Precast concrete structures, precast tilt-up concrete structures and methods of making same

• US 8,555,584 B2
• Filed: 09/28/2011
• Issued: 10/15/2013
• Est. Priority Date: 09/28/2011
• Status: Active Grant

• Current Assignee: Romeo Ilarian Ciuperca
• Original Assignee: Romeo Ilarian Ciuperca
• Inventors: Ciuperca, Romeo Ilarian
• Primary Examiner(s): Gilbert, William
• Assistant Examiner(s): FORD, GISELE D
• Application Number:
  US13/247,256
• Publication Number:
  US 20130074433A1
• Time in Patent Office: 748 Days
• Field of Search: 523094-30912
• US Class Current: 52/309.7
• CPC Class Codes: E04B 1/14 the elements being composed of two or more materials of reinforced concrete E04B1/04
• CPC Class Codes: E04B 1/355 characterised by the tilting up of whole buildings or sections thereof, e.g. walls, portal frames
• CPC Class Codes: E04B 1/41 Connecting devices specially adapted for embedding in concrete or masonry joist hangers E04B1/2612; shear dowels E04B1/483; spacers other than masonry wall ties for cavity walls E04B2/30, E04B2/44; connectors for reinforcing elements E04C5/16; fastening frames to the border of openings E06B1/56
• CPC Class Codes: E04B 2/8647 with ties going through the forms
• CPC Class Codes: E04B 2103/02 of ceramics, concrete or other stone-like material
• CPC Class Codes: E04C 2/044 of concrete E04C2/049 takes precedence
• CPC Class Codes: E04C 2/06 reinforced
• CPC Class Codes: E04C 2/205 of foamed plastics, or of plastics and foamed plastics, optionally reinforced
• CPC Class Codes: E04C 2/22 reinforced E04C2/205 takes precedence
• CPC Class Codes: E04C 2/243 one at least of the material being insulating
• CPC Class Codes: E04C 2/288 composed of insulating material and concrete, stone or stone-like material
• CPC Class Codes: E04F 13/045 Means for fastening plaster-bases to a supporting structure
• CPC Class Codes: E04F 13/077 composed of several layers, e.g. sandwich panels E04F13/075 takes precedencenot used, see E04F13/0866
• CPC Class Codes: E04F 13/0803 with load-supporting elongated furring elements between wall and covering elements
• CPC Class Codes: E04F 13/0873 the visible surface imitating natural stone, brick work, tiled surface or the like E04F13/105, E04F13/123, E04F13/147, E04F13/165, E04F13/185 take precedence
• CPC Class Codes: E04G 21/16 Tools or apparatus devices for erecting fences E04H17/26
• CPC Class Codes: E04G 21/165 specially adapted for in situ prefabricated building elements to be tilted up in position
• CPC Class Codes: Y10T 428/24926 including ceramic, glass, porcelain or quartz layer

Abstract

The invention comprises a method of forming a concrete structure. The method comprises placing plastic concrete in a form of a desired shape, encasing the concrete in insulating material having insulating properties equivalent to at least 1 inch of expanded polystyrene and allowing the plastic concrete to at least partially cure inside the insulating material. An insulated concrete form and a method of using the insulated concrete form are also disclosed.

Claims

1. A product comprising:

a rectangular foam panel, the panel having a first primary surface and a second primary surface;

a layer of cementitious material disposed on the first primary surface of the foam panel, the layer of cementitious material having a first primary surface and an opposite second primary surface;

an elongate anchor member having a first end and an opposite second end, a first portion of the anchor member penetrating the foam panel from the first primary surface to the second primary surface, a second portion of the anchor member extending outwardly from the first primary surface of the foam panel and the second end terminating intermediate the first and second primary surfaces of the layer of cementitious material;

a first flange formed on the elongate anchor member intermediate the ends thereof, the first flange contacting the first primary surface of the foam panel;

a locking cap attached to the first end of the anchor member and contacting the second primary surface of the foam panel, such that the foam panel is captured between the first flange and the locking cap.

2. The product of claim 1, wherein the second end of the anchor member comprises a second flange.

3. The product of claim 2, wherein the second end of the anchor member further comprises a clamping member for receiving and retaining an elongate reinforcing member.

4. The product of claim 1, wherein the locking cap can be received on the first end of the elongate anchor member but cannot be removed therefrom.

5. The product of claim 1 further comprising a layer of reinforcing material disposed on the second surface of the foam panel so that at least a portion of the layer of reinforcing material is disposed between the locking cap and the second surface of the foam panel.

