U.S. patent application number 13/990874 was filed with the patent office on 2014-02-06 for reinforced wall system and method.
This patent application is currently assigned to CEMEX RESEARCH GROUP AG. The applicant listed for this patent is Bryan Goerger, Marcelo Ortiz, Patrick Thiel, Francisco Uzcategui. Invention is credited to Bryan Goerger, Marcelo Ortiz, Patrick Thiel, Francisco Uzcategui.
Application Number | 20140033638 13/990874 |
Document ID | / |
Family ID | 45316108 |
Filed Date | 2014-02-06 |
United States Patent
Application |
20140033638 |
Kind Code |
A1 |
Goerger; Bryan ; et
al. |
February 6, 2014 |
REINFORCED WALL SYSTEM AND METHOD
Abstract
A method of constructing a wall to meet an applicable building
code, and a wall created by this method. The method may include
placing insulating concrete forms, having a cavity, where the wall
is to be constructed; placing a limited quantity of metal
reinforcement steel within the cavity, such that the limited
quantity of reinforcing steel is insufficient to meet the
applicable building code; and pouring a mix of aggregate, sand,
cement, fly ash, and mineral fibers into the cavity; and allowing
the mix to cure, thereby meeting the applicable building code
without additional metal reinforcement. The mix may between 45 and
50% stone, between 30 and 35% sand, between 10 and 12% Portland
cement, between 5 and 8% fly ash, between 1 and 2% mineral fibers,
and between 0 and 1% admixtures by weight. The mix may contain
mineral fibers of different grades and/or dimensions.
Inventors: |
Goerger; Bryan; (Houston,
TX) ; Ortiz; Marcelo; (Houston, TX) ;
Uzcategui; Francisco; (Houston, TX) ; Thiel;
Patrick; (Houston, TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Goerger; Bryan
Ortiz; Marcelo
Uzcategui; Francisco
Thiel; Patrick |
Houston
Houston
Houston
Houston |
TX
TX
TX
TX |
US
US
US
US |
|
|
Assignee: |
CEMEX RESEARCH GROUP AG
Brugg
CH
|
Family ID: |
45316108 |
Appl. No.: |
13/990874 |
Filed: |
November 30, 2011 |
PCT Filed: |
November 30, 2011 |
PCT NO: |
PCT/US11/62519 |
371 Date: |
October 17, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61419171 |
Dec 2, 2010 |
|
|
|
Current U.S.
Class: |
52/742.13 |
Current CPC
Class: |
Y02W 30/91 20150501;
E04B 2/86 20130101; Y02W 30/92 20150501; E04B 1/00 20130101; C04B
28/04 20130101; C04B 28/04 20130101; C04B 14/06 20130101; C04B
14/465 20130101; C04B 18/08 20130101; C04B 28/04 20130101; C04B
14/06 20130101; C04B 14/465 20130101; C04B 16/06 20130101; C04B
18/08 20130101 |
Class at
Publication: |
52/742.13 |
International
Class: |
E04B 2/86 20060101
E04B002/86; E04B 1/00 20060101 E04B001/00 |
Claims
1. A method of constructing a structure to meet an applicable
building code, the method including the steps of: placing a
concrete form, having a cavity, where the structure is to be
constructed; placing a limited quantity of metal reinforcement
within the cavity, such that the limited quantity of metal
reinforcement is insufficient to meet the applicable building code;
pouring a mix of aggregate, sand, cement, fly ash, and mineral
fibers into the cavity; and allowing the mix to cure, thereby
meeting the applicable building code without additional metal
reinforcement.
2. The method according to claim 1, wherein the step of pouring a
mix includes pouring a mix that contains multiple grades of the
mineral fibers.
3. The method according to claim 1, wherein the step of pouring a
mix includes pouring a mix that contains multiple lengths of the
mineral fibers.
4. The method according to claim 1, wherein the step of pouring a
mix includes pouring a mix that contains multiple thicknesses of
the mineral fibers.
5. The method according to claim 1, wherein the mix contains
approximately 48.24% stone, 33.15% sand, 10.32% Portland cement,
6.88% fly ash, 1.41% mineral fibers, and preferably less than
0.005% of admixtures by weight.
