22, 24 (where multiple guides or tracks 20 are used) can have any spacing with respect for each other that allows them to operate together or independently of each other, in some cases, two or more of the guides are spaced at intervals on the track 20. In some cases, the intervals are regular, while in some cases they are irregular. In some cases, the intervals have a distance less than a width (or a height or any other dimension) of the screed tool (although in some cases, the intervals are approximately equal to or greater than the width or another dimension of the screed tool. Some embodiments of the guides are spaced approximately between 1 cm and 6 m apart, or any subrange thereof. For example, some embodiments of the guides are spaced about 1 m apart, 2 m apart, 3 m apart, or any other suitable distance between about 1 cm and 6 m apart (or, in some cases, even greater than 6 m apart). By way of non-limiting illustration, FIG. 5 shows a track 20 with a first guide 22 and a second guide 24 spaced apart from each other, parallel to each other, and set a uniform distance away from a surface 44, such that a screed tool can travel along the guides to screed a surfacing material 60 to a uniform thickness.

Although the guide 22, 24 can be any length, in some cases the guide has a length (or height) between approximately 1 cm and approximately 100 m, or any subrange thereof. For example, in some cases, the guide is between 0.5 m and 10 m long (e.g., between 1 m and 4 m). In some cases, the guide is approximately the same size as (or shorter than or longer than) the height or length of the surface. Similarly, although the guide can be any suitable size, in some cases, the guide has a diameter (or width) of between approximately 1 mm and approximately 50 cm, or any subrange thereof. For example, in some cases, the guide has a diameter (or width) of between 0.2 cm and 1 cm. In some cases, the guide has a diameter of approximately the same size as a diameter of a wire of a mesh 46 (as described in greater detail below) but in some cases, the guide is thicker or thinner than the wires in the mesh 46. In some cases where multiple guides are used, the guides have the same length or size, but in some cases, the guides have different lengths or sizes.

The guides 22, 24 can also have any suitable orientation (with respect to each other, with respect to the surface 44 to be screeded, or otherwise). For example, any particular guide can be disposed vertically, horizontally, diagonally, or can otherwise be disposed at any other orientation. By way of non-limiting illustration, FIG. 5 shows a track 20 with guides 22, 24 that are substantially vertical.

Although the guide 22 can be made of any suitable material (e.g., wood, metal, glass, plastic, carbon fiber, polymer material, cardboard, paper, nylon, fabric, netting, ceramic, fiberglass, or any other material), in some cases, the guide is made of or otherwise comprises metal (e.g., steel or another metal or metal alloy). By way of non-limiting illustration, FIGS. 6A-10C show various guides 20 that are substantially in the form of wires formed as part of a wire mesh. In some embodiments, the guide comprises a material that is configured not to rust.

In some embodiments, at least part of the guide 22 is configured to become embedded or incorporated in the surfacing material. For example, some embodiments of the guide include an inner portion 26 (e.g., a portion of the guide facing toward the surface 44) and an outer portion 28 (e.g., a portion of the guide facing away from the surface). In some embodiments, during the application of the surfacing material, the guide becomes buried in the surfacing material. In some embodiments, during the screeding process, the screed tool is pressed against the outer portion of the guide (e.g., through the surfacing material) and moved along the guide, thus scraping away excess surfacing material that is farther away from the surface than the outer portion, thereby providing a smooth and uniform surface to the surfacing material. In some embodiments, this leaves the outer portion (or a tangent) of the guide minimally or partially exposed. Indeed, in some embodiments, if any portion of the guide is exposed, the exposed outer portion is minimal. By way of non-limiting illustration, if the guide includes a wire, a rod, rail, or another generally cylindrical or linear component, some embodiments allow for screeding that exposes only a point (if any) of the guide that is tangential to the circumference (e.g., so that only a thin sliver of the guide is exposed, and the rest is embedded in the surfacing material). In some embodiments, the exposed portion is not noticeable, is covered as the surfacing material cures or hardens, or it is covered with a secondary surfacing material. In some embodiments, the screeding process does not uncover even the outer portion of the guide, such that at least a thin layer of the surfacing material covers the entire guide upon completion of the screeding.

