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US 12,098,547 B2Granted
Method of forming a composite wall structure
AssigneeEnviroCast, LLC
InventorsJeff VanHoose, Don Atkins
Life of this patent
Estimating the term…
Abstract
A precast composite wall structure and method for forming the wall structure are disclosed. The method includes providing a casting bed defining a plurality of shapes corresponding to a three-dimensional outer surface of a wall structure, placing a first layer of uncured concrete to conform to the shapes defined by the lower surface, positioning a forming member in overlying relation above the frame, the forming member defining a plurality of rectangular-shaped channels therebetween, positioning a stud frame within the casting bed along the forming member, placing a second layer of uncured concrete within the casting bed to conform to the rectangular-shaped channels between the rectangular protrusions, and allowing the concrete to cure.
Claims18
A method of forming a wall structure, the method comprising:
- providing a casting bed having a plurality of upright surfaces defining a generally rectangular interior area and a lower surface defining a plurality of shapes corresponding to a three-dimensional outer surface of a wall structure;
- placing a first layer of uncured concrete within the casting bed and allowing the first layer of concrete to conform to the shapes defined by the lower surface;
- positioning a forming member in overlying relation above the lower surface, the forming member comprising a one-piece layer of insulating material sized to extend fully along a width dimension of the casting bed, the forming member defining a plurality of integrally-formed rectangular protrusions, each said integrally-formed rectangular protrusion having a length dimension extending fully along a length dimension of the forming member in a parallel and spaced-apart relationship to one another to define a plurality of rectangular-shaped channels therebetween;
- positioning a frame within the casting bed along the forming member opposite the first layer of uncured concrete, the frame comprising first and second spaced apart members extending fully along the width dimension of the casting bed and a plurality of studs interconnecting the first and second spaced apart members, the studs each extending fully along a length dimension of the frame, wherein the frame and the forming member are placed within the casting bed to provide a first space between the forming member and the frame first member and a first upright surface of the casting bed and to provide a second space between the forming member and the frame second member and an opposite second upright surface of the casting bed;
- placing a second layer of uncured concrete within the casting bed and allowing the second layer of concrete to conform to the rectangular-shaped channels between the rectangular protrusions;
- placing a third layer of uncured concrete within the casting bed and allowing the third layer of concrete to fill at least one space between the frame and the upright surfaces of the casting bed;
- and
- allowing the concrete to cure.
5 more elements
A method of forming a wall structure, the method comprising:
- providing a casting bed having a plurality of upright surfaces defining a generally rectangular interior area and a lower surface defining a plurality of shapes corresponding to a three-dimensional outer surface of a wall structure;
- positioning one or more elements along the lower surface of the casting bed;
- placing a first layer of uncured concrete within the casting bed and allowing the first layer of concrete to conform to the shapes defined by the lower surface, wherein the elements are configured to be anchored to the concrete;
- positioning a forming member in overlying relation above the lower surface, the forming member comprising a one-piece layer of insulating material sized to extend fully along a width dimension of the casting bed, the forming member defining a plurality of integrally-formed rectangular protrusions, each said integrally-formed rectangular protrusion having a length dimension extending fully along a length dimension of the forming member in a parallel and spaced-apart relationship to one another to define a plurality of rectangular-shaped channels therebetween;
- positioning a frame within the casting bed along the forming member opposite the first layer of uncured concrete, the frame comprising first and second spaced apart members extending fully along the width dimension of the casting bed and a plurality of studs interconnecting the first and second spaced apart members, the studs each extending fully along a length dimension of the frame;
- placing a second layer of uncured concrete within the casting bed and allowing the second layer of concrete to conform to the rectangular-shaped channels between the rectangular protrusions;
- and
- allowing the concrete to cure.
5 more elements
A method of forming a wall structure, the method comprising:
- providing a casting bed having a plurality of upright surfaces defining a generally rectangular interior area and a lower surface defining a plurality of shapes corresponding to a three-dimensional outer surface of a wall structure;
- positioning one or more pattern stamps along the lower surface of the casting bed;
- placing a first layer of uncured concrete within the casting bed and allowing the first layer of concrete to conform to the shapes defined by the lower surface, wherein the elements are configured to be anchored to the concrete;
- positioning a forming member in overlying relation above the lower surface, the forming member comprising a one-piece layer of insulating material sized to extend fully along a width dimension of the casting bed, the forming member defining a plurality of integrally-formed rectangular protrusions, each said integrally-formed rectangular protrusion having a length dimension extending fully along a length dimension of the forming member in a parallel and spaced-apart relationship to one another to define a plurality of rectangular-shaped channels therebetween;
- positioning a frame within the casting bed along the forming member opposite the first layer of uncured concrete, the frame comprising first and second spaced apart members extending fully along the width dimension of the casting bed and a plurality of studs interconnecting the first and second spaced apart members, the studs each extending fully along a length dimension of the frame;
- placing a second layer of uncured concrete within the casting bed and allowing the second layer of concrete to conform to the rectangular-shaped channels between the rectangular protrusions;
- and
- allowing the concrete to cure.
5 more elements
Dependencies are inferred from the claim text.