Rammed Earth Formwork-Facade

The present disclosure generally relates to rammed earth structures, and particularly to reinforced rammed earth walls that may be a formwork for constructing rammed earth/concrete structures as well as a facade after construction.

Rammed earth is formed by compacting a moist mixture of soil with certain ratios of sand, gravel, clay, and silt and stabilizers like lime, cement, or asphalt between two wooden plates as a formwork. Such formwork consists of two parallel plates that are locked and bracketed together spaced apart from each other at about 20 to 35 centimeters. An exemplary soil mixture is poured between these two plates and compacted up to about 50% of their height. These steps are repeated to an extent that a wall eventually reaches with a desired height. As soon as a wall is finished, its strength is to a level that the formwork can be removed from both sides of the wall. In all traditional methods, a formwork is removed after pounding each layer and is mounted again for constructing next layer.

Commonly used formworks include plywood formworks, metal formworks, large panels, plastic formworks, etc. Although formworks are made of different materials, molding mechanism and steps are similar in most of them. Typically, at first, a foundation, a wall, or a roof is reinforced using steel bars; then, formworks are established in place; and after the end of concreting, formworks are collected for use in other projects.

For example, SIREWALL Company has proposed a formwork for implementing rammed earth constructs in their US patent numbered as U.S. Pat. No. 8,375,669B2. The same formwork used for implementing concrete constructs is currently applied to implement rammed earth constructs. However, SIREWALL's invention focused on metal formwork that can be assembled. An exemplary metal formwork is mounted on walls and removed at the end of the work. There are also numerous other inventions related to building formworks for facades, but they are mostly formworks that can be assembled; hence, they are not envisioned as permanent formworks.

Establishment and then removing the formworks entail spending a lot of time and money. After several times of use, these formworks are no longer usable; hence, they should be discarded or recycled, which itself necessitates the spending of a lot of energy. On the other hand, after holding a formworks up, final exterior view would be a concrete facade, and there is a need for further facade-working in most cases because a concrete facade looks cold and dry. Meanwhile, concrete walls are known for high thermal exchange and ready transferring of the cold and the heat, which causes a lot of energy losses in buildings. Making of a facade on walls and concrete columns, as well, has its specific problems because installation of a facade on smooth and tough surface of concrete is not easy. There is also problem of facade's separation from underlying concrete surface in many cases, which jeopardizes safety of residents and passersby. In addition, construction operation of concrete and/or rammed earth structures using traditional formworks turns a construction site into a place with a mass of tools and equipment. Then, the site's management and safety would always be considered a serious challenge. Another challenge of using common formworks is requirement of establishing a facade which is usually made of stone, concrete, brick, etc. that are non-recyclable and very polluting regarding environmental points of view. This causes irreparable damage to the environment.

Hence, there is a need for a permanent formwork in construction of rammed earth structures and/or concrete buildings that is not required to remove after construction. Also, there is a need for a permanent formwork compatible with environment while having a desirable exterior view as well as being non-expensive. In addition, there is a need for a formwork with a low thermal exchange with surrounding to avoid energy loss. Furthermore, formworks with higher safety are essentially needed.

This summary is intended to provide an overview of the subject matter of this patent, and is not intended to identify essential elements or key elements of the subject matter, nor is it intended to be used to determine the scope of the claimed implementations. The proper scope of this patent may be ascertained from the claims set forth below in view of the detailed description below and the drawings.

In one general aspect, the present disclosure is directed to a permanent rammed earth formwork-facade for a rammed earth and/or a concrete structure. In an exemplary embodiment, the permanent rammed earth formwork-facade may include 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, a plurality of galleys, and a plurality of Ω-shaped fasteners.

In an exemplary embodiment, each respective side panel of the two side panels may include a double-layered rammed earth wall, a mesh network placed inside the double-layered rammed earth wall, a strand of barbed wire perpendicularly woven into the mesh network, a first plurality of rebars fastened to the mesh network, and a plurality of L-shaped anchor bolts.

