Method and apparatus for fabricating a low density wall panel with interior surface finished

Abstract

A fabricated low density concrete foundation/wall panel is provided with a plurality of insulation panels and reinforcing ribs to improve strength and reduce the density of the wall panel. The wall panels are easily placed and interconnected together to quickly provide a foundation adapted to support the main walls of a home, for example. The fabricated wall panels in one embodiment generally includes an inner wall sheathing that is interconnected to the load-supporting segments of the wall panel during fabrication.

1 . A low density, concrete wall panel having a first end, a second end and laterals edges extending therebetween, comprising: 
 a concrete exterior face wall extending between said first end and said second end;    a plurality of foam panels positioned adjacent to said concrete exterior face wall, said plurality of foam panels operably spaced to define a reinforcing rib between each of said foam panels which is filled with concrete;    at least one reinforcing rod positioned within each of said reinforcing ribs; and    an interior sheathing material interconnected to said plurality of foam panels on a side opposite said exterior face wall.    
   
   
       2 . The low density wall panel of  claim 1 , further comprising a reinforcing rib extending around a perimeter edge of said wall panel, said reinforcing rib comprised of concrete and a metal reinforcement material.  
   
   
       3 . The low density wall panel of  claim 1 , further comprising a plurality of utility channels extending at least partially between said first end and said second end which are adapted to receive electrical wiring, piping or other utilities.  
   
   
       4 . The low density wall panel of  claim 1 , further comprising a lifting lug interconnected to at least one of said first end and said second end.  
   
   
       5 . The low density wall panel of  claim 1 , wherein said perimeter edges are comprised of concrete extending from said exterior face wall to said interior face wall.  
   
   
       6 . A method for fabricating a low density concrete building panel, comprising the steps of: 
 a) providing a casting form having a first end, a second end, and lateral edges extending therebetween;    b) positioning a flexible plastic material within the confines of the form;    c) interconnecting at least one foam core panel to an interior face building material;    d) positioning the at least one foam core panel and said interior face building material within said form on said flexible plastic material, wherein a channel is formed between two of said foam core panels;    e) positioning at least one reinforcing bar in said channel;    f) providing a layer of concrete within said chapels and on an upper surface of said at least one foam core panel;    g) curing said concrete; and    h) removing said lightweight, concrete building panel from said form.    
   
   
       7 . The method of  claim 6 , further comprising the step of positioning an interior frame within said casting form prior to said providing a layer of concrete, wherein an opening for a window or a door is provided.  
   
   
       8 . The method of  claim 6 , further comprising the step of positioning at least one lift anchor within said concrete building panel to facilitate the removal of said lightweight building panel from said casting form.  
   
   
       9 . The method of  claim 6 , wherein said foam core is comprised of at least one of an expanded polystyrene material, an extruded polypropylene and a polyisocyanurate material.  
   
   
       10 . The method of  claim 6 , further comprising the step of reinforcing at least one of a plurality of perimeter edges of said concrete building panel with at least one of a metallic reinforcing bar and a carbon fiber material.  
   
   
       11 . The method of  claim 6 , further comprising the step of vibrating said first concrete material, wherein a density of said first concrete material is increased.  
   
   
       12 . The method of  claim 6 , wherein interconnection of said at least one foam core panel and said interior face building material is accomplished within the casting form.  
   
   
       13 . The method of  claim 12 , where said interior face building material is poured within said casting form during fabrication of the low density building panel.  
   
   
       14 . A low density fabricated concrete wall panel, comprising an upper end, a lower end and lateral edges extending between, comprising: 
 an interior sheathing material positioned substantially between said upper end, said lower end and said lateral edges;    a plurality of foam panels positioned adjacent to said interior sheathing material and oriented to define a space between said at least two of said plurality of foam panels between said upper end and said lower end;    a cavity extending within at least one of said plurality of foam panels between said upper end and said lower end, said cavity adapted to receive a utility;    a concrete material positioned on an exterior surface of said plurality of foam panels to define an exterior face and within said space between said at least two of said plurality of foam panels to define a reinforcing rib.    
   
   
       15 . The low density wall panel of  claim 14 , wherein said sheathing material is comprised at least partially of a gypsum material.  
   
   
       16 . The low density wall panel of  claim 14 , wherein said plurality of foam panels are comprised of at least one of an expanded polystyrene material, an extruded polypropylene and a polyisocyanurate material.  
   
   
       17 . The low density wall panel of  claim 14 , further comprising a metallic rod positioned within said space and formed between said at least two of said plurality of foam panels.  
   
   
       18 . The low density wall panel of  claim 14 , Further comprising a lift anchor positioned along a perimeter edge to facilitate lifting the low density wall panel.