Method and arrangement for prefabricated wall assembly

Abstract

A wall assembly includes a plurality of girders each including a first insulator and having a longitudinal axis, the plurality of first insulators spaced apart along a first direction transverse to the longitudinal axes. Further, the wall assembly includes one or more second insulators, and fastening elements coupled to the plurality of girders and supporting the one or more second insulators along the first direction between sequentially spaced ones of the plurality of girders. Furthermore, the wall assembly includes a first concrete layer coupled to surfaces of the plurality of first insulators and the one or more second insulators.

We claim: 
     
         1 . A wall assembly, comprising:
 a plurality of girders each including a first insulator and having a longitudinal axis, the plurality of first insulators spaced apart along a first direction transverse to the longitudinal axes;   one or more second insulators;   fastening elements coupled to the plurality of girders and supporting the one or more second insulators along the first direction between sequentially spaced ones of the plurality of girders; and   a first concrete layer coupled to surfaces of the plurality of first insulators and the one or more second insulators.   
     
     
         2 . The wall assembly of  claim 1 , further comprising a second concrete layer, wherein the first and second concrete layers sandwich the plurality of first insulators and the one or more second insulators. 
     
     
         3 . The wall assembly of  claim 2 , wherein surfaces of the plurality of first insulators and the one or more second insulators are substantially co-planar. 
     
     
         4 . The wall assembly of  claim 2 , wherein the first concrete layer, the second concrete layer, or both comprise fiber reinforced concrete (FRC). 
     
     
         5 . The wall assembly of  claim 1 , wherein the fastening elements comprise one or more clips each having a vertex and a first leg with a first end, each first end supporting one of the one or more second insulators between sequentially spaced ones of the plurality of girders. 
     
     
         6 . The wall assembly of  claim 5 , wherein the first ends are configured to urge the one or more second insulators towards the first concrete layer. 
     
     
         7 . The wall assembly of  claim 5 , wherein each of the one or more clips has a second leg with a second end, the first and second ends configured to urge sequentially spaced ones of the one or more second insulators towards the first concrete layer. 
     
     
         8 . The wall assembly of  claim 5 , further comprising, for each girder from the plurality of girders:
 a rod extending parallel to the longitudinal axis of the girder, the vertexes of the one or more clips coupled to the rod.   
     
     
         9 . The wall assembly of  claim 8 , wherein each girder from the plurality of girders comprises one or more connectors coupling the girder to the rod. 
     
     
         10 . The wall assembly of  claim 9 , wherein, for each rod from the plurality of rods, the one or more connectors alternate with the one or more clips along a longitudinal axis of the rod. 
     
     
         11 . The wall assembly of  claim 1 , wherein each of the plurality of first insulators comprises Extruded Polystyrene Insulation (XPS), and each of the one or more second insulators comprises Expanded Polystyrene Insulation (EPS). 
     
     
         12 . The wall assembly of  claim 1 , wherein the plurality of first insulators alternate with the one or more second insulators along the first direction. 
     
     
         13 . The wall assembly of  claim 1 , wherein the plurality of girders are coupled to each other along the first direction through at least one of: a plurality of angle shaped connectors, a plurality of box connectors, and a plurality of iron bars. 
     
     
         14 . A method of manufacturing a wall assembly comprising:
 arranging a plurality of girders spaced apart from each other along a first direction transverse to longitudinal axes of the plurality of girders, each of the plurality of girders including an associated first insulator;   coupling a first concrete layer to the plurality of first insulators;   securing one or more second insulators between adjacent ones of the plurality of girders along the first direction; and   coupling a second concrete layer to the first concrete layer such that the first and second concrete layers sandwich the plurality of girders, the plurality of first insulators, and the one or more second insulators.   
     
     
         15 . The method of  claim 14 , wherein securing the one or more second insulators between the adjacent ones of the plurality of girders comprises urging the one or more second insulators towards the first concrete layer. 
     
     
         16 . The method of  claim 15 , further comprising, for each of the plurality of girders, anchoring one or more clips along the longitudinal axis of the girder, each of the one or more clips comprising a vertex and a first leg extending therefrom, the first leg opposing a surface of one of the one or more second insulators. 
     
     
         17 . The method of  claim 16 , wherein each of the one or more clips further comprises a second leg extending from a corresponding vertex in a direction opposite the first direction, the second leg opposing a surface of another of the one or more second insulators. 
     
     
         18 . The method of  claim 16 , wherein, for each of the plurality of girders, anchoring the one or more clips along the longitudinal axis of the girder comprises coupling the vertexes of the one or more clips to a corresponding rod extending from a surface of the first insulator. 
     
     
         19 . The method of  claim 14 , wherein coupling the first concrete layer to the plurality of first insulators comprises:
 elevating surfaces of the plurality of first insulators above a floor of a mold;   introducing a concrete mixture into the mold to a height substantially abutting the surfaces of the plurality of first insulators; and   allowing the concrete mixture to harden, thereby forming the first concrete layer.   
     
     
         20 . The method of  claim 14 , wherein each of the plurality of first insulators comprises Extruded Polystyrene Insulation (XPS), and each of the one or more second insulators comprises Expanded Polystyrene Insulation (EPS). 
     
     
         21 . The method of  claim 14 , wherein the first concrete layer and the second concrete layer comprise fiber reinforced concrete (FRC). 
     
     
         22 . A wall assembly, comprising:
 a first wall panel disposed opposite a second wall panel, thereby defining a volume therebetween;   a fastening assembly comprising a girder coupled to a first insulator and disposed within the volume, wherein a longitudinal axis of the first insulator corresponds to a height of the volume and a second axis transverse to the longitudinal axis corresponds to a length of the volume; and   one or more second insulators disposed within the volume and secured along the length of the volume by the fastening assembly.   
     
     
         23 . The wall assembly of  claim 22 , wherein the fastening assembly further comprises one or more clips, each of the one or more clips comprising a first section and a first leg having a first end, and the first end and the first wall panel sandwiching the first insulator. 
     
     
         24 . The wall assembly of  claim 23 , wherein the one or more clips are spaced apart along the height of the girder. 
     
     
         25 . The wall assembly of  claim 23 , wherein the fastening assembly further comprises an upper chord engaging each of the one or more first sections. 
     
     
         26 . The wall assembly of  claim 25 , wherein each of the one or more first sections comprises a bend for engaging the upper chord. 
     
     
         27 . The wall assembly of  claim 25 , wherein the girder comprises a lattice girder including one or more lower chords, the upper chord, and one or more connectors coupling the one or more lower chords to the upper chord. 
     
     
         28 . The wall assembly of  claim 25 , further comprising a third insulator, wherein the first insulator and the third insulator are disposed on opposite sides of the girder along the second axis, wherein each of the one or more clips further comprises:
 a second leg extending from the first section opposite the first leg along the second axis, the second leg having a second end, the second leg configured to support the third insulator within the volume.   
     
     
         29 . The wall assembly of  claim 25 , wherein the girder comprises one or more connectors supporting the upper chord. 
     
     
         30 . The wall assembly of  claim 29 , wherein the one or more connectors are spaced apart along the height of the girder. 
     
     
         31 . The wall assembly of  claim 23 , wherein each of the one or more first legs is configured to support the first insulator within the volume. 
     
     
         32 . The wall assembly of  claim 31 , wherein each of the one or more the first legs is configured to urge the first insulator against the first wall panel. 
     
     
         33 . The wall assembly of  claim 22 , wherein the first insulator, the second insulator, or both comprise a modular insulator block.