6. The method according to claim 5, wherein the step of pouring a
mix includes pouring a mix that contains multiple grades of the
mineral fibers.
7. The method according to claim 5, wherein the step of pouring a
mix includes pouring a mix that contains multiple lengths of the
mineral fibers.
8. The method according to claim 5, wherein the step of pouring a
mix includes pouring a mix that contains multiple thicknesses of
the mineral fibers.
9. The method according to claim 1, wherein the mix contains
between 40 and 50% stone, between 30 and 40% sand, between 10 and
15% Portland cement, between 5 and 10% fly ash, between 0.5 and 2%
mineral fibers, and between 0.005 and 5% admixtures by weight.
10. The method according to claim 9, wherein the step of pouring a
mix includes pouring a mix that contains multiple grades of the
mineral fibers.
11. The method according to claim 9, wherein the step of pouring a
mix includes pouring a mix that contains multiple lengths of the
mineral fibers.
12. The method according to claim 9, wherein the step of pouring a
mix includes pouring a mix that contains multiple thicknesses of
the mineral fibers.
13. The method according to claim 1, wherein the mix contains
between 45 and 50% stone, between 30 and 35% sand, between 10 and
12% Portland cement, between 5 and 8% fly ash, between 1 and 2%
mineral fibers, and between 0 and 1% admixtures by weight.
14. The method according to claim 13, wherein the step of pouring a
mix includes pouring a mix that contains multiple grades of the
mineral fibers.
15. The method according to claim 13, wherein the step of pouring a
mix includes pouring a mix that contains multiple lengths of the
mineral fibers.
16. The method according to claim 13, wherein the step of pouring a
mix includes pouring a mix that contains multiple thicknesses of
the mineral fibers.
17. The method according to claim 1, wherein the mix relies on
chemical bonding of its ingredients, as opposed to mechanical
bonding, to provide a required strength to meet the applicable
building code, without additional metal reinforcement.
18. The method according to claim 1, wherein the step of pouring a
mix includes pouring a mix that replaces between 20 and 40% cement
with fly ash.
19. A method of constructing a wall to meet an applicable building
code, the method including the steps of: placing concrete forms,
having a cavity, where the wall is to be constructed; placing a
limited quantity of metal reinforcement within the cavity, such
that the limited quantity of metal reinforcement is insufficient to
meet the applicable building code; and pouring a mix of aggregate,
sand, cement, fly ash, and mineral fibers into the cavity, wherein
the mix contains approximately 48.24% stone, 33.15% sand, 10.32%
Portland cement, 6.88% fly ash, 1.41% mineral fibers of different
grades, and less than 0.005% of admixtures by weight, allowing the
mix to cure in the forms, thereby meeting the applicable building
code without additional metal reinforcement.
20. A method of constructing a wall to meet an applicable building
code, the method including the steps of: placing insulating
concrete forms, having a cavity, where the wall is to be
constructed; placing a limited quantity of metal reinforcement
steel within the cavity, such that the limited quantity of
reinforcing steel is insufficient to meet the applicable building
code; pouring a mix of aggregate, sand, cement, fly ash, mineral
fibers, and synthetic fibers into the cavity, wherein the mix
contains approximately 48.24% stone, 33.15% sand, 10.32% Portland
cement, 6.88% fly ash, 1.41% mineral fibers of different
dimensions, and less than 0.005% of admixtures by weight; and
allowing the mix to cure in the insulating concrete forms, thereby
meeting the applicable building code without additional metal
reinforcement.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is the National Stage of International
Patent Application No. PCT/US2011/062519, entitled "Reinforced Wall
System and Method," filed Nov. 30, 2011, which claims the benefit
of priority to U.S. Provisional Application No. 61/419,171,
entitled "Reinforced Wall System and Method," filed Dec. 2, 2010,
all of the foregoing applications being hereby incorporated by
reference in their entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
REFERENCE TO APPENDIX
[0003] Not applicable.
