US20250347111A1

US20250347111A1 - Method and arrangement for forming precast concrete panels

Info

Publication number: US20250347111A1
Application number: US18/658,620
Authority: US
Inventors: Thulasilingam Mahendran; Pratheep Kumar Rajendran; Mc Gil Domingo Agcaoili
Original assignee: Onx Inc
Current assignee: Onx Inc
Priority date: 2024-05-08
Filing date: 2024-05-08
Publication date: 2025-11-13
Also published as: WO2025235134A1

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.

Description

FIELD OF THE INVENTION

The present disclosure generally relates to construction technology. In particular, the present disclosure relates to a method and an arrangement for forming and/or constructing precast concrete structures, such as, precast concrete panels for use in construction technology.

BACKGROUND OF THE INVENTION

Existing construction technologies involve one-off (e.g., customized) build-on site approaches in which construction material is brought to the construction site where the actual construction is performed. This has been the traditional methodology and approach for many years but has certain inherent challenges, including non-availability of skilled workforce (e.g., manual labor), heavy and expensive on-site machinery, incorrect estimate of completion time of construction projects, delays in delivery of projects, inclement weather, poor quality and wastage of materials, noise and air pollution, and cost involved in disposal of debris. This approach is also “one-off” as it provides no repeatability or scalability leverage. Each building is constructed, and each project is performed differently, and results vary widely, which may be undesirable considering present day demand for symmetrical construction projects with enhanced look and feel. However, constructing or casting each individual component of a building on site incurs significant expenditures in time and resources. It also increases a project's vulnerability to unforeseen factors, such as poor weather, worksite accidents, improper pour, etc.
In order to address the aforesaid shortfalls of such build or cast-on site approaches, some construction projects use precast modules. Examples of the precast modules may include wall panels, that are built in factories under factory scaling, repeatability, and in-factory conditions.
Moreover, the problem of thermal insulation in buildings has been a persistent issue, leading to energy inefficiency and discomfort for occupants. The need for improved insulation arises from traditional construction materials and methods that often fail to provide adequate thermal performance and strength to the building. Addressing this problem is crucial to enhance energy efficiency, reduce heating and cooling costs, and create more comfortable living and working environments along with increasing the structural strength.
Accordingly, there is a need for technical solutions that address the needs described above, as well as other inefficiencies of the state of the art. Specifically, there is a need in the art for a precast structure that meets thermal insulation and structural strength requirements.

SUMMARY OF THE INVENTION

Embodiments for a method and arrangement for forming precast concrete panels for construction projects are disclosed that address at least some of the above challenges and issues.
The following represents a summary of some embodiments of the present disclosure to provide a basic understanding of various aspects of the disclosed herein. This summary is not an extensive overview of the present disclosure. It is not intended to identify key or critical elements of the present disclosure or to delineate the scope of the present disclosure. Its sole purpose is to present some embodiments of the present disclosure in a simplified form as a prelude to the more detailed description that is presented below.
In an aspect, the present disclosure is directed to a precast concrete panel. The precast concrete panel comprises 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.
In some embodiments of the present disclosure, the core is sandwiched between the first layer and the second layer.
In some embodiments of the present disclosure, the precast concrete panel further includes a load bearing element traversing, at least in part, through the first layer, the core, and the second layer. In some embodiments, the load bearing element comprises a lattice girder having an upper bar and two lower bars connected through a triangulated framework of lacing members.
In some embodiments of the present disclosure, the reinforcement structure includes a single-layer metal mesh.
In some embodiments of the present disclosure, the fiber includes one or more of metal fibers, glass fibers, synthetic fibers, and natural fibers.
In some embodiments of the present disclosure, the thermally insulating material comprises one or more of polystyrene (EPS), polyurethane foam (PUR), and mineral wool.
In some embodiments of the present disclosure, the precast concrete panel further includes a connecting member for interconnecting the precast concrete panel to an adjacent precast concrete panel. In some embodiments, 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. In some embodiments, the precast concrete panel includes a plurality of connecting members along an edge of the precast concrete panel.
In some embodiments of the present disclosure, the precast concrete panel includes a first recessed section at a bottom side of the precast concrete panel for coupling to a foundation. In some embodiments, the precast concrete panel includes a second recessed section at a top side of the precast concrete panel for coupling to another precast concrete panel.
In some embodiments of the present disclosure, the core has a variable thickness throughout the length of the precast concrete panel.
In an aspect, the present disclosure is directed to a method of forming precast concrete panels. The method includes forming a first layer of the precast concrete panel using concrete with a reinforcement structure, wherein the first layer forms a rear-side of the precast concrete panel; placing a core comprising 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.
In some embodiments of the present disclosure, the method further includes 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.
In some embodiments of the present disclosure, the reinforcement structure comprises a single-layer metal mesh.
In some embodiments of the present disclosure, the method further includes 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. In some embodiments, 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.
In some embodiments of the present disclosure, the method further includes forming a first recessed section at a bottom side of the precast concrete panel for coupling to a foundation. In some embodiments, the method further includes forming a second recessed section at a top side of the precast concrete panel for coupling to another precast concrete panel.
The above summary is provided merely for the purpose of summarizing some example embodiments to provide a basic understanding of some aspects of the disclosure. Accordingly, it will be appreciated that the above-described embodiments are merely examples and should not be construed to narrow the scope or spirit of the disclosure in any way. It will be appreciated that the scope of the disclosure encompasses many potential embodiments in addition to those here summarized, some of which will be further described below.

