared to steel. Using fiberglass in
place of steel rebar has a dramatic reduction in heat transfer
across the wall 11 without compromising structural performance.
[0034] Referring to FIGS. 1 and 6, the spar sets 33 are disposed
between bracing ladders 23 at between 4 and 8 feet spacing along
the length 12L of foundation 12 (not all ladders shown). In one
embodiment of the invention, only two spar sets 33--a lower spar
set 33a and an upper spar set 33b (FIG. 6)--are disposed at a given
location for walls 11 having heights 11H of thirty feet or more.
Upper spar set 33b is located near the top 11b of the wall 11
directly above lower spar set 33a near the bottom 11a of the wall
11. Surprisingly, a wall with only two spar sets 33a and 33b at
locations near the bottom and top of the wall 11 is as strong and
performs as well, if not better, than a wall having more than two
spar sets 33 at a given foundation location. The distance between
the wall bottom 11a and lower spar set 33a and the wall top 11b and
the upper spar set 33b can range from a 1 or 2 feet to 5 or 6 feet,
depending on the overall height 11H of the wall 11. In order to
keep the membranes 44 and 48 from buckling under heavy loads, tie
rods 41 span and extend beyond internal wall space 18 with their
ends embedded in the membranes 44 and 48. In one embodiment, tie
rods 41 have the same shape as spars 37 and 38 and are placed
between spar sets 33 every 3 to 4 feet along the height 11H of the
wall 11.
[0035] Referring to FIGS. 1, 2 and 3, anchor dowels 17 are cast
into the concrete base foundation 12 and extend vertically above
the base foundation approximately the same height as between one
and two stacked ICF panels 14 (see FIG. 3). The anchor dowels 17
terminate in the foundation in a standard hook 17a and are
distributed along the length of the base foundation 12 in opposing
pairs 17p, with each dowel 17 near one edge of the base foundation
12. The dowels 17 of a given pair 17p are spaced apart a greater
distance than the width of ICF 13, by 1 to 3 inches and preferably
2 inches (these number could change with walls having thicker
membranes). Anchor dowel pairs 17p are spaced along the length of
the base foundation 12 to match the locations of the spar members
sets 33 which are typically spaced every 4 to 8 feet.
[0036] Referring to FIGS. 1, 2, 3 and 5, adjacent each anchor dowel
17 is a connecting rod 22 that extends vertically in close
proximity to the end sections 30 and 31 of cross spar members 28
and 32, as well as the end sections 37b of U-shaped spar members 37
and 38. The spar ends 30, 31 and 37b are secured to the connecting
rods 22 by connectors 36. The combination of the joined spar sets
33 and connecting rods 22 creates a truss structure, giving the
wall 11 all of the structural advantages of a truss. The connectors
36 that join spars 28, 32, 37 and 38 and connecting rods 22 can be
a weld, a twist tie (not illustrated), a mechanical bracket or any
other known means for securing rod members together. Connecting
rods 22 and anchor dowels 17 can be made from steel rebar (e.g.,
#4) without increasing thermal conductivity across the wall 11,
since they do not span the interior wall space 18 and are connected
by fiberglass spar members and thus do not create a low conductance
path that could compromise the R-value of the finished wall 11.
[0037] Referring to FIGS. 1, 2 and 3, in a manner known in the art,
a wire mesh curtain 56 is disposed exteriorly of surfaces 14b of
panels 14 to facilitate the application of concrete 46 that forms
exterior membrane 48 and interior membrane 44. The membranes 44 and
48 are formed by concrete (shotcrete) applied under pressure to the
exterior surfaces 14b of panels 14 to a thickness of approximately
3 inches to fully encase the anchor dowels 17, spar member end
sections 30, 31 and 37b, the connecting rods 22, the ends of tie
rods 41 and wire mesh curtain 56, all in a manner well known in the
art. All of the components encased in the interior membrane 44 are
physically joined to the components encased in the exterior
membrane 48 by spars sets 33 and tie rods 41, forming a truss of
exceptional structural integrity and performance.
[0038] Referring to FIGS. 1, 4 and 6, once the first few tiers of
ICFs 13 are in place and the lower spar member sets 33a in place,
the interior wall space 18 formed by those tiers is filled with
insulating foam 53 that surrounds the section of bracing ladders 23
and portions of spars sets 33 and tie rods 41 that are located in
space 18. That same process is repeated for subsequent tiers of
ICFs until the desired height of the wall is reached. Prior to
filling the final few tiers with foam 53, the upper spar sets 33b
are put in place.
