Noise barriers and methods of their manufacture

A method of producing a sound barrier wall panel comprising the steps of:

• providing a plurality of frame elements formed from a cold rolled or cold formed steel in accordance with ASTM 1003, wherein each frame element comprises a plurality of vertical frame members and a plurality of horizontal frame members;
• assembling the plurality of frame elements;
• providing a plurality of strapping elements, each strapping element including a first end and a second end;
• the first end of each of at least a nonintersecting pair of the plurality of strapping elements secured to a front surface of one of the vertical frame members;
• the second end of each of at least the nonintersecting pair secured to a front surface of one of the horizontal frame members in a diagonal orientation through one or more fasteners;
• providing a sheathing layer, an insulation layer and a cover layer to form a laminate;
• attaching the laminate to the plurality of frame element using the plurality of strapping elements;
• and
• applying a weather barrier to only an outer perimeter of the sound barrier wall panel at a connection of the sheathing layer and the plurality of frame elements;
• and
• wherein the plurality of strapping elements are configured to strengthen each frame element when under a wind load;
• and
• wherein each strapping element is a single unitary piece further secured to a diagonal intersection of at least some of the horizontal frame members within each respective frame element;
• and
• wherein the sound barrier wall panel is eight lb/ft2 or less in weight;
• and
• wherein each frame element is twenty four feet in length and either four or eight feet in height.

A sound dampening wall comprising:

• a supporting foundational element;
• a plurality of wall panels, wherein each of the plurality of wall panels is formed from a laminate and is held together by a steel frame comprising a plurality of vertical frame members, a plurality of horizontal frame members, and a plurality of strapping elements, the plurality of strapping elements including a nonintersecting pair, wherein each strapping element includes a first end and a second end, the first end of each of at least a nonintersecting pair of the plurality of strapping elements secured to a front surface of the vertical frame member at a top corner of the steel frame and the second end of each of at least the nonintersecting pair secured to a front surface of a lowest of the horizontal frame members in a diagonal orientation through one or more fasteners;
• an access opening frame provided in at least one of the plurality of wall panels;
• and
• at least one of a tactile or aesthetic element provided on at least one of the plurality of wall panels;
• and
• wherein the plurality of strapping elements are configured to strengthen the steel frame when under a non-vertical load;
• and
• wherein the laminate is comprised of a sheathing layer, an insulation layer, a cover layer, an air and weather barrier layer, a basecoat and mesh coating layer;
• and
• wherein each strapping element is a single unitary strap abutting a diagonal intersection of each of the horizontal frame members within each respective steel frame;
• and
• wherein each wall panel is eight lb/ft2 or less in weight;
• and
• wherein each wall panel is configured to reduce a noise level by at least ten decibels;
• and
• wherein the air and weather barrier is applied to only an outer perimeter of each panel at a connection between the sheathing layer and the respective steel frame.