BRIEF DESCRIPTION OF THE DRAWINGS

Further advantages of the disclosure will become apparent by reference to the detailed description of preferred embodiments when considered in conjunction with the drawings. In the drawings, identical numbers refer to the same or a similar element.

FIG. 1A is a detailed view of a precast concrete panel, in accordance with some embodiments.

FIG. 1B is a three-dimensional perspective view of the precast concrete panel, in accordance with some embodiments.

FIG. 2A is another detailed view of the precast concrete panel, in accordance with some embodiments.

FIG. 2B is a perspective view of a load bearing element, in accordance with some embodiments.

FIG. 3 is a perspective view of a connecting member interconnecting the precast concrete panel to an adjacent precast concrete panel, in accordance with embodiments of the present disclosure.

FIG. 4 is a three-dimensional perspective view of a building structure employing the precast concrete panel, in accordance with some embodiments.

FIG. 5 illustrates steps of a method of forming the precast concrete panels, in accordance with some embodiments of the present disclosure.

DETAILED DESCRIPTION

The following detailed description is presented to enable any person skilled in the art to make and use the disclosure. For purposes of explanation, specific details are set forth to provide a thorough understanding of the present disclosure. However, it will be apparent to one skilled in the art that these specific details are not required to practice the disclosure. Descriptions of specific applications are provided only as representative examples. Various modifications to the preferred embodiments will be readily apparent to one skilled in the art, and the general principles defined herein may be applied to other embodiments and applications without departing from the scope of the disclosure. The present disclosure is not intended to be limited to the embodiments shown but is to be accorded the widest possible scope consistent with the principles and features disclosed herein.
With modernization in construction-related methodologies and technologies, there has been a rapid shift from normal customized build on-site construction methodologies to construction using modules or blocks that are able to be built off-site and then assembled on-site to form a construction or a building. Further, as discussed above, there is a need for improved thermal insulation in buildings and for improved structural strength of the building.
The prevailing solutions to address the problem of insulation in buildings or building components, such as, walls, while also strengthening the wall typically involve a combination of thermal insulation and structural enhancement. These solutions aim to improve energy efficiency, indoor comfort, and structural integrity, but have associated challenges. For example, one solution is to add insulation material to the exterior of the wall, however, this might alter the building's appearance. Further, proper installation is crucial to moisture retention or interstitial condensation. Another approach is to add insulation to the interior surface of the wall. However, this may reduce the room's internal space, and may require thermal bridging at junctions with other walls and elements. In conclusion, the problem of thermal insulation in buildings has been a persistent issue, leading to energy inefficiency and discomfort for occupants. The need for improved insulation, that also provides structural strength while maximizing room space, arises from traditional construction materials and methods that often fail to provide adequate thermal performance and strength to the building. Addressing this problem is crucial to enhance energy efficiency, reduce heating and cooling costs, and create more comfortable living and working environments along with increasing the structural strength.
The presently claimed invention aims to provide a solution by integrating insulation technology into precast building structures, thereby enhancing thermal performance, reducing energy consumption, providing the structural strength requirement for resisting the wind loads of hurricane zones, and maximizing available indoor living space.
Certain terms and phrases have been used throughout the disclosure and will have the following meanings in the context of the ongoing disclosure.
“Cast-in-place concrete” or “Cast-in-situ concrete” is a building-construction technology where elements of a building structure are cast at the site in formwork.
“Precast structure” refers to a construction product produced by casting concrete in a reusable mold or form which is then cured in a controlled environment at an offsite location, transported to a construction site, and maneuvered into a targeted place. Examples include precast beams, slabs, wall panels, and the like.