[0039] Unlike conventional concrete structures having a concrete
core that has moderate thermal conductance, the core material of
the wall 11 of the present invention is all insulating material
(ICFs 13 and foam 53), both having very low thermal
conductance.
[0040] Foam 53 is applied as a combination of liquids that expand
when exposed to the air to fill all of space 18. Such foam systems
are known in the building industry and are capable of producing
foam in a range of densities. Gaco Western offers a liquid pour
system: Low density, rigid polyurethane foam for cavity fill which
uses as a Blowing Agent--245fa Enovate. Gaco's product designation
is Polyfoam.TM. CF-200, which is a zero ozone depleting liquid pour
system for general use in cavity fill applications. It is co-blown
with HFC and water and cures to a low density rigid polyurethane
closed cell foam. High density rigid polyurethane closed cell foam
is also available. In either case, the closed cell structure of the
foam 53 prevents the intrusion of water into the interior wall
space 18 that could, if present, diminish the R-value of the wall.
In the same way, foam 53 also prevents any insect infestation or
other undesirable material from entering the space 18.
[0041] The method of the present invention for constructing a wall
11 of superior structural integrity and high thermal resistance
(high R-Value) onto a base foundation 12 wherein vertically
extending opposing pairs 17p of anchor dowels 17 are cast into and
spaced apart along the length 12L of the base foundation 12,
comprises:
[0042] (1) attaching to the base foundation 12 preassembled
vertically oriented mid-wall bracing ladders 23 at spaced apart
locations along the length 12L of base foundation 12;
[0043] (2) stacking a base run of ICFs 13 several panels 14 high in
a running bond onto the base foundation 12 wherein the ICFs 13
define an interior wall space 18 that includes bracing ladders
23;
[0044] (3) disposing at spaced apart locations along the length 12L
of base foundation 12 adjacent to the anchor dowel pairs 17 and
spaced above the base foundation 12, a lower spar set 33a of
multiple spar members that span the interior wall space 18 and
penetrate the ICF panels 14 locating end sections of the spar
members outside of the ICFs 13;
[0045] (4) injecting rigid polyurethane foam 53 in the interior
wall space 18 and thereby surround the bracing ladders 23 and the
portions of the spar sets 33 within the interior wall space 18;
[0046] (5) stacking onto the existing foam filled run of ICFs 13
additional runs of ICFs 13 each to a height of several panels
14;
[0047] (6) injecting rigid polyurethane foam 53 in the interior
wall space 18 of each additional run of ICFs 13 before adding an
additional run of ICFs 13;
[0048] (7) repeating steps (5 and 6) until one additional run of
ICFs 13 would reach within several panel heights of the top 11b of
wall 11;
[0049] (8) stacking a top run of ICFs onto the uppermost foam
filled run of ICFs;
[0050] (9) disposing in the top run of ICFs in line with the lower
spar sets 33a an upper spar set 33b that spans the interior wall
space 18 and penetrates the ICFs 13 locating the end sections of
the spars of the upper spar set 33 outside of ICFs 13;
[0051] (10) injecting rigid polyurethane foam 53 in the interior
wall space 18 of the top run of ICFs 13;
[0052] (11) securing next to each anchor dowel 17 a connecting rod
22 that extends vertically to a height that disposes it adjacent an
upper spar set 33b;
[0053] (12) securing to each connecting rod the end sections of the
spars of a lower spar set 33a and an upper spar set 33b;
[0054] (13) securing wire fabric 57 exteriorly of surfaces 14b of
the panels 14 of ICF 13; and
[0055] (14) applying a concrete membrane (typically pneumatically
placed shotcrete or gunnite) to the exterior surfaces 14b of the
ICF panels 14 to a thickness that encapsulates the anchor dowels
17, connecting rods 22 and end sections of spar sets 33.
[0056] Of course, various changes, modifications and alterations in
the teachings of the present invention may be contemplated by those
skilled in the art without departing from the intended spirit and
scope thereof. As such, it is intended that the present invention
only be limited by the terms of the appended claims.
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