BACKGROUND OF THE INVENTION
[0004] 1. Field of the Invention
[0005] The inventions disclosed and taught herein relate generally
to reinforced concrete walls; and more specifically relate to
reinforced concrete walls using insulating forms.
[0006] 2. Description of the Related Art
[0007] U.S. Patent Application Publication No. 20090229205
discloses an "insulated concrete form system having a pair of
bottom U-shaped channels secured to a concrete slab that serve as a
footprint for a concrete wall. Exterior and interior foam sheets
are aligned within the bottom U-shaped channels that define the
wall. Top U-shaped channels are slipped over a top edge of the foam
sheets. A plurality of strongbacks are used to provide structural
support for the foam sheets during a concrete pour of the wall. The
strongbacks each have a pair of hangers adapted to be secured over
the top U-shaped channels to secure the strongbacks to the foam
sheets. A top wall spacer is used to join a strongback on one side
of the wall cavity to a strongback on a second side of the cavity
to resist pressure exerted outward on the foam sheets during a
concrete pour to form the wall." An ultra high strength
[0008] U.S. Patent Application Publication No. 20090000241
discloses a "method for forming integrally insulated concrete
sandwich walls or wall components is disclosed. The walls are
fabricated by casting the walls vertically and pumping the concrete
from the bottom of the form or from sides near the base. Walls
fabricated thus can be used in commercial, industrial, residential,
and agricultural buildings. These walls can be cast on-site or in a
manufacturing plant."
[0009] U.S. Patent Application Publication No. 20080289276
discloses "an improved cementitious mixture used to form structural
components that are strong, lightweight, heat and fire resistant,
and very economical to produce. The material includes a mixture of
cement, water, ribbon-like virgin polyethylene strips and aggregate
materials. The aggregate preferably includes recycled industrial
waste products. Examples of these industrial wastes include
shredded tires, wood by-products, waste coal combustion
by-products, recycled waste gypsum products, recycled industrial
foundry sand, and waste foam products such a Styrofoam. This new
cementitious material is strong and lightweight. It has a lower
thermal conductivity than conventional concrete and therefore
improved insulative properties. The use of industrial recyclables
not only enhances the performance characteristics of the components
made from this material but aids in maintaining the environment by
providing a practical use for industrial waste."
[0010] U.S. Patent Application Publication No. 20090071378
discloses an "ultra high strength fiber-reinforced mortar or
concrete that shows a higher fluidity (workability) at the fresh
state, a higher bending strength with a less content of metal fiber
by enhancing both the absolute value of the compressive strength of
mortar-matrix excluding metal fiber and the ratio of the bending
strength relative to the compressive strength simultaneously at the
hardened state, and acceptability of fine aggregate being used in
ordinary ready-mixed concrete. An ultra high strength
fiber-reinforced cement composition is characterized in that it
contains cement, silica fume, coal gasification fly ash, gypsum and
metal fiber and that the mass ratio of silica fume:coal
gasification fly ash is 95 through 50 portions: 5 through 50
portions. Ultra high strength fiber-reinforced mortar or concrete
contains such a cement composition and fine aggregate. An ultra
high strength cement additives is characterized in that it contains
silica fume, coal gasification fly ash and gypsum as principal
ingredients and the mass ratio of silica fume: coal gasification
fly ash is 95 through 50 portions: 5 through 50 portions."
[0011] U.S. Patent Application Publication No. 20070289502
discloses a "mixture of metal fiber concrete based on cement,
granular elements and water, comprising metal fibers whose diameter
ranges from 1.15 mm and 1.8 mm, et wherein the form coefficient
thereof is 35-t 45. The dosing of metal fibers is at least 80
kg/m.sup.3. This concrete mixture is particularly adapted to the
creation of structural elements such as floor slabs without
traditional reinforcements."
