Composite insulated precast and tilt-up concrete structures

• US 8,745,943 B2
• Filed: 09/30/2013
• Issued: 06/10/2014
• Est. Priority Date: 09/28/2011
• Status: Expired due to Fees

• 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:
  US14/040,977
• Publication Number:
  US 20140041329A1
• Time in Patent Office: 253 Days
• Field of Search: 523094-30912, 524/15, 524/18, 524/19, 524/26, 524/31, 524/32, 524/38, 524/42
• 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 foam insulating panel having a first primary surface and a 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 terminating in a portion configured to receive and retain a concrete reinforcing member;

a first flange formed on the elongate anchor member intermediate the first and second ends of the elongate anchor member; and

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

2. The product of claim 1 further comprising a second flange on the second portion of the elongate anchor member adjacent the portion configured to receive a reinforcing member.

3. The product of claim 1 further comprising a layer of reinforcing material disposed on the second primary surface of the foam insulating panel and at least a portion of the layer of reinforcing material is disposed between the cap member and the second primary surface of the foam insulating panel.

4. The product of claim 3 wherein the layer of reinforcing material is attached to the second primary surface of the foam insulating panel.

5. The product of claim 1 further comprising an elastomeric membrane coating on the second primary surface of the foam insulating panel.

6. The product of claim 1, wherein the portion configured to receive a concrete reinforcing member comprises a U-shaped portion.

7. The product of claim 1, wherein the portion configured to receive a concrete reinforcing member comprises a rebar chair.

8. The product of claim 1, wherein the portion configured to receive a concrete reinforcing member comprises a clamping member to receive and retain a rebar member.

9. The product of claim 1 further comprising a layer of cementitious material disposed on the first primary surface of the foam insulating panel such that the portion of the elongate anchor member configured to receive a concrete reinforcing member is disposed within the layer of cementitious material.

10. The product of claim 1 further comprising an exterior wall cladding material disposed on the second primary surface of the foam insulating panel.

11. The product of claim 9 further comprising an exterior wall cladding material disposed on the second primary surface of the foam insulating panel.

12. The product of claim 11, wherein the exterior wall cladding material comprises metal panels, wood siding, composite siding, stone panels, stucco, brick or thin brick.

13. A product comprising:

a foam insulating panel having a first primary surface and a 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 terminating in a portion configured to receive and retain a concrete reinforcing member;

a flange adjacent the first end of the elongate anchor member and contacting the second primary surface of the foam insulating panel.

14. The product of claim 13 further comprising a layer of reinforcing material disposed on the second primary surface of the foam insulating panel and at least a portion of the layer of reinforcing material is disposed between the flange and the second primary surface of the foam insulating panel.

15. The product of claim 14 wherein the layer of reinforcing material is attached to the second primary surface of the foam insulating panel.

16. The product of claim 13 further comprising an elastomeric membrane coating on the second primary surface of the foam insulating panel.

17. The product of claim 13, wherein the portion configured to receive a concrete reinforcing member comprises a U-shaped portion.

18. The product of claim 13, wherein the portion configured to receive a concrete reinforcing member comprises a rebar chair.

19. The product of claim 13, wherein the portion configured to receive a concrete reinforcing member comprises a clamping member to receive and retain a rebar member.

20. The product of claim 13 further comprising a layer of cementitious material disposed on the first primary surface of the foam insulating panel such that the portion of the elongate anchor member configured to receive a concrete reinforcing member is disposed within the layer of cementitious material.

21. The product of claim 13 further comprising an exterior wall cladding material disposed on the second primary surface of the foam insulating panel.

22. The product of claim 20 further comprising an exterior wall cladding material disposed on the second primary surface of the foam insulating panel.

23. The product of claim 22, wherein the exterior wall cladding material comprises metal panels, wood siding, composite siding, stone panels, stucco, brick or thin brick.

24. A product comprising:

a foam insulating panel having a first primary surface and a 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 terminating in a means for receiving and retaining a concrete reinforcing member;

a flange adjacent the first end of the elongate anchor member and contacting the second primary surface of the foam insulating panel.