High performance, reinforced insulated precast concrete and tilt-up concrete structures and methods of making same

Abstract

The invention comprises a product. The product comprises a foam insulating panel, the panel having a first primary surface and an opposite second primary surface, wherein the foam insulating panel defines at least one recessed channel in the first primary surface, the at least one recessed channel being sized and shaped to provide a mold for a structural reinforcing member. The product also comprises a concrete panel formed on the first primary surface and filling the at least one recessed channel so as to provide a structural reinforcing member for the concrete panel. The product further comprises an elongate anchor member in the foam insulating panel and extending from the first primary surface of the foam insulating panel into the concrete panel. A method of making a composite reinforced insulated concrete structure is also disclosed.

Description

FIELD OF THE INVENTION[0001]The present invention generally relates to the forming of concrete structures. More particularly, this invention relates to precast concrete structures, especially precast and tilt-up concrete panels. The present invention also relates to insulated precast and tilt-up concrete panels, especially architectural structural loadbearing precast and tilt-up concrete panels. The present invention also relates to a reinforced insulated concrete panel or structure that uses less concrete and reinforcing steel than a conventional structure or panel. The present invention also relates to methods of making insulated precast concrete structures and insulated precast tilt-up concrete structures, especially concrete panels. The present inventions relates to an insulated precast roof panel system. The present inventions also related to highway noise barrier systems that can absorb and reflect sound. The present invention further relates to a highly energy efficient build...

AI Technical Summary

Benefits of technology

The present invention aims to provide an improved insulated concrete panel system that uses minimal amounts of concrete and reinforcing steel in areas of minimal stress, while incorporating various structural reinforcing elements of different thickness in areas of maximum stress. Additionally, this invention also provides an improved sound abatement structure.

Problems solved by technology

In buildings, the majority of energy loss takes place through the building envelope.

However, there are several drawback of this system.

Batt insulation may not completely fill the cavity wall and over time it can sag, leaving no insulation in some places.

Moisture condensation inside the cavity wall is common which dampens and compresses the batt insulation.

When this occurs, the damp batt insulation loses most, if not all, insulating properties.

These pressure differences cause air to move through the exterior wall system.

Simply stated, cavity wall framed systems have poor energy efficiency, among many other problems.

In addition, framing construction has a very poor record sustaining storm and flood damage.

Concrete has high thermal mass, which makes it rather expensive to heat or cool in extreme temperatures.

However, such insulation does little to improve energy efficiency as it is generally on the wrong side of the wall; i.e., the interior wall surface.

Concrete walls have the advantage that they are barrier systems; i.e., no air can flow through from inside to the outside, but still have poor energy efficiency.

While concrete-type building construction does very well in storms and floods, it does not do as well in seismic areas due to its massive weight and minimal flexibility.

Prior art precast concrete wall panels also have a large thermal mass when exposed to ambient temperatures.

Therefore, buildings built with precast concrete panels generally have relatively poor energy efficiency.

Such buildings usually require a relatively large amount of energy to keep them warm in the winter and cool in the summer.

This method however does not create a highly energy efficient building envelope.

And, since batt insulation of significant thickness is required the interior frame system takes valuable floor space and creates a cavity wall.

The second layer is therefore still relatively thick and heavy.

The weight of the second layer added to the weight of the first layer makes the entire panel relatively heavy.

Generally this is a costly system.

However these panels are heavier and therefore more expensive to manufacture.

The thinner the concrete wythes, the more brittle they become which requires use of pre-stressed cable reinforcement or expensive carbon fiber reinforcements.

However some of these loads are not equally distributed along a structure or panel.

This creates an unnecessary amount of concrete and steel used in the areas of minimal stress that is not needed.

While this is a known factor, the limitation of construction practices makes it impractical and expensive to form concrete panels with various concrete thicknesses and varying steel reinforcement to accommodate the various stresses within a concrete panel or slab.

In addition, the aesthetic appearance of a concrete panel with various structural reinforcing elements cast within may not be desirable.

However the structural limitations of the foam panels make them prone to other shortcomings.

Also, while concrete noise barriers may be longer lasting, they are heavy and have very limited architectural features.

While such roof systems are very popular, they are highly susceptible to storm or wind damage.

While this provides greater wind resistance, it is not a very energy efficient roof system.

The biggest drawback of any roofing system that uses poured concrete on a metal roof deck is that the metal deck acts like a pan and it collects moisture.

Furthermore, lightweight concrete has significant amounts of air pockets and types of aggregate that retain water.

Due to weather cycles, this trapped moisture has nowhere to go but up thereby causing failure of the roof membrane with resulting potential severe damage to the interior of the building.

Due to the specific design limitations, precast insulated sandwich concrete panels are seldom if ever used for a roof deck.

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