In an exemplary embodiment, the double-layered rammed earth wall may include two layers of rammed earth compacted to each other. In an exemplary embodiment, the double-layered rammed earth wall may have an interior surface and an exterior surface each with a rectangular shape having a length and a width. In an exemplary embodiment, the mesh network may be 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. In an exemplary embodiment, the rammed earth and/or the concrete structure may be received within a hollow space between the interior surfaces of the two side panels. In an exemplary embodiment, the strand of barbed wire may include a plurality of sharped edges inserted into the two layers of rammed earth. In an exemplary embodiment, the strand of barbed wire may be perpendicularly woven into the mesh network and tighten the mesh network to the two layers of rammed earth. In an exemplary embodiment, the first plurality of rebars may be fastened to the mesh network. In an exemplary embodiment, the first plurality of rebars may extend 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. In an exemplary embodiment, each respective L-shaped anchor bolt of the plurality of L-shaped anchor bolts may include a long end and a short end. In an exemplary embodiment, the long end of each respective L-shaped anchor bolt may be 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. In an exemplary embodiment, the short end of each respective L-shaped anchor bolt may have a thread placed along a thickness of the double-layered rammed earth wall perpendicular to the interior surface and the exterior surface. In an exemplary embodiment, the thread may protrude from the interior surface.

In an exemplary embodiment, each galley of the plurality of galleys may extend transversally between the two side panels and interlock the two side panels to each other.

In an exemplary embodiment, each Ω-shaped fastener of the plurality of Ω-shaped fasteners may include a base, two hooks, and two lateral walls. In an exemplary embodiment, the base may include a central hole. In an exemplary embodiment, the Ω-shaped fastener may be screwed to a side panel of the two side panels via a thread of a respective L-shaped anchor bolt that may pass through the central hole. In an exemplary embodiment, the Ω-shaped fastener may be fastened to the respective side panel using a nut. In an exemplary embodiment, the two hooks may protrude from the interior surface of the respective side panel. In an exemplary embodiment, the two hooks may be secured into the rammed earth and/or the concrete structure. In an exemplary embodiment, each hook may include a groove that may receive a galley of the plurality of galleys therein; allowing for interconnecting the two opposite side panels to each other. In an exemplary embodiment, the two lateral walls may extend from two respective opposite end edges of the base to the two respective hooks.

In an exemplary embodiment, a thickness of each side panel of the two side panels may be in a range of about 3 cm to about 10 cm. In an exemplary embodiment, the exterior surface may include a smooth anti-scratch waterproof surface.

In an exemplary embodiment, the mesh network may include a wire grid panel made of at least one of a metal, a metal alloy, a geosynthetic material, and combinations thereof. In an exemplary embodiment, the wire grid panel may include a plurality of square-shaped openings. In an exemplary embodiment, each square-shaped opening of the plurality of square-shaped openings may include a side length in a range of about 1 cm to about 3 cm.

In an exemplary embodiment, the first plurality of rebars may be arranged parallel to each other with a distance between each two adjacent rebars being in a range of about 10 cm to about 30 cm. In an exemplary embodiment, each rebar of the first plurality of rebars may include a rebar with a diameter in a range of about 8 mm to about 20 mm. In an exemplary embodiment, the first plurality of rebars may be welded to the mesh network. In an exemplary embodiment, each side panel may further include a plurality of twisted wires fastening the first plurality of rebars to the mesh network.

In an exemplary embodiment, each rebar of the first plurality of rebars may be 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. In an exemplary embodiment, at least two elements of a set of elements, including 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 may be fastened together via a twisted wire of the plurality of twisted wires. In an exemplary embodiment, the strand of barbed wire may interlock at least two elements of a set of elements, including 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. In an exemplary embodiment, each sharp edge of the plurality of sharped edges of the strand of barbed wire may have a length in a range of about 0.5 cm to about 1 cm.

In an exemplary embodiment, a length of each galley of the plurality of galleys extended between two side panels may be 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 corresponding groove of a respective Ω-shaped fastener of the plurality of Ω-shaped fasteners.

In an exemplary embodiment, each side panel of the two side panels may further include an insulator layer with a thickness in a range of about 2 mm to about 10 cm coated on the interior surface of the double-layered rammed earth wall. In an exemplary embodiment, the insulator layer may include 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. In an exemplary embodiment, the insulator layer may include 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. In an exemplary embodiment, the insulator layer may be firmly fastened to the interior surface of the corresponding 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.

In an exemplary embodiment, at least two permanent rammed earth formwork-facades are abutted side by side forming a pair of permanent rammed earth formwork-facade walls. In an exemplary embodiment, each permanent rammed earth formwork-facade wall may have dimensions larger than the length and the width of the double-layered rammed earth wall.

In an exemplary embodiment, each lateral wall of the two lateral walls of each Ω-shaped fastener may include an opening. In an exemplary embodiment, a connecting rod of a first plurality of connecting rods interconnecting two respective adjacent side panels of the two permanent rammed earth formwork-facades may be passed through the opening. In an exemplary embodiment, a connecting rod of a second plurality of connecting rods interconnecting two respective adjacent side panels of the two permanent rammed earth formwork-facades may be 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.