[0012] U.S. Patent Application Publication No. 20070062144
discloses "a form panel system that is capable of constructing a
frame structure including a wall of a concrete-based building and a
concrete structure including various retaining walls for
civil-engineering works. The form panel system comprises
compression cement boards disposed opposite to each other while
being spaced a predetermined distance from each other, the
compression cement boards being reinforced with fiber materials,
reinforcing boards obtained by forming the compression cement
boards in predetermined shapes, or foamed plastic heat insulating
panels, and metal plate studs disposed between the compression
cement boards. The metal plate studs are composed of metal plates
having predetermined thicknesses and distances therebetween, which
are selected depending on the durability of concrete. Each of the
metal plate studs has at least one opening formed therein. Each of
the metal plate studs is provided at both opposite side ends
thereof with bent parts. The metal plate stud is fixed to the
respective compression cement boards by means of fixing pieces, and
concrete is injected and cured into the space between the
compression cement boards, to which the metal plate studs are fixed
and the foamed plastic heat insulating panels are attached.
According to the present invention, the fiber-reinforced
compression cement boards, the foamed plastic heat insulating
panels, the metal plate studs having the openings are vertically or
horizontally arranged without limits."
[0013] U.S. Patent Application Publication No. 20040258911
discloses a "concrete article comprised of concrete having therein
a reinforcing fiber, where at least about 50 percent of the
reinforcing fibers are frayed only at an end or ends of the
reinforcing fibers, may be made by mixing concrete, water and a
reinforcing fiber for a sufficient time to fray the ends of at
least 50 percent of the fibers and curing the mixture to form the
concrete article. The fiber may be a reinforcing fiber comprised of
at least two filaments bonded together and the filaments being
comprised of a polymeric core and a polymeric sheath comprised of a
fusing-fraying polymer, such that the reinforcing fiber, when mixed
with inorganic particulates, frays predominately only at an end or
ends of the fiber."
[0014] The inventions disclosed and taught herein are directed to
an improved method of constructing a concrete insulated form
wall.
BRIEF SUMMARY OF THE INVENTION
[0015] The present invention relates to a method of constructing a
wall to meet an applicable building code, and a wall created by
this method. The method may include placing insulating concrete
forms, having a cavity, where the wall is to be constructed;
placing a limited quantity of metal reinforcement steel within the
cavity, such that the limited quantity of reinforcing steel is
insufficient to meet the applicable building code; and pouring a
mix of aggregate, sand, cement, fly ash, and mineral fibers into
the cavity; and allowing the mix to cure, thereby meeting the
applicable building code without additional metal reinforcement.
The mix may contain between 40 and 50% stone, between 30 and 40%
sand, between 10 and 15% Portland cement, between 5 and 10% fly
ash, between 0.5 and 2% mineral fibers, and between 0.005 and 5%
admixtures by weight. More specifically, the mix may contain
between 45 and 50% stone, between 30 and 35% sand, between 10 and
12% Portland cement, between 5 and 8% fly ash, between 1 and 2%
mineral fibers, and between 0 and 1% admixtures by weight. In one
specific example, the mix may contain approximately 48.24% stone,
33.15% sand, 10.32% Portland cement, 6.88% fly ash, 1.41% mineral
fibers, and preferably less than 0.005% of admixtures by weight.
The mix may contain mineral fibers of different grades and/or
dimensions.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0016] FIG. 1 illustrates a prior art reinforced wall built using
traditional Insulated Concrete Form (ICF) techniques;
[0017] FIG. 2 illustrates a traditional pattern of rebar that may
be needed to reinforce the wall of FIG. 1, in order to meet an
applicable building code requirement;
[0018] FIG. 3 illustrates a particular embodiment of a reinforced
wall 100 using certain aspects of the present invention;
[0019] FIG. 4 illustrates an improved pattern of rebar that may be
used to reinforce the wall of FIG. 3, in order to meet the
applicable building code requirement; and
[0020] FIG. 5 illustrates a method of constructing a wall to meet
the applicable building code according to certain aspects of the
present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0021] The Figures described above and the written description of
specific structures and functions below are not presented to limit
the scope of what Applicants have invented or the scope of the
appended claims. Rather, the Figures and written description are
provided to teach any person skilled in the art to make and use the
inventions for which patent protection is sought. Those skilled in
the art will appreciate that not all features of a commercial
embodiment of the inventions are described or shown for the sake of
clarity and understanding. Persons of skill in this art will also
appreciate that the development of an actual commercial embodiment
incorporating aspects of the present inventions will require
numerous implementation-specific decisions to achieve the
developer's ultimate goal for the commercial embodiment. Such
implementation-specific decisions may include, and likely are not
limited to, compliance with system-related, business-related,
government-related and other constraints, which may vary by
specific implementation, location and from time to time. While a
developer's efforts might be complex and time-consuming in an
absolute sense, such efforts would be, nevertheless, a routine
undertaking for those of skill in this art having benefit of this
disclosure. It must be understood that the inventions disclosed and
taught herein are susceptible to numerous and various modifications
and alternative forms. Lastly, the use of a singular term, such as,
but not limited to, "a," is not intended as limiting of the number
of items. Also, the use of relational terms, such as, but not
limited to, "top," "bottom," "left," "right," "upper," "lower,"
"down," "up," "side," and the like are used in the written
description for clarity in specific reference to the Figures and
are not intended to limit the scope of the invention or the
appended claims.
