Pre-Engineered/Prefabricated Wall Assembly

Abstract

A pre-engineered/prefabricated wall assembly that has inner and outer sidewall panels of rigid insulation material that acts as both thermal insulation and concrete forms. The inner and outer sidewall panels are connected by connecting rods that secures a metal stud wall frame to the interior of the wall assembly, and a metal stud wall frame to the exterior of the wall assembly. The connecting rods serve to align the inner and outer sidewall panels separate from, and parallel to, each other, thereby providing a space for rebar and concrete to form a reinforced concrete wall. The mortar-less brick/stone veneer is attached to the wall assembly by inserting an attaching rod through the outer and inner sidewall panels, and is secured with a mechanical fastener, thereby securing the mortar-less brick/stone veneer in place until the poured concrete permanently secures the mortar-less brick/stone veneer to the exterior of the wall assembly.

1 . A pre-engineered/prefabricated wall assembly comprising:
 a first inner sidewall panel running the length and width of the wall assembly; and   a second outer sidewall panel spaced from the first sidewall panel running the length and width of the wall assembly.   
     
     
         2 . The pre-engineered/prefabricated wall assembly according to  claim 1 , wherein the inner sidewall panel runs parallel to and equidistance from the outer sidewall panel; and wherein a space is provide between the inner sidewall panel and the outer sidewall panel for the placing of rebar and the pouring of concrete. 
     
     
         3 . The pre-engineered/prefabricated wall assembly according to  claim 1 , wherein the inner and outer sidewall panels are constructed of polystyrene, polyurethane, or other rigid insulation material. 
     
     
         4 . The pre-engineered/prefabricated wall assembly according to  claim 1 , further comprising:
 a lower horizontal metal track and an upper horizontal metal track coupled to and running the length of the inner sidewall panel; and   a plurality of vertical metal wall studs located in the lower horizontal metal track and the upper horizontal metal track and secured thereto with metal framing screws;   wherein a rectangular wall frame is formed consisting of upper and lower horizontal metal tracks and vertical metal wall studs that form interior wall framing for the attachment of gypsum board or other wall covering, and provides a space for the placement of electrical wiring or other utilities.   
     
     
         5 . The pre-engineered/prefabricated wall assembly according to  claim 1 , further comprising:
 a lower horizontal metal track and an upper horizontal metal track coupled to and running the length of the outer sidewall panel; and   a plurality of vertical metal wall studs located in the lower horizontal metal track and the upper horizontal metal track and secured therein with metal framing screws;   wherein a rectangular wall frame is formed consisting of upper and lower horizontal metal tracks and vertical metal wall studs that provide exterior wall framing for the attachment of wall ties to secure brick, stone, architectural concrete, or other exterior veneers, or for the attachment of exterior wall sheathing, vinyl siding, wood siding, composite siding, or other sidings.   
     
     
         6 . The pre-engineered/prefabricated wall assembly according to  claim 2 , further comprising:
 at least one connecting rod for securing a metal stud wall frame to the wall assembly;   wherein the at least one connecting rod is inserted through both the inner and outer wall panels, and   wherein the at least one connecting rod is secured in place on the exterior side of the wall assembly by at least one threaded nut, speed washer, or other mechanical fastener.   
     
     
         7 . The pre-engineered/prefabricated wall assembly according to  claim 6  wherein the at least one connecting rod comes with different lengths which allow for a spacing of different widths between the inner sidewall panel and outer sidewall panel for attachment of rebar and pouring of concrete in various wall thicknesses. 
     
     
         8 . The pre-engineered/prefabricated wall assembly according to  claim 7  wherein an attaching rod located in a preformed hole in a mortar-less veneer is adapted to secured the mortar-less veneer to the wall. 
     
     
         9 . A mortar-less brick, mortar-less stone, mortar-less rock, mortar-less architectural concrete, or other mortar-less veneer wherein a hole is placed into the back of said mortar-less veneer during the manufacturing process. 
     
     
         10 . A pre-engineered/prefabricated wall assembly comprising: an inner sidewall panel constructed of polystyrene, polyurethane, or other rigid insulation; 
     
     
         11 . The pre-engineered/prefabricated wall assembly according to  claim 10 , further comprising:
 a lower horizontal metal track and an upper horizontal metal track coupled to and running the length of the inner sidewall panel; and   a plurality of vertical metal wall studs located in the lower horizontal metal track and the upper horizontal metal track and secured thereto with metal framing screws;   wherein a rectangular wall frame is formed consisting of upper and lower horizontal metal tracks and vertical metal wall studs that form interior wall framing for the attachment of gypsum board or other wall covering, and provides a space for the placement of electrical wiring or other utilities.   
     
     
         12 . The pre-engineered/prefabricated wall assembly according to  claim 10 , further comprising:
 exterior wall sheathing material running the length and width of the wall assembly for the attachment of wall ties to secure brick, stone, architectural concrete, or other exterior veneers, and for the attachment of vinyl siding, wood siding, composite siding, or other sidings.   
     
     
         13 . The pre-engineered/prefabricated wall assembly according to  claim 10 , further comprising: at least one connecting rod, threaded rod, threaded bolt, screw, or other connecting devise for securing the exterior wall sheathing to the wall assembly;
 wherein the at least one connecting rod is inserted through the interior metal stud wall framing, the inner sidewall panel, and the exterior wall sheathing;   wherein at least one connecting rod, threaded rod, threaded bolt, screw, or other connecting devise is secured in place on the exterior side of the wall assembly by at least one threaded nut, speed washer, or other mechanical fastener.