Thin shell cementitious coated shear wall structural panel assembly and method of manufacture

Abstract

This invention relates to an improved shear wall structural panel assembly that is able to resist gravity loads and lateral forces imposed by wind and earthquake loads. The panel comprises a substantially rectangular frame assembly that is constructed from a plurality of vertical frame members dispensed between and perpendicular to two horizontal frame members. There is a water barrier that is approximately the size of the frame assembly that is fixedly attached to and covering one side of the frame assembly. A reinforcement layer covers and is attached to the water barrier. Four outer frame members are fixedly attached to the perimeter of the frame assembly holding the aforementioned water barrier and reinforcement layer securely in place. A cementitious layer is adjacent to, covering and bonded to said reinforcement layer.

1 . A shear wall structural panel assembly for resisting gravity and shear loads, comprising:
 a substantially rectangular frame assembly having a plurality of parallel vertical frame members dispensed between and perpendicular to two horizontal frame members, said frame assembly having an outer perimeter, a first side and a second side opposite said first side;   a water barrier approximate the size of said frame assembly fixedly attached to and covering said first side of said frame assembly;   a reinforcement layer approximate the size of said frame assembly fixedly attached to said frame assembly and covering said water barrier; and   an outer frame assembly fixedly attached to said outer perimeter of said frame assembly; and   a cementitious layer disposed on, covering and bonding to said reinforcement layer;   wherein, the shear wall structural panel assembly is a combined load bearing wall, shear wall, and exterior siding.   
   
   
       2 . The shear wall structural panel assembly of  claim 1 , wherein said vertical frame members and said horizontal frame members are nominal two inch by six inch wood studs. 
   
   
       3 . The shear wall structural panel assembly of  claim 1 , wherein said water barrier is breathable plastic sheeting. 
   
   
       4 . The shear wall structural panel assembly of  claim 1 , wherein said reinforcement layer is a polymer mesh. 
   
   
       5 . The shear wall structural panel assembly of  claim 1 , wherein said outer frame assembly is a plurality of nominal two inch by four inch wood studs. 
   
   
       6 . The shear wall structural panel assembly of  claim 1 , wherein said cementitious layer is concrete comprising, on a dry basis, 45 to 75 weight percent cementitious power, 10 to 30 weight percent sand, 1 to 5 weight percent polyvinyl alcohol fibers, and 0.5 to 2.0 weight percent chemical admixture, said continuous phase being reinforced with polyvinyl alcohol fibers. 
   
   
       7 . The shear wall structural panel assembly of  claim 1 , further comprising at least two corner reinforcement brackets fixedly attached to at least two exterior corners of said outer flame assembly. 
   
   
       8 . The shear wall structural panel assembly of  claim 1 , wherein each of said vertical flame members has a wood lath fixedly attached to and extending the length of said vertical flame members, wherein said wood lath secures said reinforcement layer to said frame assembly prior to application of said cementitious layer. 
   
   
       9 . The shear wall structural panel assembly of  claim 1 , wherein said cementitious layer is sprayed onto and bonded to said reinforcement layer with said the shear wall structural panel assembly vertically oriented. 
   
   
       10 . The shear wall structural panel assembly of  claim 1 , further comprising at least one weep opening extending through said cementitious layer, through said reinforcement layer and through said water barrier, wherein moisture inside the panel is allowed to escape. 
   
   
       11 . The shear wall structural panel assembly of  claim 10 , further comprising a portion of flashing spanning between and perpendicular to each of said vertical frame members, said flashing extends downward from said second side of said frame assembly to said first side of said frame assembly and below said weep openings. 
   
   
       12 . The shear wall structural panel assembly of  claim 1 , wherein said outer frame assembly is extended a distance above said first side of said frame assembly creating a frame step, said cementitious layer is dispensed on said reinforcement layer and said outer frame assembly creating a cementitious step having a height of said distance, wherein, said frame step provides added strength to the shear wall structural panel assembly. 
   
   
       13 . The shear wall structural panel assembly of  claim 1 , wherein said cementitious layer further comprises a colorant eliminating the need for exterior painting. 
   
   
       14 . The shear wall structural panel assembly of  claim 1 , wherein said cementitious layer  15  further comprises an exterior having aesthetic surface features. 
   
   
       15 . The shear wall structural panel assembly of  claim 12 , wherein said features are embedded stone veneer. 
   
   
       16 . The shear wall structural panel assembly of  claim 12 , wherein said features are embedded brick veneer. 
   
   
       17 . A method of manufacturing a shear wall structural panel assembly, comprising the steps of:
 providing a first frame structure having a plurality of parallel vertical frame members dispensed between and perpendicular to two horizontal frame members, said frame assembly having an outer perimeter, and a first side;   attaching a water barrier approximate the size of said frame assembly covering said first side of said frame assembly;   attaching a reinforcement layer approximate the size of said frame assembly to said frame assembly and covering said water barrier;   attaching an outer frame assembly to said outer perimeter of said frame assembly creating a structural assembly having an assembly perimeter;   providing a mold having an outer dimension approximate that of said assembly perimeter;   dispensing a cementitious material to a depth in said mold;   placing said structural assembly with said first side down onto said cementitious material in said mold, said cementitious layer bonding to said reinforcement layer;   wherein, the shear wall structural panel assembly is a load bearing wall, shear wall, and exterior siding.   
   
   
       18 . The method of  claim 17 , wherein said outer frame assembly is extended a distance above said first side of said frame assembly creating a frame step, said cementitious layer is dispensed on said reinforcement layer and said outer frame assembly creating a cementitious step having a height of said distance, wherein, said frame step provides added strength to the shear wall structural panel assembly. 
   
   
       19 . The method of  claim 17 , further comprising the step of attaching at least two corner reinforcement brackets to at least two exterior corners of said outer frame assembly. 
   
   
       20 . The shear wall structural panel assembly of  claim 1 , wherein said outer frame assembly, said vertical frame members, and said horizontal frame member of said frame assembly and are light gauge steel.