[0022] Applicants have created a method of constructing a wall to
meet an applicable building code, and a wall created by this
method. The method may include placing insulating concrete forms,
having a cavity, where the wall is to be constructed; placing a
limited quantity of metal reinforcement steel within the cavity,
such that the limited quantity of reinforcing steel is insufficient
to meet the applicable building code; pouring a mix of aggregate,
sand, cement, fly ash, and mineral fibers into the cavity; and
allowing the mix to cure, thereby meeting the applicable building
code without additional metal reinforcement. The mix may contain
between 40 and 50% stone, between 30 and 40% sand, between 10 and
15% Portland cement, between 5 and 10% fly ash, between 0.5 and 2%
mineral fibers, and between 0.005 and 5% admixtures by weight. More
specifically, the mix may contain between 45 and 50% stone, between
30 and 35% sand, between 10 and 12% Portland cement, between 5 and
8% fly ash, between 1 and 2% mineral fibers, and between 0 and 1%
admixtures by weight. In one specific example, the mix may contain
approximately 48.24% stone, 33.15% sand, 10.32% Portland cement,
6.88% fly ash, 1.41% mineral fibers, and preferably less than
0.005% of admixtures by weight. The mix may contain mineral fibers
of different grades and/or dimensions.
[0023] Building code requirements typically require steel
reinforcement, such as one half inch #4 rebar and/or five eighth
inch #5 rebar depending on loads, in an Insulated Concrete Form
(ICF) wall, irrespective of a thickness of concrete found in a
center cavity of the ICF form. Without this traditional steel
reinforcement in concrete building envelopes, an ICF wall system to
not achieve building code requirements, especially during peak
loading. Of course, inclusion of traditional steel reinforcement is
costly, both in terms of materials and labor.
[0024] One relatively recent attempt to solve this problem is to
replace some of the rebar with steel fiber. For example,
Propex.RTM.'s Novamesh ICF mix design relies heavily on steel-fiber
reinforcement to replace the structural strength achieved with
traditional steel rebar reinforcement. Similarly to traditional
steel rebar reinforcement, the steel fibers, when blended with
concrete, are mechanically-bound within the hardened concrete
matrix. The steel fibers provide the structural strength necessary
to produce a concrete mix design with enough strength to meet
building code requirements and/or American Society of Testing and
Measures (ASTM) and/or American Concrete Institute (ACI)
comparative tests. Consequently, the removal of steel-fiber
reinforcement in the ICF building envelope would cause a Novamesh
wall system to not develop enough strength during peak loading
conditions to meet building code requirements. Additionally, the
limited amount of polypropylene fibers found in the Novamesh ICF
mix would not provide enough strength to, independently, provide
the necessary structural reinforcement during peak loading
conditions as the fibers are not actually structural fibers.
Instead, the polypropylene fibers are included in the mix design to
provide non-structural protection against shrinkage.
[0025] In addition, current steel fiber reinforcement has
difficulty dispersing properly in the concrete matrix due to the
"interlocking" nature of the steel fibers as they are blended.