While the guide 22 can be coupled to the surface 44 in any suitable manner, some embodiments of the track 20 include one or more couplers 30 configured to couple the guide to the surface. The coupler can couple the guide to the surface in any suitable manner, such as through bonding, welding, interference or friction fits, being embedded within another component, adherence, fasteners, catches, clamps, clips, being integrally formed with, or through the use of any other suitable coupling mechanism. Some implementations of the coupler include one or more bases 34 (e.g., for interfacing with the surface), one or more connectors 32 (e.g., for coupling the guide to the base), or any other components useful for coupling the guide to the surface. By way of non-limiting illustration, FIGS. 1-4 and 6A-10 show some embodiments of tracks 20 having couplers 30 that include one or more connectors 32 configured to connect guides 22 to bases 34. Additionally, FIG. 5 shows a track 20 with a first guide 22 and a second guide 24, with the guides being coupled to couplers 30 that include connectors 32 configured to couple the track directly to the surface 44 to be screeded.

As touched on above, and although some implementations lack a base, some other implementations of the coupler 30 include one or more bases 34. The base can include any component configured to interface with the surface 44 in any manner, such as by abutting, being embedded in, connecting to, being fastened to, being integrally formed with, or otherwise interfacing with the surface. For example, some embodiments of the base include one or more plates, flat objects, shoulders, flanges, frameworks, meshes, lattices, grids, ribbons of a suitable material, meshes, wires, pieces of grid material, anchors, or any other suitable components configured to be secured to the surface. Where the surface contains one or more flat portions, the base can include one or more flat portions to correspond to the surface. Where the surface contains one or more non-flat portions, the base can include one or more non-flat portions having a complementary geometry (to a geometry of the surface) in order to better interface with the surface. In some embodiments, the base is flexible (or otherwise configured to conform with a surface). In some embodiments, the base is adjustable (e.g., it can be disposed at a variety of angles with respect to the guide 22).

In some embodiments, the base 34 includes one or more components configured to fit over an edge, a corner, a process, a recess, decorative feature, or any other feature of the surface in order to allow the base to be more easily or securely coupled to the surface. For example, some embodiments of the base are configured to be used in connection with an inside corner, such as by being bent or otherwise shaped to an angle of less than 180 degrees with respect to a portion of the surface (e.g., between 5 and 170 degrees), with the guides 22, 24 extending toward an interior of the angle. Some embodiments of the base are configured to be used in connection with an outside corner, such as by being bent or otherwise shaped to an angle of less than 359 degrees (e.g., less than 180 degrees, at an acute angle, at a right angle, or at an obtuse angle), with the guides extending toward an exterior of the angle. Some embodiments are configured to be used in connection with an edge, such as by being bent or otherwise shaped in a general U-shape (e.g., a U-shape, a V-shape, a horseshoe shape, a semi-circle shape, a cap shape, or any other shape configured to fit over an edge or other suitable portion of a wall, a panel, or other structure). In some such cases, guides are included on one or both sides of the edge piece such that guides are provided on one or both sides of the wall or panel, as desired.

By way of non-limiting illustration, FIGS. 1 and 2 show, in accordance with some embodiments, tracks 20 having bases 34 configured to couple to a generally flat surface. FIG. 3 shows, according to some embodiments, a track 20 with a plurality of bases 34 that can individually couple to one or more surfaces (e.g., at various angles or depths or otherwise independently of one another). FIG. 4 shows, according to some embodiments, a track 20 with a base 34 coupled to a surface 44 of a panel body 42. FIG. 5 shows, according to some embodiments, a track 20 that does not necessarily have a separate component to act as a base per-se, but it has connectors 32 configured to operate as a base by coupling the guides 22, 24 to the surface 44. FIGS. 6A-10C show some embodiments of tracks 20 having guides 22 coupled to bases 34, with the bases being substantially in the form of a wire mesh or grid. Further, the embodiments of the bases 34 of FIGS. 6A-6D are relatively planar (e.g., configured to be coupled to a relatively flat surface, or to bend in order to conform to a contoured or otherwise not flat surface), the embodiments of the bases 34 of FIGS. 7A-7B are bent or otherwise shaped such that the track 20 is configured to be coupled to an inside corner, the embodiment of the base 34 of FIG. 8 is bent or otherwise shaped such that the track 20 is configured to be coupled to an outside corner, FIG. 9 shows embodiments of bases 34 as used in connection with both inside and outside corners, and FIGS. 10A-10C show tracks 20 with generally U-shaped bases 34 such that the tracks are configured to be used in connection with an edge of a panel or wall (or any other suitable structure).

