Composite foam and concrete foundation, composite foam and concrete wall and method of mounting composite foam and cement wall to the foundation

Abstract

A composite foam and concrete wall includes a foam layer having a top surface, a bottom surface, a left wall surface and a right wall surface wherein the foam layer comprises at least two foam panels that define a seam that is substantially parallel to the top surface and the bottom surface. A concrete layer is secured to a surface of the foam layer.

1 . A composite foam and concrete wall comprising;
 a foam layer having a top surface, a bottom surface, a left wall surface and a right wall surface wherein the foam layer comprises at least two foam panels that define a seam that is substantially parallel to the top surface and the bottom surface; and   a concrete layer secured to a surface of the foam layer.   
     
     
         2 . The composite foam and concrete wall of  claim 1  and wherein the foam layer comprises:
 a plurality of spaced apart channels extending from proximate the bottom surface to proximate the top surface; and 
 a plurality of pilasters within the channels and extending from the concrete layer. 
 
     
     
         3 . The composite foam and concrete wall of  claim 2  and wherein the plurality of spaced apart channels and the plurality of pilasters comprise a dovetail cross-section. 
     
     
         4 . The composite foam and concrete wall of  claim 1  and further comprising:
 a left channel extending into the foam layer along the left wall surface; 
 a right channel extending into the foam along the right wall surface; and 
 a top channel extending into the foam along the top surface. 
 
     
     
         5 . The composite foam and concrete wall of  claim 4  and further comprising:
 a left concrete pilaster extending from the concrete layer and positioned within the left channel; 
 a right concrete pilaster extending from the concrete layer and positioned within the right channel; and 
 a top concrete pilaster extending from the concrete layer and positioned within the top channel. 
 
     
     
         6 . The composite foam and concrete wall of  claim 1  and further comprising a top plate secured to a top surface of the concrete layer from the left surface to the right surface. 
     
     
         7 . The composite foam and concrete wall of  claim 1  and further comprising:
 spaced apart lifting mechanisms positioned through the top plate wherein the spaced apart lifting mechanism are configured to engage a lifting mechanism such that the wall can be raised to a substantially vertical or standing position. 
 
     
     
         8 . The composite foam and concrete wall of  claim 1  and wherein the foam layer has a nominal thickness in the range of about 3 inches to about 10 inches. 
     
     
         9 . The composite foam and concrete wall of  claim 1  and wherein the concrete layer has a nominal thickness in the range of about 2 inches to about 6 inches such that the wall is a structural, load bearing wall. 
     
     
         10 . A method of constructing a composite foam and concrete wall, the method comprising:
 positioning a plurality of foam panels proximate each other to form a foam layer of a selected height and width;   forming a plurality of spaced apart channels in the foam layer extending from proximate a bottom end to proximate a top end;   positioning rebar within the spaced apart channels;   positioning a form about a perimeter of the foam layer wherein the form extends above an upper edge of the foam layer a selected distance; and   placing concrete on the foam panel and within the form to form a concrete layer with a plurality of pilasters extending into the foam layer and within the plurality of spaced apart channels.   
     
     
         11 . The method of  claim 10  and wherein forming the plurality of spaced apart channels comprises forming dovetail cross-sectional channels and wherein the placed concrete forms dovetail cross-sectional pilasters. 
     
     
         12 . The method of  claim 10  and wherein positioning a form about a perimeter of the foam layer comprises:
 cutting an angled slot about the perimeter of the foam layer; and 
 positioning brackets about the perimeter wherein each bracket comprises:
 a bottom portion positioned on the foam layer; 
 a angled tang extending from the bottom portion and positioned within the angled slot; 
 a wall extend from the bottom portion wherein a thickness the concrete layer is defined by a height of the wall; and 
 a screed portion substantially parallel to the bottom portion wherein the brackets are retained to the concrete layer and forms a finished surface. 
 
 
     
     
         13 . The method of  claim 10  and wherein positioning a form about a perimeter of the foam layer comprises:
 positioning boards about the perimeter of the foam layer wherein the board at the top end comprises a top plate; 
 securing the boards together; and 
 after the concrete layer has cured, removing the form from the wall wherein the top plate is retained to the wall. 
 
     
     
         14 . The method of  claim 10  and further comprising:
 cutting an area for a window from the foam layer; and 
 positioning a window frame within the cut out area wherein the cut out area is larger than the window frame such that when the concrete is placed the concrete encases the window frame. 
 
     
     
         15 . The method of  claim 10  and further comprising:
 cutting an area for a door from the foam layer; and 
 positioning a door frame within the cut out area wherein the cut out area is larger than the door frame such that when the concrete is placed the concrete encases the door frame. 
 
     
     
         16 . The method of  claim 10  and further comprising:
 forming a plurality of spaced apart grooves within the foam layer and between the spaced apart channels wherein the spaced apart grooves have a smaller cross-sectional area and depth relative to the cross-sectional area of the spaced apart channels wherein when the concrete is placed the grooves are filled with concrete. 
 
     
     
         17 . A composite foam and concrete wall comprising;
 a foam layer having a top surface, a bottom surface, a left wall surface and a right wall surface wherein the foam layer comprises at least two foam panels that define a seam that is substantially parallel to the top surface and the bottom surface;   a form secured to a top surface of the foam layer and extending from a perimeter of the foam layer; and   a concrete layer placed onto a surface of the foam layer wherein the form is retained to the foam layer and provides a finished surface to the concrete layer.   
     
     
         18 . The composite foam and concrete wall of  claim 17  and wherein the foam layer comprises:
 a plurality of spaced apart channels extending from proximate the bottom surface to proximate the top surface; and 
 a plurality of pilasters within the channels and extending from the concrete layer. 
 
     
     
         19 . The composite foam and concrete wall of  claim 18  and wherein the plurality of spaced apart channels and the plurality of pilasters comprise a dovetail cross-section. 
     
     
         20 . The composite foam and concrete wall of  claim 17  and wherein the foam layer has a nominal thickness in the range of about 3 inches to about 10 inches. 
     
     
         21 - 22 . (canceled)