Insulated concrete wall construction method and apparatus

Abstract

An insulated concrete form panel assembly for constructing insulated concrete walls includes a frame comprising a plurality of steel studs and at least two cross members that connect the studs together. A pair of insulating panels are fastened to and span respective inner and outer opposing sides of the frame so as to define concrete receiving cavities between the panels and the studs. A brick ledge may be constructed by separating a laterally extending, generally rectangular elongated mid portion of the outer insulating panel from a remainder of the outer insulating panel. An upper edge of the mid portion is then moved a predetermined distance outward from the remainder of the outer insulating panel such that the mid portion is disposed in a desired position at an angle to the remainder of the outer insulating panel. The mid portion is then secured in the desired position relative to the frame.

We claim:  
     
         1 . An insulated concrete form panel assembly including: 
 a frame comprising a plurality of steel studs and at least two cross members that connect the studs together; and    a pair of insulating panels fastened to and spanning respective inner and outer opposing sides of the frame so as to define concrete receiving cavities between the panels and the studs.    
     
     
         2 . The assembly of  claim 1  in which the studs are oriented vertically and generally parallel to one another.  
     
     
         3 . The assembly of  claim 2  in which the cross members are elongate steel angle strips.  
     
     
         4 . The assembly of  claim 3  in which two top angle strips are fastened across the studs adjacent opposite sides of upper ends of the studs; and 
 two angle strips are fastened across the studs adjacent opposite side of respective bottom ends of the studs.  
 
     
     
         5 . The assembly of  claim 1  in which each stud includes: 
 an elongated main panel; and  
 a pair of opposing elongated parallel flanges that integrally extend generally perpendicularly from along the length of the main panel; and  
 the studs are supported in the frame such that the main panels the main panels are disposed in a facing relationship to one another.  
 
     
     
         6 . The assembly of  claim 2  in which each stud has a length generally equal to a desired height of an insulated concrete wall to be constructed.  
     
     
         7 . The assembly of  claim 1  in which a plurality of longitudinal horizontal apertures are spaced along the length of each stud, each aperture configured and aligned to receive a steel-reinforcing rod such that the rod extends generally horizontally through corresponding apertures in each stud.  
     
     
         8 . The assembly of  claim 1  in which each insulating panel comprises a sheet of commercially available insulating foam.  
     
     
         9 . The assembly of  claim 8  in which each sheet of foam preferably comprises a two-inch thick sheet of extruded polystyrene.  
     
     
         10 . The assembly of  claim 1  in which fasteners extending through elongate fastening strips secure the foam panels to the respective inner and outer sides of the frame.  
     
     
         11 . The assembly of  claim 10  in which the fastening strips are oriented vertically against the panels in alignment with the studs.  
     
     
         12 . The assembly of  claim 1  in which a mid portion of the outside panel is configured to angle outward and upward from the rest of the outside panel to form an outer insulating wall of a brick ledge.  
     
     
         13 . The assembly of  claim 12  in which the mid portion of the outside panel is at least one foot in vertical width.  
     
     
         14 . The assembly of  claim 12  in which the mid portion of the outside panel angles outward and upward from the rest of the outside panel at an angle of less than 45 degrees.  
     
     
         15 . The assembly of  claim 12  in which a plurality of brick ledge ties secure the outwardly angled portion of the foam panel to the studs.  
     
     
         16 . The assembly of  claim 15  in which each brick ledge tie is bent to include a generally U-shaped anchor portion shaped to form an interference fit when oriented horizontally within interior contours defined by the main panel, flanges and the lips of a stud.  
     
     
         17 . The assembly of  claim 1  in which each brick ledge tie includes: 
 an arm portion that extends from the anchor portion horizontally to the top outer edge of the outwardly angled portion; and  
 a retainer portion that extends from an outer end of the arm and is configured to grasp the upper edge of the outwardly angled foam panel portion.  
 
     
     
         18 . A method of forming insulated concrete walls that includes: 
 providing a plurality of steel studs;    providing inner and outer insulating panels;    forming a frame by connecting a cross member between the steel studs; and    forming an insulated concrete form panel by attaching the inner and outer insulating panels to respective opposite inner and outer sides of the frame such that the panels generally span the inner and outer sides of the frame.    
     
     
         19 . The method of  claim 18  in which the step of forming a frame includes orienting the studs vertically and parallel to one another.  
     
     
         20 . The method of  claim 18  in which the step of forming an insulated concrete form panel includes configuring the insulated concrete form panel to form a brick ledge when concrete is provided within the panel.  
     
     
         21 . The method of  claim 20  in which the step of configuring the insulated concrete form panel to form a brick ledge includes: 
 at least partially separating a laterally extending, generally rectangular elongated mid portion of the outer insulating panel from a remainder of the outer insulating panel;  
 moving an upper edge of the mid portion a predetermined distance from the remainder of the outer insulating panel such that the mid portion is disposed in a desired position at an angle to the remainder of the outer insulating panel; and  
 securing the mid portion in the desired position relative to the frame.  
 
     
     
         22 . The method of  claim 18  including the additional steps of: 
 transporting the insulated concrete form panel to a job site.  
 standing the insulated concrete form panel upright in a predetermined position where a wall is to be constructed;  
 providing lengths of steel reinforcing rod in the apertures in the steel studs such that the reinforcing rods are disposed horizontally to one another and perpendicular to the studs;  
 connecting the insulated concrete form panel to an adjacent insulated concrete form panel; and  
 providing concrete in cavities formed between the studs and the insulating panels.  
 
     
     
         23 . The method of  claim 20  in which in which the step of configuring the insulating concrete form panel to form a brick ledge follows the transporting step.