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:
 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.   
     
     
         2 . The method of  claim 1  including the step of placing spacers between the foam form and the panel to define a gap between the foam form and the panel; and the pouring step includes the step of pouring the structural material into the gap. 
     
     
         3 . The method of  claim 2  including the step of extending bars outward from the foam form. 
     
     
         4 . The method of  claim 3  wherein the foam form includes a front foam sheet positioned adjacent a front side of the panel and a rear foam sheet and a rear foam sheet positioned adjacent a rear side of the panel; and including the step of positioning a right end board adjacent a right side of the panel and the front and rear foam sheets, and a left end board adjacent a rear side of the panel and the front and rear foam sheets to close off the front and rear foam sheets so essentially no structural material escapes during the pouring step. 
     
     
         5 . The method of  claim 4  wherein pouring the structural material step includes the step of pouring uncured concreate, and wherein the step of extending the bars includes the step of extending the bars through the panel and the front and rear foam sheets. 
     
     
         6 . The method of  claim 5  including the step of attaching bracing with the bars about the front and rear foam sheets to hold the front and rear foam sheets and the panel together while the uncured concrete is poured and then allowed to harden. 
     
     
         7 . The method of  claim 6  wherein the step of placing spacers includes the step of placing spacers so a bottom side of the panel rests on spacers so uncured concrete can flow under the bottom side and cover the bottom side during the pouring step. 
     
     
         8 . The method of  claim 7  including after the letting step there is the step of removing the bracing. 
     
     
         9 . The method of  claim 8  wherein the panel has a core with a 3D wire mesh matrix extending through and out the core. 
     
     
         10 . The method of  claim 9  wherein the panel provides sound dampening and temperature insulation. 
     
     
         11 . The method of  claim 10  wherein the core is formed of styrene foam.