Rammed earth formwork-facade

Abstract

Disclosed herein is a permanent rammed earth formwork-façade, including two parallel side panels, a plurality of galleys and/or rebars fastened transversally between the two side panels interconnecting the two side panels to each other, and a plurality of Ω-shaped fasteners fastening the plurality of galleys between the two side panels and receiving rebars connecting side by side adjacent side panels of two or more of the permanent rammed earth formwork-facades in large formwork-facades. Each side panel includes a double-layered rammed earth wall reinforced by a mesh network there inside, a barbed wire woven into the mesh network, a plurality of rebars fastened to the mesh network, and a plurality of L-shaped anchor bolts fastened to the mesh network, a respective Ω-shaped fastener, and a respective rebar. Each side panel further includes a water-proof thermal insulator layer coated on an interior surface of the double-layered rammed earth wall.

What is claimed is: 
     
         1 . A permanent rammed earth formwork-facade for a rammed earth and/or a concrete structure, the permanent rammed earth formwork-facade comprising:
 two side panels placed parallel with each other spacing apart with a distance equal to a thickness of the rammed earth and/or the concrete structure, each respective side panel comprising:
 a double-layered rammed earth wall comprising two layers of rammed earth compacted to each other, the double-layered rammed earth wall having an interior surface and an exterior surface each with a rectangular shape having a length and a width; 
 a mesh network placed inside the double-layered rammed earth wall between the two layers of rammed earth parallel with both the interior surface and the exterior surface; 
 a strand of barbed wire perpendicularly woven into the mesh network, the strand of barbed wire comprising a plurality of sharped edges inserted into the two layers of rammed earth tightening the mesh network to the two layers of rammed earth; 
 a first plurality of rebars fastened to the mesh network extending along at least one of the length of the interior surface and the exterior surface, the width of the interior surface and the exterior surface, and combinations thereof; 
 a plurality of L-shaped anchor bolts, each respective L-shaped anchor bolt comprising a long end and a short end, the long end fastened to the mesh network and at least one rebar of the first plurality of rebars along at least one of the length of the interior surface and the exterior surface, the width of the interior surface and the exterior surface, and combinations thereof, the short end having a thread placed along a thickness of the double-layered rammed earth wall perpendicular to the interior surface and the exterior surface, the thread protruding from the interior surface; and 
 an insulator layer coated on the interior surface of the double-layered rammed earth wall, the insulator layer comprising a sheet made of at least one of a moisture-proof material, a thermal insulator material, and combinations thereof, the insulator layer fastened to the interior surface via screwing protruding respective threads of the plurality of L-shaped anchor bolts from the interior surface onto the insulator layer; 
   a plurality of galleys, each respective galley extending transversally between the two side panels interlocking the two side panels to each other;   a plurality of transversal connectors transversally interconnecting the two side panels to each other, the plurality of transversal connectors comprising at least one of a second plurality of rebars, a plurality of strip anchors, and combinations thereof, each respective transversal connector comprising a first end fastened to a first panel of the two side panels and a second end fastened to a second panel of the two side panels, each respective transversal connector is fastened to each side panel of the two side panels at a respective hole inside the side panel using a soldier pile and a wing nut, the soldier pile being placed onto the exterior surface of the side panel; and   a plurality of Ω-shaped fasteners, each respective Ω-shaped fastener comprising:
 a base comprising a central hole, the Ω-shaped fastener being screwed to a side panel of the two side panels via a thread of a respective L-shaped anchor bolt passing through the central hole, the Ω-shaped fastener being fastened to the respective side panel using a nut; 
 two hooks protruding from the interior surface and/or the insulator layer of the respective side panel and secured into the rammed earth and/or the concrete structure, each respective hook comprising a groove receiving a galley of the plurality of galleys therein interconnecting the two opposite side panels; and 
 two lateral walls extending from two respective opposite end edges of the base to the two respective hooks, 
   wherein the rammed earth and/or the concrete structure is received within a hollow space between the respective interior surfaces of the two side panels.   
     
