The Spray-In-Place building system uses Exceptional Wall technology applied on the building’s jobsite as opposed to being precast or prefabricated.  It is considered an EIFS since it has all of a typical EIFS’s eleven materials/layers, consolidated into four, including exterior insulation and an elastomeric wall face finish.  US Patent #10,954,665 was issued in March, 2021.

The process may either spray-cast the concrete cladding or it may use third party claddings such as siding boards.  In both cases at least the polyurethane foam is sprayed against the backside of the cladding to bond it to the building frame.

One sided forms facing inward & set 2” outside of building frame

Form faces may have recessed moulding areas

Forms as light as 2 lbs/sf

Before

After

US Patent #10,954,665

Ribbed siding panels may be attached to studs or trusses and then filled with spray foam that bonds and seals everything together as well as provides the structural support.

  

                        

     

Ribbed panels                         Same panel filled

nailed to studs/trusses            with spray foam

Temporary braces may be positioned outside a stud wall for positioning siding boards which are secured by a foam cube between the stud and siding board until the spray foam blanket is applied to complete the installation.

Step 1:   The process starts by arranging forms, having a pattern form face, around the outside perimeter of a building's floor, facing inward, and about 2” outside of a partially erected 2x4 wall frame.

Step 2:  After a release agent is applied on the forms, a 1/8” thick highly durable, colored elastomeric concrete face layer is sprayed onto the forms.  A different colored face layer may be sprayed into recessed areas of the form to create window/door moulding for example.

Step 6:   The forms are removed on the following day and reveal an integrally colored and textured wall face with cast stone window moulding.

Step 3:  After at least 20 minutes, a 3/8” or thicker backing layer is applied in one or more layers to the backside of the face layer.  The backing layer is spaced about 1” or more from the wall frame.

Step 4:  Optional anchors attach cementitious layers to wall frame.  Optional reinforcement ribs greatly increases wall's flexural stiffness.

Step 5:   Two or more inches of polyurethane foam may be sprayed on the same day and by the same crew as the cementitious layers.  The foam is sprayed onto the cementitious backing layer and then  expands to partially embed the frame and thereby bonds the cementitious layers to the wall frame.   The foam provides thermal insulation and an air, vapor and moisture barriers.

Step 7:  Corners & Seams:   While forms may be designed to accentuate or hide seams in recessed wall areas, the prototype forms were designed to butt up to one another in both a straight line and at corners where a first form overruns the corner and a second form butts into the first form's face.  In both cases some face material leakage is bound to happen as seen in the below pictures.  However, since the face material has either no sand or extremely fine sand, the leakage may be ground/sanded down so that the seams disappear, assuming straight line forms are in the same plane to avoid shadows.

Special hangers and spacers may be self-adhered to  backside of off-the-shelf siding boards with only .25” laps.  Attached spacers are nailed to studs/trusses and foam sprayed on the backside 

US Patent #10,954,665

US Patent #10,954,665

US Patent #10,954,665