Prefabricated exterior wall panel assembly

Abstract

An exterior wall panel assembly may include a metal stud wall panel frame including a bottom track, a top plate, vertically extending studs between the bottom track and the top plate, and a window opening. An assembly may include an exterior sheathing formed from panels of sheathing. An assembly may include a window assembly, the window assembly installed within the window opening. An assembly may include a sealant applied between the panels of sheathing, between the exterior sheathing and the window assembly, and along the side edges and the top edge of the exterior sheathing. An assembly may include a support ledge positioned at the top of the wall panel and connected to a pour stop. An assembly may include a lintel positioned above the window opening, the lintel connected to the frame.

1 . A prefabricated exterior wall panel, comprising:
 a metal stud frame including a bottom track, a top plate, and vertically extending studs extending therebetween;   an exterior sheathing connected to the metal stud frame, wherein the exterior sheathing is formed from panels of sheathing and include an insulation layer, a weather proofing layer, side edges, a top edge and an exterior surface;   a sealant applied between the panels of sheathing and over fasteners connecting the panels of sheathing to the metal stud frame to form a continuous air- and water-barrier on the exterior surface of the exterior sheathing;   a pour stop connected to the top plate and having a vertical leg extending upward from the top plated and inward from an interior surface of the exterior sheathing; and   at least one reinforcement rod connected to an inner face of the vertical leg of the pour stop and extending horizontally and inward therefrom, the reinforcement rod configured to reinforce a concrete slab poured around the at least one reinforcement rod.   
     
     
         2 . The prefabricated exterior wall panel of  claim 1 , further comprising:
 a window opening formed in the metal stud frame;   a sheathing opening formed in the exterior sheathing and aligned with the window opening of the metal stud frame; and   a window assembly installed within the window opening of the metal stud frame and the sheathing opening, wherein the window assembly includes a glass pane positioned within a window frame, and the sealant is applied between the exterior sheathing and the window assembly.   
     
     
         3 . The prefabricated exterior wall panel of  claim 2 , further comprising a lintel connected to the metal stud frame above the window opening, wherein the lintel is configured to support cladding above the window opening. 
     
     
         4 . The prefabricated exterior wall panel of  claim 3 , wherein the lintel is configured to support the cladding a distance away from the exterior surface of the exterior sheathing such that moisture between the exterior sheathing and the cladding is able to drain in an air space therebetween. 
     
     
         5 . The prefabricated exterior wall panel of  claim 1 , wherein the sealant is applied to the side edges of the exterior sheathing and to the top edge of the exterior sheathing. 
     
     
         6 . The prefabricated exterior wall panel of  claim 5 , wherein the sealant applied to the side edges of the exterior sheathing comprises first and second strips of joint sealing tape applied on the exterior surface of the exterior sheathing proximate the side edges and the sealant applied to the top edge of the exterior sheathing comprises a third strip of joint sealing tape applied on the exterior surface of the exterior sheathing proximate the top edge, the first and second strips of joint sealing tape folded over the respective side edges of the exterior sheathing and adhered to the respective vertically extending stud and the third strip of joint sealing tape folded over a top edge of the exterior sheathing and adhered in place over the top edge of the exterior sheathing. 
     
     
         7 . The prefabricated exterior wall panel of  claim 1 , further comprising a support ledge connected to the metal stud frame and extending laterally from a top portion of the exterior surface of the exterior sheathing and configured to support cladding. 
     
     
         8 . The prefabricated exterior wall panel of  claim 7 , wherein the support ledge is configured to support the cladding in spaced relation from the exterior surface of the exterior sheathing such that moisture between the exterior sheathing and the cladding is able to drain in an air space therebetween. 
     
     
         9 . The prefabricated exterior wall panel of  claim 1 , further comprising a support ledge connected to the pour stop, wherein the support ledge extends outward from the exterior surface of the exterior sheathing and is configured to support cladding. 
     
     
         10 . The prefabricated exterior wall panel of  claim 9 , wherein the support ledge includes at least one mounting tab connected between the support ledge and the vertical leg of the pour stop. 
     
     
         11 . The prefabricated exterior wall panel of  claim 1  wherein the at least one reinforcement rod is threadingly coupled to a threaded receiver mounted the inner face of the vertical leg of the pour stop. 
     
     
         12 . A method of assembling a prefabricated exterior wall panel, comprising:
 forming a metal stud frame, wherein the steps of forming the metal stud frame comprise:
 positioning studs between a bottom track and a top plate; 
 applying a compressive force to the bottom track and the top plate to compress the top plate and the bottom track against the studs extending therebetween; 
 welding joints between each of the studs and the bottom track and between each of the studs and the top plate, before releasing the compressive force; and 
 connecting a pour stop to the metal stud frame, wherein the pour stop includes a vertical leg projecting upward from the top plate when the prefabricated exterior wall panel is oriented vertically and at least one reinforcement rod is connected to and projecting transverse to and inward from the vertical leg of the pour stop such that concrete may be poured around the at least one reinforcement rod to reinforce a concrete slab formed by the concrete; 
   connecting panels of sheathing that include an insulation layer and a weather proofing layer to the metal stud frame using fasteners to form an exterior sheathing;   removing excess portions of the exterior sheathing such that the exterior sheathing complements the metal stud frame; and   sealing between the panels of sheathing and over fasteners connecting the panels of sheathing to the metal stud frame to form a continuous air- and water-barrier on an exterior surface of the exterior sheathing.   
     
     
         13 . The method of assembling the prefabricated exterior wall panel of  claim 12 , further comprising securing a window assembly in a window opening formed in the metal stud frame and sealing between the exterior sheathing and the window assembly, wherein the window assembly includes a glass pane positioned within a window frame. 
     
     
         14 . The method of assembling the prefabricated exterior wall panel of  claim 13 , further comprising connecting a lintel above the window opening, wherein the lintel is configured to support cladding above the window opening. 
     
     
         15 . The method of assembling the prefabricated exterior wall panel of  claim 12 , further comprising sealing side edges of the exterior sheathing and a top edge of the exterior sheathing. 
     
     
         16 . The method of assembling the prefabricated exterior wall panel of  claim 15 , wherein sealing side edges of the exterior sheathing comprises:
 applying joint sealing tape on the exterior surface of the exterior sheathing proximate the side edges;   folding the joint sealing tape over the respective side edges of the exterior sheathing; and   adhering the joint sealing tape to an adjacent one of the respective studs of the metal stud frame.   
     
     
         17 . The method of assembling the prefabricated exterior wall panel of  claim 12 , wherein the pour stop is welded to a top plate of the metal stud frame adjacent an interior surface of a top portion of the exterior wall panel. 
     
     
         18 . The method of assembling the prefabricated exterior wall panel of  claim 12 , further comprising connecting a support ledge to the metal stud frame, wherein the support ledge extends laterally from a top portion of the exterior surface of the exterior sheathing and is configured to support cladding. 
     
     
         19 . The method of assembling the prefabricated exterior wall panel of  claim 12 , further comprising connecting a support ledge to the pour stop, wherein the support ledge extends from the exterior surface of the exterior sheathing and is configured to support cladding. 
     
     
         20 . The method of assembly the prefabricated exterior wall panel of  claim 19 , further comprising welding at least one mounting tab to the support ledge and the pour stop.