     
         2 . A permanent rammed earth formwork-facade for a rammed earth and/or a concrete structure, the permanent rammed earth formwork-facade comprising:
 two side panels placed parallel with each other spacing apart with a distance equal to a thickness of the rammed earth and/or the concrete structure, each respective side panel comprising:
 a double-layered rammed earth wall comprising two layers of rammed earth compacted to each other, the double-layered rammed earth wall having an interior surface and an exterior surface each with a rectangular shape having a length and a width; 
 a mesh network placed inside the double-layered rammed earth wall between the two layers of rammed earth parallel with both the interior surface and the exterior surface; 
 a strand of barbed wire woven into the mesh network, the strand of barbed wire comprising a plurality of sharped edges inserted into the two layers of rammed earth tightening the mesh network to the two layers of rammed earth; 
 a first plurality of rebars fastened to the mesh network extending along at least one of the length of the interior surface and the exterior surface, the width of the interior surface and the exterior surface, and combinations thereof; and 
 a plurality of L-shaped anchor bolts, each respective L-shaped anchor bolt comprising a long end and a short end, the long end fastened to the mesh network and at least one rebar of the first plurality of rebars along at least one of the length of the interior surface and the exterior surface, the width of the interior surface and the exterior surface, and combinations thereof, the short end having a thread placed along a thickness of the double-layered rammed earth wall perpendicular to the interior surface and the exterior surface, the thread protruding from the interior surface; 
   a plurality of galleys, each respective galley extending transversally between the two side panels interlocking the two side panels to each other; and   a plurality of Ω-shaped fasteners, each respective Ω-shaped fastener comprising:
 a base comprising a central hole, the Ω-shaped fastener being screwed to a side panel of the two side panels via a thread of a respective L-shaped anchor bolt passing through the central hole, the Ω-shaped fastener being fastened to the respective side panel using a nut; 
 two hooks protruding from the interior surface of the respective side panel and secured into the rammed earth and/or the concrete structure, each respective hook comprising a groove receiving a galley of the plurality of galleys therein interconnecting the two opposite side panels; and 
 two lateral walls extending from two respective opposite end edges of the base to the two respective hooks, 
   wherein the rammed earth and/or the concrete structure is received within a hollow space between the respective interior surfaces of the two side panels.   
     
     
         3 . The permanent rammed earth formwork-facade of  claim 2 , wherein a thickness of each side panel of the two side panels is in a range of 3 cm to 10 cm. 
     
     
         4 . The permanent rammed earth formwork-facade of  claim 2 , wherein the mesh network comprises a wire grid panel made of at least one of a metal, a metal alloy, a geosynthetic material, and combinations thereof, the wire grid panel comprising a plurality of square-shaped openings, each respective square-shaped opening comprising a side length in a range of 1 cm to 3 cm. 
     
     
         5 . The permanent rammed earth formwork-facade of  claim 2 , wherein the first plurality of rebars comprises a plurality of rebars with a diameter in a range of 8 mm to 20 mm arranged parallel to each other with a distance between each two adjacent rebars being in a range of 10 cm to 30 cm. 
     
     
         6 . The permanent rammed earth formwork-facade of  claim 2 , wherein each rebar of the first plurality of rebars is welded to at least one of the mesh network, an L-shaped anchor bolt of the plurality of L-shaped anchor bolts, and combinations thereof. 
     
     
         7 . The permanent rammed earth formwork-facade of  claim 2 , wherein each respective side panel further comprises a plurality of twisted wires,
 wherein at least two elements of a set of elements comprising a rebar of the first plurality of rebars, the mesh network, an L-shaped anchor bolt of the plurality of L-shaped anchor bolts, and combinations thereof are fastened together via a twisted wire of the plurality of twisted wires.   
     
     
         8 . The permanent rammed earth formwork-facade of  claim 2 , wherein the strand of barbed wire interlocks at least two elements of a set of elements comprising a rebar of the first plurality of rebars, the mesh network, an L-shaped anchor bolt of the plurality of L-shaped anchor bolts, a layer of the two layers of rammed earth of the double-layered rammed earth wall, and combinations thereof together. 
     