The base 34 can be coupled to the surface 44 in any suitable manner (e.g., through bonding, welding, soldering, wire-tying, stapling, nailing, bolting, bonding, interference or friction fits, use of an adhesive, use of fasteners, being integrally formed with, or any other manner to form a permanent, semi-permanent, or selective attachment). By way of non-limiting illustration, some embodiments of the base are configured to be coupled to the surface via a fastener (e.g., one or more nails, rods, screws, bolts, threaded engagements, staples, eyelets, magnets, hook-and-loop fasteners, adhesives, welds, interference fits, friction fits, tongue-and-groove connections, mechanical engagements, anchors, snaps, ties, rivets, clips, stakes, PVC wire ties, epoxy coated wires, rebar wire ties, zip-ties, and any other suitable fastener for attaching the base to the surface). In some embodiments, a wire grid, scaffold, or other structure is coupled to the surface, and the base is part of or is coupled to such structure. In some embodiments, the base comprises such structure.

Where the track 20 comprises one or more bases, the base 34 can have any dimensions suitable for allowing the base to be attached to a surface (and to support the guide 22). In some embodiments, the base has a length of between 1 mm and 100 m, or within any subrange thereof. By way of example, FIG. 1 shows an embodiment of a track 20 with a length L, and both the base 34 and the guide 22 have a length that is approximately the same as the length of the track. FIG. 2 shows an embodiment of a base 34 with a length that is less than the length of the guide 22. In some embodiments, however, the length of the base is greater than the length of the guide. The base can also have any suitable width (e.g., providing more surface area with which the base can contact the surface), such as between 1 mm and 100 m, or any subrange thereof. The base can also have any suitable depth (e.g., if the base includes a plate or another similar component, the plate or other component can have any suitable thickness), such as between 0.01 mm and 1 m, or any subrange thereof.

Some embodiments of the track 20 include only a single base 34, but as shown in FIG. 3, some embodiments of the track include multiple bases 34. Indeed, the track can include any suitable number of bases, and the bases can be disposed in any suitable manner in relation to each other. For example, in some cases, the bases are approximately even with each other or aligned with each other, whereas in some cases, the bases are offset from one another (e.g., the bases can be disposed at different x, y, or z positions to allow for coupling to an uneven surface, to obtain more lateral support, or to otherwise vary how the guide 22 couples to the surface). In some cases, the base (or any other component, such as the connectors 32 and the guides 22, 24) are formed of one or more pieces of mesh (e.g., wire mesh or any other suitable mesh). By way of non-limiting illustration, FIGS. 6A-10C show some embodiments of tracks 20 formed of pieces of wire mesh, in each case having a base 34 formed of the wire mesh, connectors 32 formed of a bent piece of the wire mesh, and one or more guides 22, 24 formed of an edge of the wire mesh. Where a mesh is used, the mesh can have any suitable feature, including any feature of the mesh 46 used in connection with a construction panel.

According to some embodiments where the track 20 includes one or more couplers 30, the coupler includes one or more connectors 32 for connecting the guide 22 to the base 34 (or directly to the surface 44 to be screeded or to anything else). The connectors can include any component configured to extend from the base and connect the guide to the base (in some embodiments, this creates a gap between the surface 44 and the guide, which gap can be filled with surfacing material). By way of non-limiting illustration, the connectors can include one or more bars, rods, wires, posts, rebars, beams, planks, boards, anchors, clips, pins, portions of wire mesh, or any other components for coupling the guide to the base. In some embodiments, the connectors are part of an integral part of a wire mesh (e.g., wires that couple to the guide 22, with the guide itself being another wire of the wire mesh).

