Tilt-up and precast construction panels

Abstract

Improved tilt-up and pre-cast constructions panels and methods for providing the same are disclosed. In some implementations, multi-layered construction panels are provided, were such panels include one or more panel cores. In some cases, the panel core includes a first core body having a first slab of insulating material and a first portion of a grid body, and a second core body having a second slab of insulating material and a second portion of a grid body. In some cases, outside layers of concrete are disposed next to the slabs of insulating material, and a concrete core is disposed between the slabs of insulating material. In some cases, the grid body includes a first outside plane grid mat, a second outside plane grid mat, and an inside plane grid mat, each of which is (in some iterations) embedded in one or more layers of concrete.

What is claimed and desired to be secured by Letters Patent is: 
     
         1 . A construction panel comprising:
 a grid body;   a panel core comprising:
 a first core body comprising:
 a first insulating core; and 
 a first portion of the grid body; 
 
 a second core body comprising:
 a second insulating core; and 
 a second portion of the grid body; 
 
   a first outside layer of concrete disposed proximate to the first insulating core;   a second outside layer of concrete disposed proximate to the second insulating core; and   a concrete core disposed between the first insulating core and the second insulating core,   wherein the grid body comprises
 a first outside grid mat at least partially disposed within the first outside layer of concrete; 
 a second outside grid mat at least partially disposed within the second outside layer of concrete; and 
 a first inside grid mat at least partially disposed within the concrete core, the first inside grid mat being separated from the first outside grid mat and the second outside grid mat by a plurality of spacer wires, the plurality of spacer wires being at least partially embedded in at least one of the first insulating core and the second insulating core. 
   
     
     
         2 . The construction panel of  claim 1 , wherein the grid body further comprises a second inside grid mat at least partially disposed within the concrete core. 
     
     
         3 . The construction panel of  claim 2 , wherein the second inside grid mat is coupled to the first inside grid mat independently of the concrete core. 
     
     
         4 . The construction panel of  claim 2 , wherein the second inside grid mat is in contact with the first inside grid mat. 
     
     
         5 . The construction panel of  claim 2 , wherein the second inside grid mat is separated from the first inside grid mat by a distance. 
     
     
         6 . The construction panel of  claim 1 , wherein each of the plurality of spacer wires is coupled to at least two of the first outside grid mat, the second outside grid mat, and the first inside grid mat. 
     
     
         7 . The construction panel of  claim 6 , wherein each of the plurality of spaces wires is coupled at a non-parallel, non-perpendicular angle to at least one of the first outside grid mat, the second outside grid mat, and the first inside grid mat. 
     
     
         8 . The construction panel of  claim 2 , wherein at least one of the plurality of spacer wires is coupled to both the first inside grid mat and the second inside grid mat. 
     
     
         9 . The construction panel of  claim 1 , wherein each of the first insulating core and the second insulating core comprises an EPS foam. 
     
     
         10 . The construction panel of  claim 1 , wherein a thickness of the first outside layer of concrete is different from a thickness of the second outside layer of concrete. 
     
     
         11 . The construction panel of  claim 1 , wherein each of the first outside grid mat, the second outside grid mat, and the first inside grid mat is spaced apart from each of the first insulating core and the second insulating core. 
     
     
         12 . The construction panel of  claim 1 , further comprising a plurality of construction panel segments joined together at a plurality of segment edges to form the construction panel. 
     
     
         13 . The construction panel of  claim 12 , further comprising a planar splice mat coupled to a first construction panel segment and to a second construction panel segment. 
     
     
         14 . The construction panel of  claim 1 , further comprising a reinforcement component selected from the group consisting of rebar, reinforcement shards, and tension strands. 
     
     
         15 . A construction panel comprising:
 a first layer of concrete;   a first insulating core positioned adjacent to the first layer of concrete;   a second layer of concrete positioned adjacent to the first insulating core;   a second insulating core positioned adjacent to the second layer of concrete;   a third layer of concrete positioned adjacent to the second insulating core; and   a grid body embedded in the first layer of concrete, the first insulating core, the second layer of concrete, the second insulating core, and the third layer of concrete.   
     
     
         16 . The construction panel of  claim 15 , further comprising a reinforcement component selected from the group consisting of rebar, a reinforcement shard, and a tension strand. 
     
     
         17 . The construction panel of  claim 16 , wherein the reinforcement component comprises the tension strand, and wherein the tension strand passes through the first layer of concrete, the second layer of concrete, and the third layer of concrete. 
     
     
         18 . A method of providing a construction panel comprising:
 a first layer of concrete;   a first insulating core positioned adjacent to the first layer of concrete;   a second layer of concrete positioned adjacent to the first insulating core;   a second insulating core positioned adjacent to the second layer of concrete;   a third layer of concrete positioned adjacent to the second insulating core; and   a grid body embedded in the first layer of concrete, the first insulating core, the second layer of concrete, the second insulating core, and the third layer of concrete,   the method comprising:
 building a form defining a perimeter of the construction panel; 
 pouring the first layer of concrete into the form; 
 laying the first insulating core on the first layer of concrete before the first layer of concrete sets, ensuring that a first portion of the grid body coupled to the first insulating core becomes embedded in the first layer of concrete; 
 pouring the second layer of concrete into the form over the first insulating core; 
 laying the second insulating core on the second layer of concrete before the second layer of concrete sets, ensuring that a second portion of the grid body coupled to the second insulating core becomes embedded in the second layer of concrete; 
 pouring the third layer of concrete over the second insulating core; and 
 allowing each of the first layer of concrete, the second layer of concrete, and the third layer of concrete to cure. 
   
     
     
         19 . The method of  claim 18 , further comprising:
 attaching a lifting attaching point to the construction panel such that it becomes partially embedded in at least one of the first layer of concrete and the third layer of concrete; and   after the first layer of concrete, the second layer of concrete, and the third layer of concrete have each cured, attaching a lifting machine to the lifting attachment point and lifting the construction panel into a vertical position.   
     
     
         20 . The method of  claim 18 , wherein a thickness of the first layer of concrete is different from a thickness of the second layer of concrete.