Prestressed concrete building panel and method of fabricating the same

Abstract

A low density concrete building panel and method of manufacturing is provided with one or more carbon fiber or steel reinforcements which may include window and door openings which can be easily transported and erected at a building site.

1 . A carbon fiber reinforced concrete building panel, comprising: 
 an inner surface, an outer surface, a first end and a second end, and a substantially longitudinal axis defined between said first end and said second end;    a tensioned first carbon fiber grid positioned within an exterior concrete layer between said first end and said second end;    a plurality of foam core panels positioned substantially adjacent to said exterior concrete layer and defining a plurality of rib channels between said plurality of foam core panels which are substantially filled with a concrete material;    at least one carbon fiber shear strip positioned within said plurality of rib channels and extending into said exterior concrete layer; and    at least one reinforcing bar positioned proximate to said at least one carbon fiber shear strip and positioned within said plurality of rib channels.    
   
   
       2 . The carbon fiber reinforced concrete building panel of  claim 1 , wherein said at least one carbon fiber shear strip is comprised of an interwoven grid of individual carbon fibers.  
   
   
       3 . The carbon fiber reinforced concrete building panel of  claim 1 , further comprising at least one lifting anchor interconnected to at least one of said first end, said second end, and lateral edges extending therebetween.  
   
   
       4 . The carbon fiber reinforced concrete building panel of  claim 1 , wherein said plurality of foam core panels is comprised of one integral foam core panel with a plurality of reinforcing rib channels positioned therein to receive concrete and reinforcing materials.  
   
   
       5 . The carbon fiber reinforced concrete building panel of  claim 1 , further comprising a nailing surface operably interconnected to said plurality of rib channels which are adapted to receive a nail, a screw, and other interconnection means.  
   
   
       6 . The carbon fiber reinforced concrete building panel of  claim 5 , wherein said nailing surface comprises at least one of a foam material, a wood material and a metal material.  
   
   
       7 . The carbon fiber reinforced concrete building panel of  claim 1 , further comprising a plurality of spacers positioned between said plurality of foam core panels which include a support member for holding a reinforcing bar.  
   
   
       8 . The carbon fiber reinforced concrete building panel of  claim 1 , further comprising a reinforced section including at least one of a reinforcing bar and a carbon fiber material positioned around a window frame or a door frame.  
   
   
       9 . The carbon fiber reinforced concrete building panel of  claim 1 , wherein said at least one first reinforcing bar is comprised of a metallic rod having a diameter of at least about 0.25 inches.  
   
   
       10 . The carbon fiber reinforced concrete building panel of  claim 1 , further comprising a second reinforcing bar which is positioned proximate to at least one of a plurality of perimeter edges of said substantially planar concrete panel.  
   
   
       11 . The carbon fiber reinforced concrete building panel of  claim 1 , further comprises a second carbon fiber sheer strip positioned proximate to at least one of a plurality of perimeter edges of said substantially planar concrete panel.  
   
   
       12 . The carbon fiber reinforced concrete building panel of  claim 1 , further comprising at least one spacer positioned at least partially around at least one first reinforcing bar, wherein there is a predetermined amount of separation between said foam core and said at least one first reinforcing bar.  
   
   
       13 . The carbon fiber reinforced building panel of  claim 1 , wherein said tensioned first carbon fiber grid has a tension of at least about 500 lbs.  
   
   
       14 . The carbon fiber reinforced building panel of  claim 1 , wherein said building panel has a density of no greater than about 20 lbs/ft 2 .  
   
   
       15 . A method for fabricating a low density concrete building panel, comprising: 
 a) providing a form having a first end, a second end, and lateral edges extending therebetween;    b) positioning a plurality of metal strands in said form;    c) applying tension to said plurality of metal strands;    d) positioning a first grid of carbon fiber material in said form;    e) applying tension to said first grid of carbon fiber material;    f) pouring a first layer of concrete material into said form;    g) positioning a layer of insulative material onto said first layer of concrete material, said insulative material having a plurality of reinforcing rib channels extending substantially between at least one of said first end and said second end or said lateral edges;    h) positioning a first reinforcing material in said plurality of rib channels;    i) pouring a second layer of concrete into said plurality of reinforcing rib channels;    j) allowing said first layer and said second layer of concrete to cure; and    k) removing said concrete building panel from said form, wherein said lightweight concrete building panel is available for transportation and use.    
   
   
       16 . The method of  claim 15 , further comprising the step of positioning at least one lifting anchor in at least one of said plurality of rib channels.  
   
   
       17 . The method of  claim 15 , further comprising positioning a second reinforced section within said form to define an opening for at least one of a window, a door, and a utility vault.  
   
   
       18 . The method of  claim 15 , wherein the step of positioning a layer of insulative material comprises orienting a plurality of individual foam core panels in a predetermined pattern on said first layer of concrete.  
   
   
       19 . The method of  claim 15 , further comprising the step of interconnecting at least some of said individual foam core panels prior to said step of positioning said individual foam core panels onto said first layer of concrete material.  
   
   
       20 . The method of  claim 18 , further comprising the step of positioning a spacer between said plurality of individual foam core panels, wherein said second layer of concrete has a substantially uniform thickness between said plurality of individual foam core panels.  
   
   
       21 . The method of  claim 15 , wherein said layer of insulative material is comprised of an expanded polystyrene material.  
   
   
       22 . The method of  claim 21 , wherein said spacer further comprises a support mechanism for holding a reinforcing bar in a predetermined location.  
   
   
       23 . The method of  claim 15 , further comprising the step of positioning at least one of a metallic reinforcing bar and a third grid of carbon fiber along at least a portion of a perimeter edge of said concrete building panel prior to said step of allowing said first layer and said second layer of concrete to cure.  
   
   
       24 . A method for fabricating a low density concrete building panel having a window or door opening, comprising: 
 a) providing a casting form having a first end, a second end, and lateral edges extending therebetween;    b) positioning a negative to a bottom portion of the casting forms in a predetermined position which defines a window opening or a door opening;    c) positioning a plurality of metal strands in said form;    d) applying tension to said plurality of metal strands;    e) positioning a first grid of carbon fiber material in said form;    f) applying tension to said first grid of carbon fiber material;    g) positioning a framing material on or proximate to said negative;    h) pouring a first layer of concrete material into said form;    i) positioning a layer of foam core onto said first layer of concrete material, said layer of foam core having a plurality of reinforcing rib channels extending substantially between at least one of said first end and said second end or between said lateral edges;    j) positioning a first reinforcing material in said plurality of reinforcing rib channels;    k) pouring a second layer of concrete into said plurality of rib channels;    l) allowing said first layer and said second layer of concrete to cure; and    m) removing said concrete building panel from said form, wherein said lightweight concrete building panel is available for transportation and use.    
   
   
       25 . The method of  claim 24 , wherein said framing material is comprised of wood.  
   
   
       26 . The method of  claim 24 , wherein at least about 500 lbs. of tension is applied to said first grid of carbon fiber material.  
   
   
       27 . The method of  claim 24 , further comprising trimming any excess carbon fiber from the window opening or door opening.  
   
   
       28 . The method of  claim 24 , wherein at least about 500 lbs. of tension is applied to said plurality of metal strands.  
   
   
       29 . The method of  claim 24 , wherein said positioning a layer of foam comprises placing a plurality of individual foam panels on said first layer of concrete in a predetermined pattern.  
   
   
       30 . The method of  claim 24 , wherein positioning a first reinforcing material in said plurality of reinforcing rib channels comprises positioning a metallic reinforcing rod on a bracket which is operatively interconnected to at least one of aid plurality of individual foam panels.