Method of Fabricating Integrally Insulated Concrete Wall or Wall Components

Abstract

A method for forming integrally insulated concrete sandwich walls or wall components is disclosed. The walls are fabricated by casting the walls vertically and pumping the concrete from the bottom of the form or from sides near the base. Walls fabricated thus can be used in commercial, industrial, residential, and agricultural buildings. These walls can be cast on-site or in a manufacturing plant.

1 . A method of fabricating a section of an integrally insulated concrete sandwich wall component in a plant or on-site, comprising the steps of:
 (a) providing a form having a bottom panel, a pair of upright, opposing side panels and insulation supported between the side panels;   (b) providing an opening in or near the bottom of the form; and   (c) introducing plastic concrete into the form through the opening.   
   
   
       2 . The method of  claim 1 , further comprising a second opening in or near the bottom of the form and introducing the plastic concrete into the form simultaneously through both openings. 
   
   
       3 . The method of  claim 2 , wherein plastic concrete of a first type is introduced into the form through the first opening and plastic concrete of a second type is introduced into the form through the second opening. 
   
   
       4 . The method of  claim 3 , wherein the first type of concrete is a different color than the second type of concrete. 
   
   
       5 . The method of  claim 3 , wherein the first type of concrete has a different aggregate composition than the second type of concrete. 
   
   
       6 . The method of  claim 3 , wherein the first type of concrete forms substantially against a first of the upright panels and the second type of concrete forms substantially against the second of the upright panels. 
   
   
       7 . The method of  claim 1 , further comprising the step of sealing the form and producing a vacuum in the form to assist in introducing the concrete into the form. 
   
   
       8 . The method of  claim 1 , wherein the plastic concrete is introduced from a pressurized hopper. 
   
   
       9 . The method of  claim 8 , wherein the pressure is produced by a pressurized fluid. 
   
   
       10 . The method of  claim 1 , wherein the two side panels have textures on their interior surfaces that are different from each other.