In some embodiments, the connectors 32 are integrally formed with the base 34, and in some embodiments, the connectors are configured to permanently, semi-permanently, or selectively attach to the base (e.g., such as through use of one or more nails, screws, bolts, staples, eyelets, magnets, hook-and-loop fasteners, adhesives, welds, interference fits, friction fits, tongue-and-groove connections, snaps, ties, rivets, stakes, PVC wire ties, epoxy coated wires, rebar wire ties, wires, or any other fasteners or components for attaching the connectors to the base). In some embodiments, the connectors are integrally formed with the guide 22, and in some embodiments, the connectors are configured to permanently, semi-permanently, or selectively attach to the guide (e.g., such as through any of the foregoing components, or any other components for attaching the connectors to the guide).

The connectors 32 can have any suitable configuration for attaching the guide 22 to the base 34. In some embodiments, the connectors are substantially straight, whereas in some embodiments they are curved, bent, contoured, twisted or otherwise shaped to hold surfacing material, or otherwise shaped. Additionally, the connectors can be any length, such as between 0.5 cm and 1 m, or any subrange thereof (e.g., between about 1 cm and about 12 cm). Indeed, in some embodiments, the connectors are about 6 cm±4 cm in length. In some embodiments, the length of the connectors 32 is adjustable. The connectors can also have any suitable orientation. For example, in some cases the connectors are perpendicular to the surface or the guide, but in some cases, the connectors are disposed at a non-perpendicular angle with respect to the surface (or longitudinal axis) of the guide. In some embodiments (as discussed above) the connectors are part of a mesh (or otherwise integrally formed with the base 34 or the guides 22, 24). In some cases, the mesh is bent (or otherwise shaped) to form the connectors and place the guides in an appropriate position.

Furthermore, the coupler 30 can include any number of connectors 32, such as between 1 and 1,000 (or even more, for larger walls), or any suitable subrange. In some cases, the coupler couples the guide to the surface at multiple points disposed at intervals along the surface. By way of non-limiting illustration, FIG. 6D shows an embodiment of a track 20 with a guide 22 coupled to a base 34 via a number of connectors 32, in accordance with some embodiments, that are formed from a bent piece of wire mesh that forms the base, with such connectors ensuring that the guide 22 is a certain distance away from the base 34 so that the thickness of the surfacing material will be proper.

In some embodiments, at least a portion (and in some cases, all) of the coupler 30 or the track 20 are configured to become embedded in the surfacing material. For example, in some cases, the base 34 is configured to become embedded in the surfacing material. In some cases, the connectors 32 are configured to become embedded in the surfacing material.

While the track 20 can be used with any surface configured to receive a layer of surfacing material, some embodiments of the track are integrated with or configured to be coupled to a construction panel (e.g., such as a construction panel 40 as shown in FIGS. 4-5). The construction panel can be any structural or aesthetic component that is configured to be used as part or all of any structure and that has a surface configured to receive a surfacing material. For example, the construction panel of some embodiments includes, or is configured to form a part of, one or more walls, floors, ceilings, columns, pillars, supports, bridges, dividers, barriers, trusses, dams, pools, overpasses, sculptures, edges, corners, ramps, doors, or any other suitable structures or portions of a structure on which it might be desirable to apply a surfacing material. In some embodiments, the panel includes one or more panel bodies 42 (e.g., for providing structure or support) and one or more surfaces 44 (e.g., on which the surfacing material can be applied).

The panel body 42 can be made of any suitable material or materials, including one or more of concrete, ashcrete, wood, metal, glass, plastic, carbon fiber, polymer material, cardboard, paper, foam, nylon, fabric, netting, foam, polystyrene, fiberglass, or any other suitable construction material. By way of non-limiting illustration, some embodiments of the panel body include expanded polystyrene (EPS) or any other suitable insulating material or other material.

The surface 44 of the panel 40 can have any shape or configuration capable of receiving a surfacing material. For example, some embodiments of the surface include one or more straight portions, curved portions, contoured portions, uneven portions, sound breaks, aesthetic features, or any other suitable surface features. In some embodiments, the surface 44 includes irregularities or other features to help the shotcrete adhere to the surface 44. In some cases, a panel has multiple surfaces (e.g., a first surface on a first side and a second surface on a second (opposing) side, each configured to receive the surfacing material).

