Method and arrangement for forming precast concrete panels

Abstract

A precast concrete panel is described. The precast concrete panel includes a first layer forming a rear-side of the precast concrete panel, wherein the first layer has concrete with a reinforcement structure, a core having a thermally insulating material, and a second layer forming a front-side of the precast concrete panel, wherein the second layer has fiber reinforced concrete. Further, the first layer, the core, and the second layer are coupled to each other to form the precast concrete panel.

We claim: 
     
         1 . A precast concrete panel comprising:
 a first layer forming a rear-side of the precast concrete panel, wherein the first layer has concrete with a reinforcement structure;   a core having a thermally insulating material; and   a second layer forming a front-side of the precast concrete panel, wherein the second layer has fiber reinforced concrete,
 wherein the first layer, the core, and the second layer are coupled to each other to form the precast concrete panel. 
   
     
     
         2 . The precast concrete panel of  claim 1 , wherein the core is sandwiched between the first layer and the second layer. 
     
     
         3 . The precast concrete panel of  claim 1 , further comprising a load bearing element traversing, at least in part, through the first layer, the core, and the second layer. 
     
     
         4 . The precast concrete panel of  claim 3 , wherein the load bearing element comprises a lattice girder having an upper bar and two lower bars connected through a triangulated framework of lacing members. 
     
     
         5 . The precast concrete panel of  claim 1 , comprising the first layer having concrete with the reinforcement structure, wherein the reinforcement structure includes a single-layer metal mesh. 
     
     
         6 . The precast concrete panel of  claim 1 , comprising the second layer having fiber reinforced concrete, wherein the fiber includes one or more of metal fibers, glass fibers, synthetic fibers, natural fibers, or a combination of these. 
     
     
         7 . The precast concrete panel of  claim 1 , wherein the thermally insulating material includes one or more of polystyrene (EPS), polyurethane foam (PUR), mineral wool, or a combination of these. 
     
     
         8 . The precast concrete panel of  claim 1 , further comprising a connecting member for interconnecting the precast concrete panel to an adjacent precast concrete panel. 
     
     
         9 . The precast concrete panel of  claim 8 , wherein the connecting member is a wire loop that overlaps with another wire loop of the adjacent precast concrete panel to create a hook, wherein a metal rod passes through the hook and locks the precast concrete panel to the adjacent precast concrete panel. 
     
     
         10 . The precast concrete panel of  claim 8 , further comprising a plurality of connecting members along an edge of the precast concrete panel. 
     
     
         11 . The precast concrete panel of  claim 1 , wherein the precast concrete panel includes a first recessed section, at a bottom side of the precast concrete panel, to be used for coupling to a foundation. 
     
     
         12 . The precast concrete panel of  claim 11 , wherein the precast concrete panel includes a second recessed section, at a top side of the precast concrete panel, to be used for coupling to another precast concrete panel. 
     
     
         13 . The precast concrete panel of  claim 1 , wherein the core has a variable thickness throughout a length of the precast concrete panel. 
     
     
         14 . A method of forming a precast concrete panel, the method comprising:
 forming a first layer of the precast concrete panel having concrete with a reinforcement structure, wherein the first layer forms a rear-side of the precast concrete panel;   placing a core having a thermally insulating material on the first layer; and   forming a second layer of the precast concrete panel having fiber reinforced concrete, wherein the second layer forms a front-side of the precast concrete panel,
 wherein the first layer, the core, and the second layer are coupled to each other to form the precast concrete panel. 
   
     
     
         15 . The method of  claim 14 , further comprising:
 adding a load bearing member along with the reinforcement structure, wherein the load bearing element comprises a lattice girder having an upper bar and two lower bars connected through a triangulated framework of lacing members.   
     
     
         16 . The method of  claim 14 , wherein the reinforcement structure comprises a single-layer metal mesh. 
     
     
         17 . The method of  claim 14 , further comprising:
 attaching one or more connecting members to an edge of the precast concrete panel for interconnecting the precast concrete panel to an adjacent precast concrete panel during installation.   
     
     
         18 . The method of  claim 17 , wherein the one or more connecting members is a wire loop that overlaps with another wire loop of the adjacent precast concrete panel to create a hook, wherein a metal rod passes through the hook and locks the precast concrete panel to the adjacent precast concrete panel. 
     
     
         19 . The method of  claim 14 , further comprising:
 forming a first recessed section, at a bottom side of the precast concrete panel, to be used for coupling to a foundation.   
     
     
         20 . The method of  claim 19 , further comprising:
 forming a second recessed section, at a top side of the precast concrete panel, to be used for coupling to another precast concrete panel.