Since the fibers do not adequately disperse, it is questionable if
the fibers are adequately distributed throughout the wall or
consolidated within isolated regions of the wall. Sporadic
placement of steel reinforcement would have significant structure
implications for steel-fiber reinforced concrete. First, if an
isolated wall section is void of steel fibers, this isolated
section would be significantly weaker than intended. Second, if an
isolated area of the wall experienced steel-fiber `balling`, this
area would lack the quantity of cement binder necessary to
mechanically fasten the steel fiber in place. In both cases,
current steel fiber reinforcement may not meet building code
requirements without expensive and time consuming installation
practices.
[0026] In contrast, the mix design of the present invention uses
minerals in place of steel-fibers to achieve the required strength
needed to achieve building code requirements and/or ASTM and/or ACI
approval for replacing traditional steel reinforcement in ICF wall
systems. The use of minerals to replace steel reinforcement in ICF
construction harnesses the synergistic relationship between unique
combinations of natural occurring minerals, such as multiple
lengths, thicknesses, compositions, and/or grades of mineral
fibers, cement, and an industrial waste product, such as fly ash.
In one preferred embodiment, the mineral fibers comprise a calcium
inosilicate mineral (CaSiO.sub.3) that may contain small amounts of
iron, magnesium, and manganese. In other embodiments, the mineral
fibers comprise one or more of the pyroxene group of minerals.
[0027] Rather than relying on mechanical bonding such as with steel
rebar, steel fiber, and synthetic reinforcement for ICF
construction, the mix design of the present invention relies on a
chemical bond created through the unique combination of natural
minerals, cement and fly ash. To put it another way, the bond which
binds synthetic and steel fiber-reinforced concrete is mechanical,
in that as the concrete dries, the fibers are bound in place,
providing the required strength. In contrast, the mix design of the
present invention relies on a chemical bond which is created during
the concrete hydration process that fuses the materials together,
creating a structural concrete matrix with enhanced reinforcement
characteristics.
[0028] Along with considerable cost savings, removing steel
reinforcement (rebar) and steel fiber reinforcement in ICF walls
will dramatically improve the workability, consistency, strength
and embodied energy of the concrete in ICF construction.
Additionally, the elimination of steel reinforcement will allow for
the reduction of labor to place and consolidate the fiber-filled
concrete by eliminating the "balling" effect characterized by
concrete with steel fiber reinforcement.
[0029] While others have used wollastonite in concrete mixtures for
non-structural applications, these applications rely on a single
grade, or length, of wollastonite and typically use 10%
wollastonite per concrete volume, or greater. This use of mineral
fibers, creates a concrete matrix with enhanced aesthetic
attributes and reduced cosmetic cracking, which cannot meet
structural building code requirements because such concrete mixes
are simply not strong enough to be considered structural.
[0030] Furthermore, in our internal testing we discovered that
combined grades of mineral fibers, when mixed with a high volume of
fly ash, develops uncharacteristically-high flexural and axial
strengths. In once embodiment, this uncharacteristically-high
flexural and axial strength was exhibited in a mix containing only
1.41% mineral fibers by concrete volume. The chemical bonding, as
opposed to traditional mechanical bonding, of the mix design of the
present invention creates a finished structural wall system that
exceeds building code requirements and/or ASTM and ACI testing
standards, thereby allowing the mix design of the present invention
to eliminate the need for most traditional steel reinforcement and
all steel-fiber reinforcement. The mix design of the present
invention, thus, meets both peak and post-peak strength
requirements without the metal reinforcement previously needed.
[0031] The mix design of the present invention may also replace 40%
of cement traditionally used with an industrial waste product, such
as fly ash, rather than the common practice to only replace up to
20% of cement with fly ash. We believe that these higher levels of
fly ash positively contribute to the chemical reactions and bonding
taking place in the concrete hydration process. For example, we
believe that pozzolons in the fly ash react with free calcium ions
in the cement and mineral fibers enhancing the chemical bonding
during the concrete hydration process.