In an exemplary embodiment, the permanent rammed earth formwork-facade may further include a plurality of transversal connectors transversally interconnecting the two side panels to each other. In an exemplary embodiment, each transversal connector of the plurality of transversal connectors may include 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. In an exemplary embodiment, the plurality of transversal connectors may include 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. In an exemplary embodiment, the first end and the second end of each transversal connector may pass through respective holes extended through a thickness of the two side panels at two respective opposite locations of the two side panels. In an exemplary embodiment, each transversal connector may be fastened to each side panel of the two side panels at the corresponding hole using a soldier pile and a wing nut. In an exemplary embodiment, the soldier pile may be placed onto the exterior surface. In an exemplary embodiment, a normal distance between each two adjacent transversal connectors of the plurality of transversal connectors may be in a range of 20 cm to 100 cm.

In the following detailed description, numerous specific details are set forth by way of examples in order to provide a thorough understanding of the relevant teachings. However, it should be apparent that the present teachings may be practiced without such details. In other instances, well known methods, procedures, components, and/or circuitry have been described at a relatively high-level, without detail, in order to avoid unnecessarily obscuring aspects of the present teachings.

Herein, a reinforced rammed earth formwork for construction of rammed earth and/or concrete walls or structures is disclosed. In an exemplary embodiment, an exemplary reinforced rammed earth formwork may be a permanent formwork that may remain in a construction site after construction a rammed earth and/or concrete wall or structure there inside, so that an exemplary reinforced rammed earth formwork may also have a role of facade for an exemplary constructed rammed earth and/or concrete wall or structure. In an exemplary embodiment, an exemplary reinforced rammed earth formwork may be used as a prefabricated facade for a building. In an exemplary embodiment, an exemplary reinforced rammed earth formwork may be used as a pre-fabricated facade for an old building whose facade have been destroyed.

show a schematic top viewand a perspective viewof a permanent rammed earth formwork-facade, respectively, consistent with one or more exemplary embodiments of the present disclosure. In an exemplary embodiment, permanent rammed earth formwork-facademay include two side panelsandarranged in parallel with each other. In an exemplary embodiment, two side panelsandmay be placed opposite to each other and firmly engaged to each other. In an exemplary embodiment, a rammed earth and/or a concrete structure may be received within a hollow spacebetween two side panelsand. In an exemplary embodiment, a normal distancebetween two side panelsandmay be adjusted equal to an intended thickness of an exemplary rammed earth and/or an exemplary concrete structure to be formed between two side panelsand. In an exemplary embodiment, two side panelsandmay have the same structure.

shows an exploded schematic viewof a side panel, consistent with one or more exemplary embodiments of the present disclosure. In an exemplary embodiment, side panelmay be similar to each of side panelsandofdescribed herein above. In an exemplary embodiment, side panelmay include a double-layered rammed earth wall, a mesh network, a strand of barbed wirewoven into mesh network, and a first plurality of rebars. In an exemplary embodiment, double-layered rammed earth wallmay include two layersandof rammed earth compacted to each other. In an exemplary embodiment, double-layered rammed earth wallmay have an interior surfaceand an exterior surface. In an exemplary embodiment, side panel, double-layered rammed earth wall, mesh network, interior surface, and exterior surfacemay have a rectangular shape with a lengthand a width.

shows a magnified exploded schematic viewof a side panel, consistent with one or more exemplary embodiments of the present disclosure. In an exemplary embodiment, mesh networkmay include a wire grid panel embedded inside side panelparallel with interior surfaceand exterior surface. In an exemplary embodiment, mesh networkmay be made of at least one of a metal, a metal alloy, a geosynthetic material, and combinations thereof. In an exemplary embodiment, mesh networkmay include a geogrid. In an exemplary embodiment, mesh networkmay include a plurality of openings. In an exemplary embodiment, each openingmay have a square-shaped openings with a dimension in a range of 1 cm to 3 cm by 1 cm to 3 cm. In an exemplary embodiment, mesh networkmay be placed in the middle of double-layered rammed earth wallbetween two layersandof rammed earth parallel with both interior surfaceand exterior surface. In an exemplary embodiment, mesh networkmay include a first plurality of parallel wires extending along lengthand a second plurality of parallel wires extending along widthwoven together. In an exemplary embodiment, mesh networkmay internally reinforce double-layered rammed earth wall.

