Composite Concrete Wall System with Insulated Frame
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Solution Overview
Problem
Conventional building construction methods require skilled labor, are costly, and lack efficient insulation, making it difficult to construct affordable, resilient, and quickly assembled housing units, especially in areas with limited skilled labor and resources.
Innovation Solution
A composite building construction system comprising a frame, wallboard with both external and internal insulation, and a sprayed concrete layer, where the wallboard is attached to the frame using key bolts and a wire grid, allowing for easy assembly and providing structural integrity and insulation without the need for skilled labor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional construction methods (wood stud, concrete block, or concrete panel) are used, then structural integrity is achieved, but skilled labor is required and construction cost increases
Solution Approach 1:
The wall assembly is segmented into distinct functional layers: frame members providing structural support, insulation material for thermal performance, and a concrete layer for durability. Each component can be manufactured and assembled independently, reducing skilled labor requirements while maintaining structural integrity.
Solution Approach 2:
The invention employs a composite construction system combining metal or wood frame members, insulation material (such as foam board), and concrete layer. This composite approach integrates the strengths of each material: structural strength from frames, thermal insulation from the core, and weather resistance from the concrete exterior, achieving code compliance without requiring skilled traditional construction methods.
2Strength
If conventional construction methods are used, then structural soundness is achieved, but construction time increases
Solution Approach 1:
Frame members and insulation panels are prepared and positioned in advance according to predetermined patterns. The insulation material is pre-cut to fit between frame members, and the assembly sequence is planned to enable rapid construction. This preliminary preparation significantly reduces on-site construction time while ensuring structural soundness.
Solution Approach 2:
The wall system is divided into modular segments that can be assembled quickly. Frame members are positioned and secured, followed by insertion of insulation panels, and finally application of the concrete layer. This segmented approach allows parallel processing and reduces overall construction time compared to conventional monolithic methods.
3Loss of energy
If insulation is placed only internally or only externally, then some insulation is provided, but thermal efficiency is insufficient
Solution Approach 1:
The insulation material is positioned in the core layer between the frame members, creating a thermal barrier at the most critical location where heat transfer occurs. This strategic placement of insulation in the center of the wall assembly maximizes thermal efficiency by interrupting the heat flow path between interior and exterior environments.
Solution Approach 2:
The composite wall structure integrates insulation material as a core component between structural frames, with the insulation serving as both thermal barrier and structural filler. This composite approach ensures that insulation is neither purely internal nor external but integrated into the wall assembly, providing superior thermal efficiency that meets or exceeds building code requirements.
4Strength
If precast concrete panels are used, then structural strength is achieved, but heavy equipment is required and transportation cost increases
Solution Approach 1:
Instead of using large precast concrete panels requiring heavy lifting equipment, the concrete is applied as a thinner layer over the frame and insulation assembly. This segmented approach allows the concrete to be applied in manageable sections using lighter equipment, reducing transportation and installation complexity while maintaining structural strength through the composite action of the entire wall system.
Solution Approach 2:
The heavy precast concrete panel is extracted from the design and replaced with an in-situ concrete application over a lightweight frame and insulation assembly. This removes the need for heavy lifting equipment and reduces transportation requirements, while the concrete layer still provides the necessary structural strength and weather resistance when integrated with the frame system.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system enables rapid, cost-effective construction of housing units that are structurally sound, weather-resistant, and well-insulated, exceeding national building codes, and can be assembled quickly with minimal skill, using prefabricated frame sections and a single unitary wallboard for both internal and external insulation.
Implementation Method 1
a concrete layer sprayed over the wallboard and support structure to complete the construction system
Data Source
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AI summary
A composite building construction system comprising a frame, an expanded wallboard, and a concrete layer. The wallboard comprises an outer portion and inset portion wherein the wallboard is attached to the frame with the outer portion covering an exterior side of the frame and the inset portion is disposed within the frame. The wallboard thus provides exterior and interior insulation for the system. The concrete layer is sprayed on to the outer portion of said wallboard, forming a strong durable composite construction system. One or more rebar supports may be attached to the frame at the exterior side by key bolts and are spaced apart from the wallboard. A wire grid may be attached to the key bolts whereby the grid and the rebar supports provide a support structure for the concrete layer. The frame comprises steel and the wallboard comprises insulative expanded polystyrene.