Reinforced wall system and method

Abstract

A method of constructing a wall to meet an applicable building code, and a wall created by this method. The method may include placing insulating concrete forms, having a cavity, where the wall is to be constructed; placing a limited quantity of metal reinforcement steel within the cavity, such that the limited quantity of reinforcing steel is insufficient to meet the applicable building code; and pouring a mix of aggregate, sand, cement, fly ash, and mineral fibers into the cavity; and allowing the mix to cure, thereby meeting the applicable building code without additional metal reinforcement. The mix may between 45 and 50% stone, between 30 and 35% sand, between 10 and 12% Portland cement, between 5 and 8% fly ash, between 1 and 2% mineral fibers, and between 0 and 1% admixtures by weight. The mix may contain mineral fibers of different grades and/or dimensions.

what is claimed is: 
     
         1 . A method of constructing a structure to meet an applicable building code, the method including the steps of:
 placing a concrete form, having a cavity, where the structure is to be constructed;   placing a limited quantity of metal reinforcement within the cavity, such that the limited quantity of metal reinforcement is insufficient to meet the applicable building code;   pouring a mix of aggregate, sand, cement, fly ash, and mineral fibers into the cavity; and   allowing the mix to cure, thereby meeting the applicable building code without additional metal reinforcement.   
     
     
         2 . The method according to  claim 1 , wherein the step of pouring a mix includes pouring a mix that contains multiple grades of the mineral fibers. 
     
     
         3 . The method according to  claim 1 , wherein the step of pouring a mix includes pouring a mix that contains multiple lengths of the mineral fibers. 
     
     
         4 . The method according to  claim 1 , wherein the step of pouring a mix includes pouring a mix that contains multiple thicknesses of the mineral fibers. 
     
     
         5 . The method according to  claim 1 , wherein the mix contains approximately 48.24% stone, 33.15% sand, 10.32% Portland cement, 6.88% fly ash, 1.41% mineral fibers, and preferably less than 0.005% of admixtures by weight. 
     
     
         6 . The method according to  claim 5 , wherein the step of pouring a mix includes pouring a mix that contains multiple grades of the mineral fibers. 
     
     
         7 . The method according to  claim 5 , wherein the step of pouring a mix includes pouring a mix that contains multiple lengths of the mineral fibers. 
     
     
         8 . The method according to  claim 5 , wherein the step of pouring a mix includes pouring a mix that contains multiple thicknesses of the mineral fibers. 
     
     
         9 . The method according to  claim 1 , wherein the mix contains between 40 and 50% stone, between 30 and 40% sand, between 10 and 15% Portland cement, between 5 and 10% fly ash, between 0.5 and 2% mineral fibers, and between 0.005 and 5% admixtures by weight. 
     
     
         10 . The method according to  claim 9 , wherein the step of pouring a mix includes pouring a mix that contains multiple grades of the mineral fibers. 
     
     
         11 . The method according to  claim 9 , wherein the step of pouring a mix includes pouring a mix that contains multiple lengths of the mineral fibers. 
     
     
         12 . The method according to  claim 9 , wherein the step of pouring a mix includes pouring a mix that contains multiple thicknesses of the mineral fibers. 
     
     
         13 . The method according to  claim 1 , wherein the mix contains between 45 and 50% stone, between 30 and 35% sand, between 10 and 12% Portland cement, between 5 and 8% fly ash, between 1 and 2% mineral fibers, and between 0 and 1% admixtures by weight. 
     
     
         14 . The method according to  claim 13 , wherein the step of pouring a mix includes pouring a mix that contains multiple grades of the mineral fibers. 
     
     
         15 . The method according to  claim 13 , wherein the step of pouring a mix includes pouring a mix that contains multiple lengths of the mineral fibers. 
     
     
         16 . The method according to  claim 13 , wherein the step of pouring a mix includes pouring a mix that contains multiple thicknesses of the mineral fibers. 
     
     
         17 . The method according to  claim 1 , wherein the mix relies on chemical bonding of its ingredients, as opposed to mechanical bonding, to provide a required strength to meet the applicable building code, without additional metal reinforcement. 
     
     
         18 . The method according to  claim 1 , wherein the step of pouring a mix includes pouring a mix that replaces between 20 and 40% cement with fly ash. 
     
     
         19 . A method of constructing a wall to meet an applicable building code, the method including the steps of:
 placing concrete forms, having a cavity, where the wall is to be constructed;   placing a limited quantity of metal reinforcement within the cavity, such that the limited quantity of metal reinforcement is insufficient to meet the applicable building code; and   pouring a mix of aggregate, sand, cement, fly ash, and mineral fibers into the cavity, wherein the mix contains approximately 48.24% stone, 33.15% sand, 10.32% Portland cement, 6.88% fly ash, 1.41% mineral fibers of different grades, and less than 0.005% of admixtures by weight,   allowing the mix to cure in the forms, thereby meeting the applicable building code without additional metal reinforcement.   
     
     
         20 . A method of constructing a wall to meet an applicable building code, the method including the steps of:
 placing insulating concrete forms, having a cavity, where the wall is to be constructed;   placing a limited quantity of metal reinforcement steel within the cavity, such that the limited quantity of reinforcing steel is insufficient to meet the applicable building code;   pouring a mix of aggregate, sand, cement, fly ash, mineral fibers, and synthetic fibers into the cavity, wherein the mix contains approximately 48.24% stone, 33.15% sand, 10.32% Portland cement, 6.88% fly ash, 1.41% mineral fibers of different dimensions, and less than 0.005% of admixtures by weight; and   allowing the mix to cure in the insulating concrete forms, thereby meeting the applicable building code without additional metal reinforcement.