Wall and Method

Abstract

A wall having a 3D wire mesh panel having a core with a 3D wire mesh matrix extending through and out the core, and a structural material, such as concrete, envelopes the panel. A form positioned about the panel is used to introduce the concrete to the panel during production. Methods for producing the wall, which include producing the wall vertically at a desired location.

1 . A method for producing a wall comprising the steps of:
 partially filling a form with uncured concrete;   positioning a 3D wire mesh panel onto the uncured concrete in the form;   allowing the panel to settle into the uncured concrete so there is uncured concrete below and around all sides of the panel and the uncured concrete bonds with the panel;   pouring additional uncured concrete onto the panel in the form to cover over the panel;   letting the uncured concrete about the panel cure; and   separating the panel with the cured concrete about the panel from the form.   
     
     
         2 . The method of  claim 1  including the step of preparing the panel. 
     
     
         3 . The method of  claim 2  including the step of preparing the form to receive the panel. 
     
     
         4 . The method of  claim 3  wherein the preparing the panel step includes the step of clipping joints and seams of the panel. 
     
     
         5 . The method of  claim 4  wherein the preparing the panel step includes the step of adding U shaped mesh to an outer edge of the panel. 
     
     
         6 . The method of  claim 5  wherein the preparing the panel step includes the step of clipping and cutting a window or door or opening in the panel. 
     
     
         7 . The method of  claim 6  wherein the preparing the form step includes preparing inner borders within a perimeter of the form where the inner borders conform with a window or door or opening in the panel. 
     
     
         8 . The method of  claim 7  including after the pouring step there is the step of finishing or stamping the uncured concrete. 
     
     
         9 . The method of  claim 8  wherein the allowing step includes the step of vibrating the panel so the panel settles into the uncured concrete. 
     
     
         10 . The method of  claim 9  wherein the panel has a core with a 3D wire mesh matrix extending through and out the core. 
     
     
         11 . The method of  claim 10  wherein the panel provides sound dampening and temperature insulation. 
     
     
         12 . The method of  claim 11  wherein the core is formed of styrene foam. 
     
     
         13 . The method of  claim 12  including after the pouring step, there is the step of screeding the uncured concrete. 
     
     
         14 . A wall comprising:
 a 3D wire mesh panel having a core with a 3D wire mesh matrix extending through and out the core and having a front side, a rear side, a top side, a bottom side, a left side, and a right side; and   structural material disposed about the panel covering the front side, the rear side, the top side, the bottom side, the left side, and the right side.   
     
     
         15 . The wall of  claim 14  wherein each side is flat, and the structural material is concrete. 
     
     
         16 . The wall of  claim 15  including an opening extending through the front side and the rear side and the concrete over the front side and rear side which defines a window or a door. 
     
     
         17 . The wall of  claim 16  which is freestanding and transportable. 
     
     
         18 . A wall of  claim 17  including a form positioned about the top side, bottom side, right side, and left side, and in contact with the concrete covering the top side, bottom side, right side, and left side, the form defining an outer border of the wall. 
     
     
         19 . The wall of  claim 18  has dimensions of about 4′×20′×8″, and weighs less than 4,600 lbs. with no openings and supports loads of more than 50,000 lbs. 
     
     
         20 . The wall of  claim 19  including eyes extending from the front side for lifting the wall. 
     
     
         21 . The wall of  claim 15  including a form positioned about the panel with the structural material disposed between the panel and form. 
     
     
         22 . The wall of  claim 21  wherein the form includes a front foam sheet disposed adjacent to and in spaced relationship with the front side and a rear foam sheet disposed adjacent to and in spaced relation with the rear side. 
     
     
         23 . The wall of  claim 22  including a right end board and a left end board adjacent to and in spaced relationship with the right side and the left side, respectively. 
     
     
         24 . The wall of  claim 23  including bracing positioned about the form to hold the form in place. 
     
     
         25 . The wall of  claim 24  including and enclosure enveloping, positioned around and in spaced relationship with the right end board, left end board, right foam sheet and left foam sheet, and wherein the structural material is disposed between the enclosure and the right end board, left end board, front foam sheet and rear foam sheet. 
     
     
         26 . A method for producing a wall comprising the steps of:
 positioning a 3D wire mesh panel vertically at a desired location, the panel having a core with a 3D wire mesh matrix extending through and out the core;   building a foam form about the panel;   pouring a structural material between the panel and foam form; and   letting the structural material harden about the panel.