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

[0044]Another object of the present inventions is to provide an improved insulated precast system that can be cast on pre-stressed cable tables of any length and then cut to size in the...

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...

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