shows a schematic side viewof side panelillustrating connections between mesh networkand double-layered rammed earth wall, consistent with one or more exemplary embodiments of the present disclosure. Referring toin addition to, strand of barbed wiremay be perpendicularly woven into mesh network; allowing for tightening and firmly connecting mesh networkto two layersandof rammed earth on both sides of mesh network. In an exemplary embodiment, strand of barbed wiremay provide further internally reinforcement to double-layered rammed earth wall. In an exemplary embodiment, strand of barbed wirefacing upward and downward may allow for firmly interaction between mesh networkand two layersandof rammed earth. In an exemplary embodiment, mesh networkmay be easily separated from two layersandof rammed earth in the absence of strand of barbed wire. In an exemplary embodiment, strand of barbed wiremay include a plurality of sharped edges inserted into two layersandof rammed earth and tightening mesh networkto two layersandof rammed earth. In an exemplary embodiment, each sharp edge of an exemplary plurality of sharped edges of strand of barbed wiremay have a length in a range of about 0.5 cm to about 1 cm. In an exemplary embodiment, strand of barbed wiremay interlock at least two of an exemplary rebar of first plurality of rebars, mesh network, an exemplary L-shaped anchor bolt of plurality of L-shaped connections, layerand/orof double-layered rammed earth wall, and combinations thereof together.

Referring again to, first plurality of rebarsmay be fastened to mesh networkalong at least one of lengthof interior surfaceand exterior surface, widthof interior surfaceand exterior surface, and combinations thereof. In an exemplary embodiment, first plurality of rebarsmay be arranged parallel with each other and placed in plane of mesh network. In an exemplary embodiment, each two adjacent rebars of first plurality of rebarsmay be spaced from each other by a distance in a range of 10 cm to 30 cm. In an exemplary embodiment, a distance between each two adjacent rebars of first plurality of rebarsmay be about 20 cm. In an exemplary embodiment, each respective rebar of first plurality of rebarsmay have a diameter in a range of 8 mm to 20 mm. In an exemplary embodiment, each respective rebar of first plurality of rebarsmay have a diameter of about 8 mm. In an exemplary embodiment, first plurality of rebarsmay be secured to mesh networkthrough welding and/or twisted wire. In an exemplary embodiment, first plurality of rebarsmay provide further internally reinforcement to double-layered rammed earth wallwhile constructing an exemplary rammed earth and/or an exemplary concrete structure being formed between two side panelsandof exemplary permanent rammed earth formwork-facadeand/or after construction of an exemplary rammed earth and/or an exemplary concrete structure inside exemplary permanent rammed earth formwork-facade.

In an exemplary embodiment, side panelmay further include a plurality of L-shaped connectionsillustrated in.shows a schematic side viewof side panelillustrating a plurality of L-shaped connections, consistent with one or more exemplary embodiments of the present disclosure. Furthermore,shows a magnified schematic side viewof side panelillustrating L-shaped connectionand attachment to side panelthereof, consistent with one or more exemplary embodiments of the present disclosure. In an exemplary embodiment, each L-shaped connectionmay include an L-shaped fastener. In an exemplary embodiment, each L-shaped connectionmay include an L-shaped anchor bolt. In an exemplary embodiment, exemplary L-shaped connectionmay include a long endand a short end. In an exemplary embodiment, long endmay be fastened to mesh networkand at least one rebar of first plurality of rebarsby at least one of welding long endto mesh network, welding long endto at least one rebar of first plurality of rebars, fastening long endto mesh networkusing a twisted wire and/or strand of barbed wire, fastening long endto at least one rebar of first plurality of rebarsusing a twisted wire and/or strand of barbed wire, and combinations thereof. In an exemplary embodiment, long endmay be arranged along at least one of lengthof interior surfaceand exterior surface, widthof interior surfaceand exterior surface, and combinations thereof. In an exemplary embodiment, short endmay have a threadplaced along a thicknessof double-layered rammed earth walland perpendicular to interior surfaceand/or exterior surface. In an exemplary embodiment, threadmay protrude from interior surface. In an exemplary embodiment, a thicknessof double-layered rammed earth wallmay be determined depending on climate conditions and structural calculations. In an exemplary embodiment, double-layered rammed earth wallmay have exemplary thicknessin a range of about 3 cm to about 10 cm.

Referring to, side panelmay further include an insulator layercoated on interior surfaceof double-layered rammed earth wall. In an exemplary embodiment, insulator layermay include 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. In an exemplary embodiment, insulator layermay include 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 thermal-insulating polymer, a moisture-proof polymer, polyisocyanurate (Polyiso), phenolic foam, and combinations thereof. In an exemplary embodiment, insulator layermay be used for reducing energy loss due to heat exchange between an exemplary rammed earth and/or an exemplary concrete structure and surrounding environment. Moreover, insulator layermay allow for prevention of structural damage to side panel, or an exemplary rammed earth, or an exemplary concrete structure, or combinations thereof due to water absorbance by soil and/or concrete. In an exemplary embodiment, insulator layermay be a protecting layer for side panelwhile moving and installing permanent rammed earth formwork-facade, so that insulator layermay act as a shock absorber and prevent damage to permanent rammed earth formwork-facade.

