Process for making insulated concrete tilt-up walls and resultant product

Abstract

In a method of making insulated concrete tilt-up panels, an insulating material such as polystyrene is formed into a desired shape corresponding to the panel shape. Attachment grooves are formed across the surface of the insulating material. Preferably, the attachment grooves have a substantially triangular cross-section. The insulating material is laid groove-side-up in a concrete form and wet concrete is poured into the form. The concrete fills the grooves, attaching the insulation to the concrete panel. When the concrete is cured, the panel may be stood up and set in place so that the insulating material forms the exterior surface of the panel. A finishing material may be applied to the exterior surface of the panel. A panel set for use in constructing low-income residential housing includes four concrete tilt-up panels. The insulating material and concrete forms may be prepared in the quantity desired for the entire construction project and transported to a casting area at the construction site. The panels may be rapidly cast and assembled, reducing the time and labor required to complete the project.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS[0001]This application claims the benefit of co-pending provisional application No. 60 / 937,027 filed Jun. 25, 2007.FIELD OF INVENTION[0002]This invention relates to concrete wall construction. This invention relates particularly to a process for creating insulated concrete tilt-up wall panels and the resultant products.BACKGROUND[0003]Building structures using tilt-up concrete wall panels are well known in the art. They can significantly reduce the initial cost of construction, increase the life of the structure and reduce maintenance cost. Tilt-up panels are made under controlled conditions and the exterior surface can be inexpensively finished with rollers to shape an attractive product. Such panels can be pre-cast, fabricated and stored in the factory and then transported to the building site, or made in-situ, forming the panels at the building site. Walls, and therefore buildings, can be assembled rapidly using the panels.[0004]In general, ...

AI Technical Summary

Benefits of technology

[0009]One or more attachment grooves are formed across the surface of the insulating material. Preferably, the attachment grooves have a substantially triangular cross-section. One edge of the insulating material may be formed with a tongue and the opposing edge formed with a groove, or the edges may be interlocking, such that one panel may be easily and securely attached to another panel.

[0011]A combination of four panels, each having a different shape, is disclosed which may be used to build the exterior walls of multiple models of residential homes, such as those in a subdivision of low-income housing. The insulating material may be prepared in the quantity desired for the entire construction project and transported to a casting area at the construction site. The panels may be rapidly cast and assembled, reducing the time and labor required to complete the project.

Problems solved by technology

Concrete walls have large thermal mass, but are poor insulators.

That is, once the heat or cold is absorbed by the concrete, it is conducted unfortunately rather well.

However, it is difficult to attach rigid foam panels to the relatively smooth finished exterior surface of a concrete tilt-up wall, and spray foam does not stick in place long enough to harden.

This solution does not take full advantage of the thermal mass of the tilt-up wall, allowing part of the wall to heat or cool without insulation while providing a smaller thermal mass for regulation of the interior temperature.

Further, the uneven heating and cooling of the wall may weaken its structural integrity.

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