The panel 40 can have any suitable dimensions. In this regard, FIG. 5 shows a panel 40 with a height H, a width W, and a thickness T. Although the thickness is often less than the height or the width, any of the height, width, and thickness can be anywhere between 1 mm and 1,000 m, or any subrange thereof. In some embodiments, the height is the same as the length L of the track 20, whereas in some embodiments the height is less than or greater than the length of the track. Similarly, in some embodiments, the width is the same as, greater than, or less than the length of the track. In some embodiments, the height is the same as, greater than, or less than the width.

The panel 40 can have any suitable orientation with respect to the track 20 that allows the track to perform its intended purpose. Indeed, according to some embodiments, the orientation of the length L of the track substantially aligns with the orientation of the height H of the panel (e.g., when used in connection with a wall panel, the track extends substantially vertically from a lower portion to an upper portion of the panel). In some embodiments, the orientation of the length of the track substantially aligns with the orientation of the width W of the panel (e.g., when used in connection with a wall panel, the track extends between two lateral edges of the panel). In some embodiments, the track is placed at a diagonal orientation with respect to the height and the width of the panel, or at any other orientation with respect to the panel.

While the panel 40 is not limited to any particular configuration, in some cases, the panel is configured to be used in connection with one or more other panels in a modular fashion to form a larger structure. In some cases, the panel 40 is substantially in the form of a tilt-up or pre-cast construction panel, such as a panel as disclosed in U.S. patent application Ser. No. 17/827,967, entitled IMPROVED TILT-UP AND PRECAST CONSTRUCTION PANELS, and filed on May 30, 2022, which is incorporated herein by reference in its entirety.

In some embodiments, after the track 20 is coupled to the panel 40, the panel is configured to receive one or more layers of surfacing material 60. The layer of surfacing material can include any surfacing material (as discussed above). The layer of surfacing material can also have any thickness or any configuration. For example, in some embodiments, the layer of surfacing material is anywhere between 0.01 mm and 1 m thick, or any subrange thereof. As a non-limiting example, some embodiments include a layer of surfacing material that includes shotcrete, and which is between 5 m and 20 cm thick.

In some embodiments, the thickness of the layer of surfacing material is approximately equal to (or slightly less than, or slightly greater than) a distance between the guide 22 and the surface 44. Stated another way, in some cases the outer portion 28 of the guide 22 is separated from the surface 44 by a distance that is greater than the desired thickness of the layer of surfacing material 60 (e.g., so that at least a portion of the track extends past the layer of surfacing material, and the track is not completely covered by the layer of surfacing material). In some embodiments, the inner portion 26 of the guide is separated from the surface by a distance that is less than the desired thickness of the layer of surfacing material (e.g., so that at least a portion of the guide is configured to be covered by, and later embedded in, the layer of surfacing material). Thus, in some cases, the guide is partially, but not completely, covered by and embedded in the layer of surfacing material. In some embodiments, the thickness of the surfacing material is non-uniform or variable (such as where the guide is contoured). In some embodiments, more surfacing material is initially applied than is needed to form the layer of surfacing material having the desired thickness, and the excess is screeded away to achieve the desired thickness.

In some embodiments, the panel 40 includes a mesh 46 disposed proximate to the surface 44. While the mesh can include any component configured to help a surfacing material stick to the surface, some embodiments of the mesh include one or more grids, nets, lattices, fabrics, weaves, textures, wires, rods, or any other suitable components that could aid a surfacing material in sticking to a surface. In some cases, the mesh assists the surfacing material in adhering to the surface (e.g., by giving the surfacing material increased surface area, processes, or structural irregularities to adhere to). In some embodiments, the mesh is configured to become embedded within the surfacing material. In some embodiments, the mesh is configured to be partially embedded within, or disposed on the surface, but in some cases the mesh is spaced apart from the surface such that there is a gap between the surface and the mesh. In some cases, the coupler 30 (e.g., the base 34 of the coupler) is configured to couple to the mesh (in addition to or instead of coupling directly to the surface). In some embodiments, the mesh is disposed between the guide 22 and the surface, and in some cases, there is a gap between the mesh and the guide.