In an exemplary embodiment, insulator layermay have a length and width, respectively equal to lengthand widthof side panel. In an exemplary embodiment, a thickness of insulator layermay be determined depending on climate conditions and structural calculations. In an exemplary embodiment, a thickness of insulator layermay be adjusted depending on a rate of heat exchange between an exemplary rammed earth and/or an exemplary concrete structure and surrounding environment. In an exemplary embodiment, a thickness of insulator layermay be adjusted regarding climate situation of a place where an exemplary rammed earth and/or an exemplary concrete structure may be formed or delivered thereto. In an exemplary embodiment, insulator layermay have a thickness in a range of about 2 mm to about 10 cm.

In an exemplary embodiment, openingsof mesh network(illustrated in) may be used for passing facility ducts there through. In an exemplary embodiment, facilities ducts may pass through openingsof mesh networkand brought to exterior surface.shows a schematic side viewof transferring electrical wiresthrough an opening(similar to openings) of mesh network, consistent with one or more exemplary embodiments of the present disclosure. In an exemplary embodiment, electricity may transfer through side panelby inserting electrical wiresin a tubepassing through openingso that a power outlet or a light may be put on exterior surface.

In an exemplary embodiment, each exemplary side paneland/orof permanent rammed earth formwork-facade, illustrated in, may be internally reinforced using mesh networkin combination with strand of barbed wirewoven into mesh networkand first plurality of rebarsas described in connection withillustrating structure of side panelas an example of each of side panelsand. In an exemplary embodiment, two side panelsandmay be firmly interconnected to each other and to an exemplary rammed earth and/or an exemplary concrete structure formed between two side panelsandusing a plurality of fastening elements. As may be seen in, an exemplary plurality of fastening elements may include a plurality of Ω-shaped fastenersin combination with a plurality of L-shaped connections(similar to plurality of L-shaped connections) and a plurality of galleys. In an exemplary embodiment, plurality of plurality of Ω-shaped fastenersmay include a plurality of brackets. In an exemplary embodiment, plurality of Ω-shaped fastenersmay include at least one of a plurality of mounting Ω-shaped brackets, a plurality of mounting u-shaped brackets, and combinations thereof. In an exemplary embodiment, each galleymay extend and fixed transversally between two side panelsandand interlock two side panelsandto each other.

Referring to, an exemplary plurality of fastening elements may further include a plurality of transversal connectorsorIn an exemplary embodiment, plurality of transversal connectorsormay include 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 transversally interconnecting two side panelsandto each other. In an exemplary embodiment, an exemplary plurality of support beams may include a plurality of square profiles. In an exemplary embodiment, an exemplary plurality of support beams may include a plurality of profiles or beams with a square-shaped cross section. In an exemplary embodiment, plurality of transversal connectorsormay pass through side panelsandvia respective holes (not illustrated) embedded in side panelsand; thereby, interconnecting side panelsandto each other. In an exemplary embodiment, a normal distancebetween each two adjacent transversal connectorsandmay be in a range of about 20 cm to about 100 cm. In an exemplary embodiment, a normal distancebetween each two adjacent transversal connectorsandmay be about 50 cm.

In an exemplary embodiment, plurality of transversal connectorsandmay be attached and fastened to side panelsandusing respective soldier pilesandwith the assistance of a respective plurality of wing nuts. In an exemplary embodiment, plurality of wing nutsmay include at least one of a plurality of washer based wing nuts, a plurality of square plate wing nuts, and combinations thereof. In an exemplary embodiment, plurality of transversal connectorsandmay be firmly fastened or screwed to side panelsandto avoid a movement due to a side pressure of concreting or ramming process while forming an exemplary rammed earth and/or an exemplary concrete structure inside permanent rammed earth formwork-facade. In an exemplary embodiment, protruding parts of plurality of transversal connectorsandfrom an exterior surface of permanent rammed earth formwork-facademay be cut or removed and a remaining part may remain inside permanent rammed earth formwork-facadeand an exemplary rammed earth and/or an exemplary concrete structure. In an exemplary embodiment, soldier pilesandmay be removed from permanent rammed earth formwork-facadeafter forming an exemplary rammed earth and/or an exemplary concrete structure. In an exemplary embodiment, plurality of transversal connectorsandmay be removed from permanent rammed earth formwork-facadeand/or an exemplary rammed earth and/or an exemplary concrete structure constructed inside permanent rammed earth formwork-facadeafter construction of an exemplary rammed earth and/or an exemplary concrete structure.

