Method of manufacturing and building preformed modular building wall sections

Claim 1

A method of constructing a building load-bearing wall structure disposed upon a supporting base foundation, the method comprising the steps of: prefabricating a plurality of elongate wall modules each comprised of an open network of spaced reinforcing bars extending along X and Y axes on opposite sides of and spaced from an insulation panel, forming a skeletal network of a frame assembly consisting of: a. seating and welding a horizontally-disposed bottom channel to a sill bolted to a base foundation, b. seating and bolting a horizontally-disposed top plate upon a top channel, c. seating spaced pairs of vertically-disposed U-shaped hat channels in back-to-back relationship with a stiffening connector sandwiched between and welded to the hat channels of at least some of said pairs, disposing each wall module into a respective rectangular portion of the frame assembly defined by portions of the top and bottom channels and the respective adjacent hat channel at each side, nesting each edge of the insulation panel of each wall module in the defined U of the respective adjacent channel, welding the hat channels and connectors to the adjacent bottom and top channels, extending a plurality of horizontally-disposed reinforcing connecting rods through strategically-aligned openings in each arrangement of hat channels and connector and into the open network of reinforcing bars on opposite sides of the respective insulation panel of each adjacent wall module, and pneumatically applying gunite to the spaces between the channels on opposite sides of the insulation panel to define a reinforced concrete structure.

Claim 2

A method of constructing a building load-bearing wall structure disposed upon a supporting base foundation, the method comprising the steps of: prefabricating a plurality of elongate wall modules each comprised of an open network of spaced reinforcing bars extending along X and Y axes on opposite sides of and spaced from an insulation panel, forming a skeletal network of a frame assembly consisting of: a. seating and welding a horizontally-disposed bottom channel to a sill bolted to a base foundation, b. seating and bolting a horizontally-disposed top plate upon a top channel, c. seating spaced pairs of vertically-disposed U-shaped hat channels in back-to-back relationship with a stiffening connector sandwiched between and welded to the hat channels of at least some of said pairs, disposing each wall module into a respective rectangular portion of the frame assembly defined by portions of the top and bottom channels and the respective adjacent hat channel at each side, nesting each edge of the insulation panel of each wall module in the defined U of the respective adjacent channel, welding the hat channels and connectors to the adjacent bottom and top channels, extending a plurality of horizontally-disposed reinforcing connecting rods through strategically-aligned openings in each arrangement of hat channels and connector and into the open network of reinforcing bars on opposite sides of the respective insulation panel of each adjacent wall module, and pneumatically applying gunite to the spaces between the channels on opposite sides of the insulation panel to define a reinforced concrete structure.