     
         9 . The permanent rammed earth formwork-facade of  claim 2 , wherein each sharp edge of the plurality of sharped edges of the strand of barbed wire has a length in a range of 0.5 cm to 1 cm. 
     
     
         10 . The permanent rammed earth formwork-facade of  claim 2 , wherein the exterior surface comprises a smooth anti-scratch waterproof surface. 
     
     
         11 . The permanent rammed earth formwork-facade of  claim 2 , wherein a length of each respective galley extended between two side panels is adjusted to be equal to the thickness of the rammed earth and/or the concrete structure using a pair of a gasket coupled to a bolt fastening each end of two ends of the galley to both sides of a respective groove of a respective Ω-shaped fastener. 
     
     
         12 . The permanent rammed earth formwork-facade of  claim 2 , wherein each side panel of the two side panels further comprises an insulator layer with a thickness in a range of 2 mm to 10 cm coated on the interior surface of the double-layered rammed earth wall, the insulator layer comprising a sheet made of at least one of a moisture-proof material, a thermal insulator material, a soundproof material, a shock absorbing material, and combinations thereof. 
     
     
         13 . The permanent rammed earth formwork-facade of  claim 12 , wherein the insulator layer comprises a layer of at least one of polycarbonate, extruded polystyrene (XPS), closed-cell spray foam, mineral wool, polyurethane foam, fiberglass with a vapor barrier, a thermal-insulating foam, a moisture-proof foam, a moisture-proof polymer, polyisocyanurate (Polyiso), phenolic foam, and combinations thereof. 
     
     
         14 . The permanent rammed earth formwork-facade of  claim 12 , wherein the insulator layer is fastened to the respective interior surface of each respective side panel by at least one of protruding respective threads of the plurality of L-shaped anchor bolts from the insulator layer, screwing the respective protruded threads of the plurality of respective L-shaped anchor bolts via respective plurality of Ω-shaped fasteners, and combinations thereof. 
     
     
         15 . The permanent rammed earth formwork-facade of  claim 2 , wherein at least two permanent rammed earth formwork-facades are abutted side by side forming a pair of permanent rammed earth formwork-facade walls, each with respective dimensions larger than the length and width of the double-layered rammed earth wall. 
     
     
         16 . The permanent rammed earth formwork-facade of  claim 15 , wherein each respective lateral wall of the two lateral walls of each Ω-shaped fastener comprises an opening,
 wherein a connecting rod of a first plurality of connecting rods interconnecting two respective adjacent side panels of the two permanent rammed earth formwork-facades is passed through the opening. 
 
     
     
         17 . The permanent rammed earth formwork-facade of  claim 15 , wherein a connecting rod of a second plurality of connecting rods interconnecting two respective adjacent side panels of the two permanent rammed earth formwork-facades is passed through a hollow space on the base of each Ω-shaped fastener defined by the two lateral walls extended out of the two opposite edges of the base. 
     
     
         18 . The permanent rammed earth formwork-facade of  claim 2 , further comprising a plurality of transversal connectors transversally interconnecting the two side panels to each other, each respective transversal connector comprising a first end fastened to a first panel of the two side panels and a second end fastened to a second panel of the two side panels, the plurality of transversal connectors comprising at least one of a plurality of support beams, a second plurality of rebars, a plurality of strip anchors, a plurality of square profiles, and combinations thereof. 
     
     
         19 . The permanent rammed earth formwork-facade of  claim 18 , wherein the first end and the second end of each transversal connector pass through respective holes extended through a thickness of the two side panels at two respective opposite locations of the two side panels, each transversal connector fastened to each side panel of the two side panels at the respective hole using a soldier pile and a wing nut, the soldier pile placed onto the exterior surface. 
     
     
         20 . The permanent rammed earth formwork-facade of  claim 18 , wherein a normal distance between each two adjacent transversal connectors of the plurality of transversal connectors is in a range of 20 cm to 100 cm.