6. The product of claim 5, wherein the layer of reinforcing material is a continuous material or a discontinuous material.

7. The product of claim 5, wherein the layer of reinforcing material is a sheet or a film.

8. The product of claim 5, wherein the layer of reinforcing material is a fabric, a mesh or a web.

9. The product of claim 5, wherein the layer of reinforcing material is made from a polymeric material.

10. The product of claim 5, wherein the layer of reinforcing material is made from polyethylene or polypropylene.

11. The product of claim 5, wherein the layer of reinforcing material is made from fibers.

12. The product of claim 5, wherein the layer of reinforcing material is made from fiberglass, basalt fibers, aramid fibers or carbon fibers.

13. The product of claim 5, wherein the layer of reinforcing material is made from a metal sheet or a metal foil.

14. The product of claim 5 further comprising a waterproof coating on the second primary surface of the foam panel.

15. A product comprising:

a quantity of at least partially cured concrete, the concrete having a first primary surface and an opposite second primary surface;

a first enlarged portion of each of a plurality of elongate anchor members embedded in the at least partially cured concrete intermediate the first and second primary surfaces, wherein each of the plurality of anchor members terminates intermediate the first and second primary surfaces of the quantity of at least partially cured concrete;

a second portion of each of the plurality of elongate anchor members extending outwardly from a first primary surface of the concrete and penetrating a foam insulating panel disposed on the first primary surface of the concrete; and

a cap member attached to the second portion of each of the plurality of elongate anchor members, such that the foam insulating panel is captured between the first primary surface of the concrete and the cap member.

16. The product of claim 15 further comprising a layer of reinforcing material disposed on a surface of the foam insulating panel opposite the concrete and at least partially disposed between the cap member and the surface of the foam insulating panel.

17. The product of claim 16 wherein the layer of reinforcing material is attached to the surface of the foam insulating panel opposite the concrete.

18. The product of claim 15 further comprising a brick tie attached to the second portion of at least one of the plurality of elongate anchor members, a portion of the brick tie extending outwardly from the foam insulating panel and being embedded in mortar between adjacent rows of brick.

19. The product of claim 15 further comprising a layer of an exterior wall finish on a surface of the foam insulating panel opposite the concrete.

20. The product of claim 16 further comprising thin brick adhesively attached to a surface of the foam insulating panel opposite the concrete.

21. A product comprising:

a foam insulating panel, the panel having a first primary surface and a second primary surface;

a layer of cementitious material disposed on the first primary surface of the foam insulating panel, the layer of cementitious material having a first primary surface and an opposite second prima surface;

an elongate anchor member having a first end, an opposite second end, a first enlarged portion adjacent the first end, and a second enlarged portion adjacent the second end, a first portion of the anchor member penetrating the foam insulating panel from the first surface to the second surface, a second portion of the anchor member extending outwardly from the first surface of the foam insulating panel and the second end terminating intermediate the first and second primary surfaces of the layer of cementitious material and the second enlarged portion disposed within the layer of cementitious material; and

a layer of reinforcing material attached to the second surface of the foam insulating panel such that the layer of reinforcing material is at least partially disposed between the second surface of the foam insulating panel and the enlarged portion of the anchor member.

22. The product of claim 21, wherein the first enlarged portion of the anchor member comprises a cap member selectively attachable to the first portion of the anchor member.

23. The product of claim 21, wherein the layer of reinforcing material is a continuous material or a discontinuous material.

24. The product of claim 21, wherein the layer of reinforcing material is a sheet or a film.

25. The product of claim 21, wherein the layer of reinforcing material is a fabric, a mesh or a web.

26. The product of claim 21, wherein the layer of reinforcing material is made from a polymeric material.

27. The product of claim 21, wherein the layer of reinforcing material is made from polyethylene or polypropylene.

28. The product of claim 21, wherein the layer of reinforcing material is made from fibers.

29. The product of claim 21, wherein the layer of reinforcing material is made from fiberglass, basalt fibers, aramid fibers or carbon fibers.

30. The product of claim 21, wherein the layer of reinforcing material is made from a metal sheet or a metal foil.

31. The product of claim 21, wherein the foam insulating panel has insulating properties equivalent to at least 1 inch of expanded polystyrene.

32. The product of claim 21, wherein the foam insulating panel comprises polystyrene foam, polyisocyanurate foam or polyurethane foam.