According to some embodiments, the track 20 (or any component thereof, such as the base 34, the connectors 32, the guides 22, 24, or any other portion) is part of the mesh 46 (e.g., incorporated with the mesh or integrally formed with the mesh). In some cases, the track includes a separate piece of mesh (e.g., that is similar to the mesh of the panel 40, or that shares any characteristics therewith). In some cases, one or more guides 22, 24 is formed of one or more parts of a mesh (e.g., the mesh of the panel, or a separate piece of mesh), such as by having a wire or strand of the mesh (e.g., on the end, in the middle, or otherwise) protrude more prominently than other parts of the mesh (e.g., by being bent outward).

Although the mesh 46 can be formed of any suitable material (such as wires, rods, bars. metal, wood, glass, plastic, carbon fiber, polymer material, cardboard, paper, nylon, fabric, netting, or any other suitable material to which a surfacing material can adhere), in some embodiments, the mesh is formed of the same material as the track 20 (or a portion thereof). In some cases, the mesh is part of the track (or vice versa). In some cases, the mesh is formed of a material that includes wires having a uniform thickness and composition. In some cases, the wires are made of metal (e.g., pure metal or metal alloys). By way of non-limiting illustration, in some cases, the mesh is formed of a plane grid including at least two sets of longitudinal and transverse wires crossing each other and coupled (e.g., bonded, glued, welded, tied, wrapped, or otherwise coupled) together at points of cross.

Although the mesh 46 can be coupled to the panel body 42 in any suitable manner (e.g., through one or more nails, screws, bolts, staples, eyelets, magnets, hook-and-loop fasteners, adhesives, welds, interference fits, friction fits, tongue-and-groove connections, snaps, ties, rivets, stakes, PVC wire ties, epoxy coated wires, rebar wire ties, or through any other suitable coupling mechanism), in some embodiments, the mesh is coupled to the panel body by one or more spacer wires 50 that are at least partially embedded within panel body (and in some cases, extending all the way through the panel body). In some embodiments, the spacer wires are integrally formed with or configured to couple to the coupler 30.

As discussed above, the base 34 can have any feature or configuration that allows it to fulfill its designated functions, but for the avoidance of doubt, some embodiments of the base include a mesh that is similar or substantially identical to the mesh 46 of the construction panel 40.

According to some embodiments, the panel 40 includes one or more insulating cores 48. The insulating core can include any component for providing insulation (e.g., of temperature, sound, electricity, or anything else) to the panel. For example, some embodiments of the insulating core include foam, fiberglass, mineral wool, cellulose, natural fibers, polystyrene, polyisocyanurate, polyurethane, perlite, cementitious foam, phenolic foam, materials with air pockets, or any other type of insulation. By way of non-limiting illustration, some embodiments include EPS or another suitable insulating foam. While the insulating core 48 can be any shape, (e.g., to match or complement the shape of any panel) in some cases, the insulating core has a general rectangular prism (cuboid) shape.

In some embodiments, the panel body 42 includes one or more features on an opposite side of the panel 40 (e.g., one or more features on a surface positioned opposite from the surface 44). In some cases, one or more second meshes are disposed on the opposite surface. In some cases, the opposite surface is configured to receive one or more opposite layers of surfacing material. In some embodiments, one or more spacer wires 50 extend all the way through the panel body 42 (noting that, in some embodiments, one or more spacer wires 50 do not extend all the way through the panel body 42, but rather terminate inside the panel body 42). In some embodiments, one or more spacer wires 50 couples to one or more features on either side of the panel (e.g., a mesh 46 on one side, and an opposing mesh on the other side). In some embodiments, the spacer wires 50 are disposed at an angle (e.g., not perpendicular to the mesh 46 or the surface 44 of the panel body 42). In some cases, the spacer wires 50 include wires disposed at different angles, such that the spacer wires 50 would resist movement of the mesh with respect to the surface 44