[0032] We also believe that the ICF forms themselves provide
optimal curing conditions that help improve the structural
performance of the mix design of the present invention. For
example, the chemical reactions may be enhanced because the
concrete matrix cures within an insulated curing cavity. This
cavity may help maintain a consistent temperature throughout the
curing process. This cavity may also allow less water to escape
during placement and curing. Both of these attributes would lead to
enhanced structural characteristics. In comparison, ICF walls
reinforced with steel fibers would not benefit from such optimal
curing since the fiber-concrete bond is mechanical rather than
chemical.
[0033] In one preferred embodiment, the mix design contains
approximately 48.24% stone, or aggregate, 33.15% sand, 10.32%
Portland cement, 6.88% fly ash, 1.41% minerals, and preferably less
than 0.005% of admixtures by weight. However, a mix according to
the present invention may contain between 30 and 50% stone, with a
preferred range being between 40 and 50% stone. A mix according to
the present invention may also contain between 30 and 50% sand,
with a preferred range being between 30 and 40% sand. A mix
according to the present invention may also contain between 5 and
20% Portland cement, with a preferred range being between 10 and
15% Portland cement. A mix according to the present invention may
also contain between 2 and 15% fly ash, with a preferred range
being between 5 and 10% fly ash. A mix according to the present
invention may also contain between 0.5 and 10% minerals, with a
preferred range being between 0.5 and 2% minerals. A mix according
to the present invention may also contain between 0 and 10%
admixtures, with a preferred range being between 0.005 and 5%
admixtures. Thus, a preferred mix may contain between 40 and 50%
stone, between 30 and 40% sand, between 10 and 15% Portland cement,
between 5 and 10% fly ash, between 0.5 and 2% minerals, and between
0.005 and 5% admixtures. The lower end of the range represents the
most commonly used percentage of the material and the upper bound
is a measure that was determined, through our lab testing, to be
unsuitable for this given application. An alternative mix may
contain between 45 and 50% stone, between 30 and 35% sand, between
10 and 12% Portland cement, between 5 and 8% fly ash, between 1 and
2% minerals, and between 0 and 1% admixtures. Additional specific
mixtures are shown below, along with the relative strength of a
given cured wall for each mixture.
TABLE-US-00001 1 2 3 4 Stone 48% 39% 35% 34% Sand 33% 42% 45% 41%
Cement 10% 10% 10% 12% Fly Ash 7% 3% 7% 9% Minerals 1% 6% 4% 4%
Admixture 0% 0% 0% 0% Strength 100% 86% 76% 75% 5 6 7 8 Stone 46%
39% 48% 46% Sand 35% 48% 33% 35% Cement 8% 10% 10% 8% Fly Ash 5% 3%
7% 5% Minerals 5% 0% 1% 5% Admixture 0% 0% 0% 0% Strength 62% 57%
44% 22% 9 10 11 Stone 39% 39% 40% Sand 48% 48% 44% Cement 10% 10%
11% Fly Ash 3% 3% 3% Minerals 0% 0% 2% Admixture 0% 0% 0% Strength
19% 12% 7%
[0034] FIG. 1 is an illustration of a prior art reinforced wall
built using traditional ICF techniques. As shown, forms 10 are
filled with a traditional concrete mix 20 with traditional rebar
reinforcement 30. FIG. 2 shows a traditional pattern of rebar 30
that may be needed to reinforce the concrete 20, in order to meet
an applicable building code requirement.
[0035] FIG. 3 is an illustration of a reinforced wall 100 built
using certain aspects of the present invention. As shown, the forms
10 are filled with a specially formulated concrete mix 120, such as
that described above, with a limited quantity of traditional rebar
reinforcement 30. When compared to FIG. 1, one can readily see that
significantly less rebar 30 is required, in order to meet the
applicable building code requirement. This results in dramatic cost
savings, both in terms of labor and materials.
[0036] FIG. 4 shows an improved pattern of rebar 30 that may be all
that is needed to reinforce the concrete 120. When compared to FIG.
2, one can readily see that significantly less rebar 30 is
required. Rather than relying as heavily on the rebar 30, or other
steel reinforcement, the reinforced wall 100 of the present
invention relies on mineral fibers 140 and other components of the
concrete mix of the present invention, as discussed above, in order
to meet the applicable building code requirement.