Furthermore with more reference to, permanent rammed earth formwork-facademay further include a plurality of abutment beamsplaced between soldier pileand side paneland/or soldier pileand side panel. In an exemplary embodiment, plurality of abutment beamsmay allow for curbing a lateral pressure of a process of concreting and/or ramming earth for forming an exemplary rammed earth and/or an exemplary concrete structure inside permanent rammed earth formwork-facade. In an exemplary embodiment, plurality of abutment beamsmay be removed from permanent rammed earth formwork-facadeafter forming an exemplary rammed earth and/or an exemplary concrete structure.

Referring to, side panelmay include Ω-shaped fastenersimilar to Ω-shaped fastenerof. In an exemplary embodiment, Ω-shaped fastenermay include a basetwo lateral wallsand two hooksas illustrated in. In an exemplary embodiment, two hooksmay be arranged parallel with each of double-layered rammed earth wall, mesh network, and/or insulator layer. In an exemplary embodiment, each of distancesand, respectively, between two hooksand interior surfaceor a surfaceof insulator layermay be adjusted in a range of about 5 cm to about 10 cm so that two hooksmay sink into an exemplary rammed earth and/or an exemplary concrete structure; allowing for securing side panelan exemplary rammed earth and/or an exemplary concrete structure inside permanent rammed earth formwork-facade. Therefore, two side panelsandmay not separate from an exemplary rammed earth and/or an exemplary concrete structure there between. In an exemplary embodiment, distancesandmay provide an amount of concrete or soil to be placed between two side panelsand; thereby, resulting in preventing separation of formwork-facadefrom an exemplary rammed earth and/or an exemplary concrete structure constructed there inside.

shows a schematic viewof a Ω-shaped bracketfastened to an L-shaped connection, consistent with one or more exemplary embodiments of the present disclosure. In an exemplary embodiment, Ω-shaped bracketmay be an exemplar of Ω-shaped fastenerofor Ω-shaped fastenerof. In an exemplary embodiment, L-shaped connectionmay be similar to L-shaped connectionof. So a structure of Ω-shaped bracketand L-shaped connection, and an attachment thereof may be described in connection withandin the following. In an exemplary embodiment, Ω-shaped bracketmay be arranged on interior surfaceor surfaceof insulator layeras shown in. In an exemplary embodiment, Ω-shaped bracketmay include a base, two lateral walls, and two hooks, respectively similar to basetwo lateral wallsand two hooksof. In an exemplary embodiment, basemay include a central hole. In an exemplary embodiment, a short endof L-shaped connectionmay pass through central holeand a threadof L-shaped connectionmay be screwed to Ω-shaped bracketusing a nut. Therefore, a tight attachment and internally reinforcement among layers of layered structure of side panel, including double-layered rammed earth wall, mesh network, barbed wire, and insulator layermay be provided. In an exemplary embodiment, insulator layermay be firmly fastened to interior surfaceof side panelby at least one of protruding respective threadsof plurality of L-shaped connectionsfrom insulator layer, screwing respective protruded threadsof plurality of L-shaped connectionsvia respective plurality of Ω-shaped fasteners, and combinations thereof.

shows a schematic viewof Ω-shaped bracketreceiving one or two galleys, consistent with one or more exemplary embodiments of the present disclosure. In an exemplary embodiment, each hookmay protrude from interior surfaceof side panelor surfaceof insulator layer. In an exemplary embodiment, each hookmay include a groovethat may receive exemplary galley. In an exemplary embodiment, galleymay be an exemplary galley of plurality of galleystransversally interconnecting two side panelsand. In an exemplary embodiment, a first endof galleymay be inserted into grooveof Ω-shaped bracketand a second endof galleymay be inserted into a corresponding groove of a corresponding Ω-shaped fastener of plurality of Ω-shaped fastenersscrewed to an exemplary opposite side panel of two side panelsand. In an exemplary embodiment, first endof galleymay be firmly fastened to hookusing a pair of a bolt and a gasket at both sidesandof hook; allowing for prevention of any movements of galley. In an exemplary embodiment, first endof galleymay be firmly fastened to sideof hookusing a boltand a gasketand an exemplary boltand gasket(illustrated in) similar to boltand gasketmay be used to fasten first endof galleyto sideof hook. In an exemplary embodiment, second endof galleymay be fastened to an exemplary corresponding hook of an exemplary Ω-shaped fastener of plurality of Ω-shaped fastenersscrewed to an exemplary opposite side panel of two side panelsandusing boltin combination with a gasket (not illustrated) similar to gasket.shows a schematic exploded viewof Ω-shaped bracketreceiving one or two galleys, consistent with one or more exemplary embodiments of the present disclosure. In an exemplary embodiment, a functional length of galley, that may include a length portion of galleyextended between two corresponding hooks (similar to hook) of two respective Ω-shaped brackets (similar to hook) fastened respectively onto side panelsandopposite to each other, may be determined equal to a thickness of an exemplary rammed earth and/or an exemplary concrete structure (or normal distancebetween two side panelsandlength). In an exemplary embodiment, after determining an exemplary functional length of galley, galleymay be fastened to each hookof exemplary corresponding hooks using exemplary pair of boltsandand gasketsandso that a length portion of galleybetween two exemplary boltsandmay be adjusted equal to an exemplary functional length.

