Wall assembly for building structures and methods for manufacturing thereof

Abstract

A wall assembly including: a plurality of stud assemblies, each of the stud assemblies including a plurality of metal studs, the stud assemblies being spaced apart from each other and forming a window opening therebetween; a sill wedge connected between the stud assemblies and forming a lower edge of the window opening; and a board layer extending around a periphery of the window opening and being attached to the stud assemblies.

What is claimed is: 
     
         1 . A wall assembly comprising:
 a plurality of stud assemblies, each of the stud assemblies comprising a plurality of metal studs, the stud assemblies being spaced apart from each other and forming a window opening therebetween;   a sill wedge connected between the stud assemblies and forming a lower edge of the window opening; and   a board layer extending around a periphery of the window opening and being attached to the stud assemblies.   
     
     
         2 . The wall assembly of  claim 1 , wherein the plurality of metal studs comprises three 2″×6″ metal studs and two 2″×4″ metal studs. 
     
     
         3 . The wall assembly of  claim 1 , wherein the board comprises ProFab board. 
     
     
         4 . The wall assembly of  claim 1 , wherein the sill wedge comprises ProFab board. 
     
     
         5 . The wall assembly of  claim 1 , wherein the wall assembly further comprises a first mesh on the board layer. 
     
     
         6 . The wall assembly of  claim 5 , wherein the wall assembly further comprises a coating layer on the first mesh. 
     
     
         7 . The wall assembly of  claim 6 , wherein the coating layer comprises ProFab Platinum Coat. 
     
     
         8 . The wall assembly of  claim 6 , wherein the wall assembly further comprises a panel is on the coating layer. 
     
     
         9 . The wall assembly of  claim 8 , wherein the wall assembly further comprises a first base coating on the panel. 
     
     
         10 . The wall assembly of  claim 9 , wherein the wall assembly further comprises a second mesh on the first base coating. 
     
     
         11 . The wall assembly of  claim 10 , wherein the wall assembly further comprises a second base coating on the second mesh. 
     
     
         12 . The wall assembly of  claim 11 , wherein the first and second base coatings comprise ProFab Base Coat. 
     
     
         13 . The wall assembly of  claim 11 , wherein the wall assembly further comprises a finish layer on the second base coating. 
     
     
         14 . The wall assembly of  claim 13 , wherein the finish layer comprises green cork layer. 
     
     
         15 . A method for manufacturing a wall assembly, the method comprising:
 forming a plurality of stud assemblies, each of the stud assemblies comprising a plurality of metal studs;   arranging the stud assemblies a distance from each other to form a window opening therebetween;   attaching a sill wedge between the stud assemblies to form a lower edge of the window opening;   attaching a board to the stud assemblies around a periphery of the window opening;   attaching a first mesh layer on the board, the sill wedge, and plurality of stud assemblies;   applying a coating layer on the mesh and the board;   attaching a window to the plurality of stud assemblies;   attaching a panel to the plurality of stud assemblies on the coating layer;   applying a first base coating layer to the panel;   attaching a second mesh layer to the panel on first base coating layer;   applying a second base coating layer on the second mesh layer; and   applying a finish layer on the second base coating layer.   
     
     
         16 . A weather protection system for an exterior surface of a wall assembly, the weather protection system comprising
 a plurality of stud assemblies, each of the stud assemblies comprising a plurality of metal studs, the stud assemblies being spaced apart from each other and having a surface that faces the exterior surface of the wall assembly;   a board layer being attached to the stud assemblies on the surface facing the exterior surface;   a first mesh on the board layer;   a coating layer on the mesh;   a panel on the coating layer;   a first base coating on the panel;   a second mesh on the first base coating;   a second base coating on the second mesh; and   a finish layer on the second base coating.   
     
     
         17 . The weather protection system of  claim 16 , wherein the board comprises ProFab board. 
     
     
         18 . The weather protection system of  claim 16 , wherein the coating layer comprises ProFab Platinum Coat. 
     
     
         19 . The weather protection system of  claim 16 , wherein the first base and second base coatings comprise ProFab Base Coat. 
     
     
         20 . The weather protection system of  claim 16 , wherein the finish layer comprises green cork layer.