Method for manufacturing a building component with a concrete layer and mesh formwork, and a building component with a concrete layer and mesh formwork

A method for manufacturing a building component, comprising:

• applying at least one layer of waterproofing material to a base comprising a wooden, metal, plastic, or composite panel, wherein the base constitutes a permanent structural layer of the building component;
• installing a permanent formwork on the base,
• wherein the formwork is made of wave-shaped segments arranged to form a closed contour with overlapping edges defining an internal space, and each formwork segment comprises at least three mesh layers, including two outer mesh layers and an inner mesh layer positioned between the outer mesh layers, wherein mesh openings in the outer mesh layers ae sized to be at least twice the size of the mesh openings of the inner mesh layer;
• placing a reinforcement into the formwork,
• wherein the reinforcement is placed on at least one support element and attached to the base by fixing at least one clamping bracket over the reinforcement, wherein the clamping bracket is secured to the base using at least one mechanical fastener passing through a hole in the clamping bracket;
• wherein the clamping bracket is a separate part from the support element and from the reinforcement, and is secured to the base by a screw, anchor, or bolt;
• wherein at least a portion of an outer mesh layer is left exposed along an external side surface of the building component, the exposed outer mesh layer providing a mechanical interlock for a cementitious joint material when the building component is positioned adjacent to another building component;
• threading at least one reinforcement bar through the formwork,
• wherein the reinforcement bar passes through an opening in at least one outer layer of the formwork with openings larger than a diameter of the threaded reinforcement bar, pierces the inner mesh layer and is attached to the reinforcement inside the space enclosed by the formwork;
• pouring a concrete mixture into the internal space enclosed by the formwork;
• and curing the concrete mixture until the building component could be moved.