In an exemplary embodiment, a length of galleymay be adjustable by loosening and/or tightening pair of boltand gasketto reach a length of galleybetween two side panelsandbeing equal to an intended thickness of an exemplary rammed earth and/or an exemplary concrete structure. In an exemplary embodiment, a length of galleymay be adjusted to be equal to an exemplary intended thickness of an exemplary rammed earth and/or an exemplary concrete structure that may be constructed inside permanent rammed earth formwork-facade. In an exemplary embodiment, an exemplary adjustable length of galleymay be an important feature for construction operations, since it may be necessary to increase or decrease a normal distancebetween two side panelsandat the time of execution.

In an exemplary embodiment, exterior surfacemay be a facade for an exemplary rammed earth and/or an exemplary concrete structure that may be constructed inside permanent rammed earth formwork-facade. In an exemplary embodiment, exterior surfacemay include at least one of a smooth surface, an anti-scratch surface, a waterproof surface, and combinations thereof. In an exemplary embodiment, exterior surfacemay be treated to become smooth, anti-scratch, and/or waterproof. In an exemplary embodiment, exterior surfacemay be a cost-effective and environmental friendly facade with a natural color spectrum since exterior surfacemay be made of soil (e.g., local soil of a construction site). In an exemplary embodiment, exterior surfacemay be used for interior decoration.

In an exemplary embodiment, lengthand widthof side panel(illustrated in) may have pre-determined magnitudes. Therefore, a permanent formwork-facade with an intended length and width larger than lengthand widthof side panelmay be formed by assembling/attaching a set of permanent rammed earth formwork-facadenext to each other. In an exemplary embodiment, each of lengthand widthmay be in a range of about 0.5 m to about 3 m; thereby, forming permanent rammed earth formwork-facadewith a 0.5-3 m×0.5-3 m rectangular shape.

shows a schematic viewof a permanent formwork-facadewith intended dimensions, consistent with one or more exemplary embodiments of the present disclosure. In an exemplary embodiment, permanent formwork-facademay include two formwork-facade wallsand. In an exemplary embodiment, permanent formwork-facademay include a plurality of formwork-facades consisting of pairs of side panelsand(similar to side panelsandof). In an exemplary embodiment, each formwork-facade wallormay include a respective plurality of side panelsorabutted side by side. In an exemplary embodiment, an exemplary plurality of adjacent side panelsand/orof each respective formwork-facade wallsand/ormay be abutted side by side using a first plurality of connecting rodsand a second plurality of connecting rodsin combination with a plurality of Ω-shaped fasteners. In an exemplary embodiment, plurality of Ω-shaped fastenersmay be similar to Ω-shaped fastenersof. In an exemplary embodiment, plurality of Ω-shaped fastenersmay include a plurality of Ω-shaped brackets similar to Ω-shaped bracketof.

shows a schematic interior viewof formwork-facade wall(or) formed by side by side attachment of two or more side panelsorof permanent rammed earth formwork-facade, consistent with one or more exemplary embodiments of the present disclosure. Referring to, Ω-shaped bracketmay include two lateral wallsextending from two respective opposite end edges of baseto two respective hooks. In an exemplary embodiment, each respective lateral wallmay include an openingthat may receive at least one of a connecting rod, a rebar, a support beam, and combinations thereof. In an exemplary embodiment, first plurality of connecting rodsmay be inserted into openingpassing there through. In an exemplary embodiment, first plurality of connecting rodsmay interconnect two adjacent side panelsof formwork-facade wall(or) via passing through openingsof plurality of Ω-shaped fasteners.