[0037] Turning now to FIG. 5, a method of constructing a wall to
meet an applicable building code according to certain aspects of
the present invention will be described. A concrete mix 120
according to the present invention is prepared, as set forth in
step A. The mix 120 of the present invention preferably includes
mineral fibers and a relative high amount of fly ash. For example,
20-40% of the cement normally used in a traditional mix may be
replaced with fly ash. As discussed above, the mix 120 may contain
mineral fibers of different compositions, grades, and/or
dimensions. This may result in significant material cost
savings.
[0038] The forms 10 are set up, or placed, where the 110 is
desired, as set forth in step B. A limited quantity of rebar 30, or
other reinforcement, is placed in the forms 10, as set forth in
step C. This limited quantity of metal reinforcement is
insufficient to meet the applicable building code, as the
reinforced wall 100 of the present invention does not rely slowly
on the rebar 30, other metal reinforcement, or even mechanical
bonding with the reinforcement, in order to meet the applicable
building code requirement. This results in significant material
cost savings.
[0039] The mix 120 is then poured into the forms 10, as set forth
in step D. Because there is less rebar 30 in the voids within the
forms, and because there is no need of metal fibers in the mix 120,
the mix 120 flows relatively easily into the forms 110.
Furthermore, because the mix 120 of the present invention is less
susceptible to the clumping problems, or "balling" effect,
associate with metal fibers in a more traditional mix, less effort
is required to ensure proper distribution of the reinforcing
materials. Finally, the mix 120 of the present invention is much
easier on equipment, as there is no need of metal fibers in the mix
120 which can be damaging to mixing, as well as on-site, equipment.
This results in significant labor and equipment cost savings.
[0040] Finally, the mix 120 is allowed to cure in the forms 10. As
discussed above, the forms 10 provide a consistent temperature
throughout the curing process and otherwise provides optimal
curing, thereby enhancing the chemical reactions, thereby improving
the structural performance of the mix 120 of the present invention.
In this manner, the mix 120 of the present invention utilizes
chemical bonding, rather than mechanical bonding, of the
reinforcement material, such as the mineral fibers discussed above,
in order to meet the applicable building code requirement with less
metal reinforcement as previously required.
[0041] Other and further embodiments utilizing one or more aspects
of the inventions described above can be devised without departing
from the spirit of Applicant's invention. For example, while the
present invention is anticipated to be ideal with four inch ICF
walls, the method and/or mix of the present invention may be used
with thinner or thicker walls, such as six or eight inch walls.
Furthermore, while the invention is particularly well suited to ICF
walls, the method and/or mix of the present invention may be used
with other forms of concrete construction, such as cast-in-place or
pre-cast walls, floors, and/or other panels or pavements. The
method and/or mix of the present invention may also be used with
tilt-up applications, such as where walls or other vertical
elements are formed horizontally and then tilted-up vertically.
Additionally, synthetic fibers may be used to supplement and/or
replace some of the mineral fibers. Further, the various methods
and embodiments of the present invention can be included in
combination with each other to produce variations of the disclosed
methods and embodiments. Discussion of singular elements can
include plural elements and vice-versa.
[0042] The order of steps can occur in a variety of sequences
unless otherwise specifically limited. The various steps described
herein can be combined with other steps, interlineated with the
stated steps, and/or split into multiple steps. For example, the
wall 100 may be constructed in sections, each with their own
iteration of one or more of the described steps. Additionally, or
alternatively, the mix may be prepared while the forms are being
placed, for example. Similarly, elements have been described
functionally and can be embodied as separate components or can be
combined into components having multiple functions.
[0043] The inventions have been described in the context of
preferred and other embodiments and not every embodiment of the
invention has been described. Obvious modifications and alterations
to the described embodiments are available to those of ordinary
skill in the art. The disclosed and undisclosed embodiments are not
intended to limit or restrict the scope or applicability of the
invention conceived of by the Applicants, but rather, in conformity
with the patent laws, Applicants intend to fully protect all such
modifications and improvements that come within the scope or range
of equivalent of the following claims.
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