Process for making insulated concrete tilt-up walls and resultant product

Abstract

In a method of making insulated concrete tilt-up panels, an insulating material such as polystyrene is formed into a desired shape corresponding to the panel shape. Attachment grooves are formed across the surface of the insulating material. Preferably, the attachment grooves have a substantially triangular cross-section. The insulating material is laid groove-side-up in a concrete form and wet concrete is poured into the form. The concrete fills the grooves, attaching the insulation to the concrete panel. When the concrete is cured, the panel may be stood up and set in place so that the insulating material forms the exterior surface of the panel. A finishing material may be applied to the exterior surface of the panel. A panel set for use in constructing low-income residential housing includes four concrete tilt-up panels. The insulating material and concrete forms may be prepared in the quantity desired for the entire construction project and transported to a casting area at the construction site. The panels may be rapidly cast and assembled, reducing the time and labor required to complete the project.

1 . An insulated tilt-up wall panel comprising:
 a. an insulating material;   b. one or more attachment grooves formed in the insulating material; and   c. concrete attached to the insulating material by the attachment grooves.   
   
   
       2 . The insulated tilt-up wall panel of  claim 1  wherein the insulating material has substantially the same shape and perimeter as the concrete. 
   
   
       3 . The insulated tilt-up wall panel of  claim 1  wherein the insulating material has substantially the same shape as the concrete and a shorter perimeter than the concrete. 
   
   
       4 . The insulated tilt-up wall panel of  claim 1  wherein the insulating material comprises a plurality of adjacent segments. 
   
   
       5 . The insulated tilt-up wall panel of  claim 4  wherein the insulating material further comprises an insulating filler, attached to the interior surface of the insulating material, which covers a seam between two adjacent segments. 
   
   
       6 . The insulated tilt-up wall panel of  claim 5  wherein the insulating filler is expanding foam glue. 
   
   
       7 . The insulated tilt-up wall panel of  claim 1 wherein the insulating material comprises an interior surface and an exterior surface and the attachment grooves are formed on the interior surface of the insulating material. 
   
   
       8 . The insulated tilt-up wall panel of  claim 7  wherein each attachment groove is narrower at the interior surface of the insulating material than the groove is inside the insulation material. 
   
   
       9 . The insulated tilt-up wall panel of  claim 8 , wherein at least a portion of the attachment groove has a substantially triangular cross section. 
   
   
       10 . The insulated tilt-up wall panel of  claim 1  further comprising a reinforcement structure. 
   
   
       11 . The insulated tilt-up wall panel of  claim 10  wherein the reinforcement structure comprises rebar. 
   
   
       12 . A method of making an insulated tilt-up wall panel, the method comprising:
 a. forming an insulating material into a desired shape;   b. forming one or more attachment grooves in the insulating material;   c. placing the insulating material onto a substantially horizontal casting surface and within a concrete form such that the opening of the attachment grooves faces up; and   d. pouring a desired amount of concrete into the concrete form, wherein the concrete substantially fills the attachment grooves and is attached to the insulating material when it cures.   
   
   
       13 . The method of  claim 12  wherein the insulating material comprises a plurality of segments, and forming the insulating material into a desired shape comprises:
 a. arranging the segments into a desired shape; and   b. attaching each segment to one or more adjacent segments.   
   
   
       14 . The method of  claim 12  further comprising positioning one or more reinforcement structures within the concrete form. 
   
   
       15 . A method of building a structure at a construction site using the tilt-up wall panel of  claim 1 , the method comprising:
 a. placing a plurality of tilt-up wall panels in a desired location such that the exterior surface of the insulating material of each panel is substantially vertical, and each panel forms a joint with at least one other panel;   b. at each joint, permanently attaching the tilt-up wall panels to each other;   c. sealing a seam between the insulating material of adjacent panels; and   d. applying a finishing material to the exterior surfaces of the insulating material of each panel.   
   
   
       16 . The method of  claim 15  further comprising covering each joint with an insulating insert. 
   
   
       17 . The method of  claim 16  wherein permanently attaching the tilt-up wall panels forming the joint to each other comprises welding one or more stainless steel fasteners to one or more stainless steel welding posts protruding from the concrete in each tilt-up wall panel. 
   
   
       18 . A set of insulated tilt-up wall panels for building a residential structure, the set comprising:
 a. a standard panel;   b. a jamb panel;   c. a lintel panel; and   d. a sill panel;   wherein each panel comprises:
 i. an insulating material; 
 ii. one or more attachment grooves formed in the insulating material; and 
 iii. concrete attached to the insulating material by the attachment grooves. 
   
   
   
       19 . The set of insulated tilt-up wall panels of  claim 18  wherein the standard panel, lintel panel, and sill panel are substantially rectangular and the jamb panel is substantially L-shaped. 
   
   
       20 . A method of building a plurality of residential structures using the set of insulated tilt-up wall panels of  claim 19 , the method comprising:
 a. placing a plurality of each of the standard panels, the jamb panels, the lintel panels, and the sill panels in desired locations such that the insulating material of each panel forms a substantially vertical exterior surface, and each panel forms a joint with at least one other panel; and   b. at each joint, permanently attaching the panels to each other.