Referring to, second plurality of connecting rodsmay interconnect two adjacent side panelsvia passing second plurality of connecting rodsthrough a hollow space on a base of each Ω-shaped fastener(similar to baseof Ω-shaped bracket). In an exemplary embodiment, an exemplary hollow space on basemay be defined by two lateral wallsextended out of exemplary two opposite edges of base. In an exemplary embodiment, a plurality of transversally connecting elementsbetween formwork-facade wallsandmay be seen in, which may be similar to transversal connectionsand/orIn an exemplary embodiment, first plurality of connecting rodsand/or second plurality of connecting rodsmay form a strengthening network in combination with each other. In an exemplary embodiment, an exemplary network may strengthen formwork-facade wallsandas well as side panels; thereby, resulting in protecting a building including formwork-facade wallsandagainst a lateral pressure that may be applied from outside to an exemplary building. In an exemplary embodiment, an exemplary network may provide formwork-facade wallsandto withstand various pressures.

In more details,shows a schematic viewof passing a plurality of rebarsas an exemplar of first plurality of connecting rodsthrough openingsof lateral walls(similar to lateral walls) of a plurality of Ω-shaped fasteners(similar to Ω-shaped fasteners), consistent with one or more exemplary embodiments of the present disclosure. Furthermore,shows a schematic viewof passing a plurality of square cross-sectioned profilesas another exemplar of first plurality of connecting rodsthrough openingsof lateral walls(similar to lateral walls) of plurality of Ω-shaped fasteners(similar to Ω-shaped fasteners), consistent with one or more exemplary embodiments of the present disclosure. In an exemplary embodiment, each two square cross-sectioned profilesmay be attached together using a screw fastener.

In another general aspect of the present disclosure, an exemplary method for constructing a permanent rammed earth formwork-facade is described.shows an exemplary flow diagram of exemplary methodfor constructing a permanent rammed earth formwork-facade, consistent with one or more exemplary embodiments of the present disclosure. In an exemplary embodiment, methodmay include constructing two side panels (step), processing an interior and an exterior surface of each side panel (step), placing an insulator layer on an exemplary interior surface of each side panel (step), and interconnecting the two side panels to each other (step). In an exemplary embodiment, an exemplary permanent rammed earth formwork-facade may be similar to permanent rammed earth formwork-facadedescribed herein above, so exemplary methodmay be described in connection within the following.

In further detail with respect to step, stepmay include constructing two exemplary side panels similar to two side panelsand. In an exemplary embodiment, each side panel(or) may be constructed using a ramming technique and reinforcing thereof.shows an exemplary flow diagram of exemplary methodfor constructing an exemplary side panel similar to each of side panelsand(step), consistent with one or more exemplary embodiments of the present disclosure. In an exemplary embodiment, methodmay include constructing a bottom rammed earth layer (step), reinforcing an exemplary side panel by placing a mesh network in combination with a strand of barbed wire onto an exemplary bottom rammed earth layer (step), further reinforcing an exemplary side panel by placing and fastening a first plurality of rebars onto an exemplary mesh network (step), fastening a plurality of L-shaped connections to an exemplary mesh network and an exemplary first plurality of rebars (step), and constructing a top rammed earth layer (step).

In further detail with respect to step, stepmay include constructing an exemplary bottom rammed earth layer. In an exemplary embodiment, an exemplary bottom rammed earth layer may be similar to layerof rammed earth. In an exemplary embodiment, layerof rammed earth may be constructed by ramming a first layer of soil inside a ramming formwork using a pneumatic hammer and planar compactors. In an exemplary embodiment, ramming an exemplary first layer of soil inside an exemplary ramming formwork may be done by ramming a soil mixture of granulated masonry including an amount of in a range of about 30% wt. to about 40% wt. In an exemplary embodiment, an exemplary soil mixture may be poured into an exemplary ramming formwork and homogeneously compacted in the entire thickness of an exemplary first layer of soil so that fine and coarse grains may be distributed congruently in all parts of an exemplary first layer of soil. In an exemplary embodiment, an exemplary thickness of an exemplary first layer of soil after ramming and compacting may be equal to a pre-determined thickness of layer, which may be half of thicknessof double-layered rammed earth wall.

In an exemplary embodiment, ramming an exemplary first layer of soil may further include remaining an exemplary first layer of soil inside an exemplary ramming formwork for about 1 to about 10 days; thereby, resulting in gradually losing moisture of ramming an exemplary first layer of soil. In an exemplary embodiment, after about 1 day to about 10 days, ramming an exemplary first layer of soil may be removed from inside an exemplary ramming formwork and may be left at ambient temperature in a range of about 20° C. to about 30° C.