“Wall panel” refers to a prefabricated multi-layered wall fabricated at an offsite location and installed on-site, wherein “on-site” denotes a construction site and “offsite” denotes allocation away from the construction site. The wall panel is able to be with or without door or window opening based on the design of the building structure.
“Slab” refers to a prefabricated structure at an offsite location and installed on-site. The slab includes a concrete base and a structural topping. The structural toppings, also referred to as topping screeds, are specialized materials applied to existing concrete base of the slab to enhance performance, durability, and aesthetic.
“Beam” refers to a construction element that is made by casting concrete into a mold and then curing it in a controlled environment at the offsite location. Beams are able to be used for both load-bearing and non-load bearing applications and be made in a variety of shapes and sizes.
“Foundation” refers to a monolithic cast-in-place foundation that is poured in one piece, typically 4-6 inches thick. It is commonly used in areas with shallow soil frost depths and is known for its durability and efficiency.
“Grout” is a filling, which when poured into a receptacle will fill in the receptacle and consolidate the adjacent edges into a solid mass, such as cementitious mortar or other cement-based materials, bentonite, bentonite/sand mixtures, graphite-based materials, carbon nanotubes and nanofibers, or similar materials.
“Sealant” refers to substances used to seal, block, or close gaps between various modules of the building structure to prevent fluids, air, and pests from passing through. These materials seal joints where dissimilar materials meet and filling any irregularities that may exist between the two surfaces.
In accordance with the embodiments of the disclosure, a precast concrete panel is disclosed. 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 comprising 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.
The embodiments of the disclosure are described in more detail with reference to FIGS. 1-5 .
FIG. 1A is a detailed view of the precast concrete panel 100, in accordance with some embodiments. As shown in FIG. 1A, the precast concrete panel 100 includes a first layer 102, a core 104, and a second layer 106, such that the first layer 102, the core 104, and the second layer 106 are coupled together to form the precast concrete panel 100. Specifically, the core 104 is sandwiched between the first layer 102 and the second layer 106.
Further, as shown in FIG. 1A, the first layer 102 forms a rear-side of the precast concrete panel 100. In some embodiments, the first layer 102 is an inner or interior layer of the precast concrete panel when it is installed in a building. The second layer 106 forms a front side of the precast concrete panel 100. In some embodiments, the second layer 106 is an outer or exterior layer of the precast concrete panel when it is installed in a building. However, it should be noted that the disclosure is not limited to the above, and the placement of the first and the second layers is able to be interchanged without departing from the scope of the current disclosure.
In accordance with some embodiments, the first layer 102 is made of concrete reinforced with a reinforcement structure 108, as shown in FIG. 1A. In some embodiments, the reinforcement structure 108 is a single-layer metal mesh or any other similar reinforcement structure or material. The reinforcement structure 108 provides the structural strength to the first layer 102 to handle subjected load or stress when installed.
In some embodiments, the reinforcement structure 108 is made from a grid or mesh of steel bars. These bars are typically arranged in both horizontal and vertical directions, creating a network within a concrete element. This enhances the structural integrity and durability of a precast structure. The mesh design ensures a uniform distribution of reinforcing material throughout the concrete element, providing strength in multiple directions. Further, mesh rebar is often prefabricated into large sheets or rolls, making it convenient to transport and handle during the precast manufacturing process. In some embodiments, the reinforcement structure 108 or the single-layer metal mesh is embedded within the first layer 102 during the casting process. This reinforcement adds tensile strength to the first layer 102, helping it withstand stresses and prevent cracking. The reinforcement structure 108 is able to be available in various sizes and configurations to suit different applications and structural requirements. For example, the mesh size and bar diameter is able to be customized based on the specific needs of the precast element.
For forming the reinforcement structure 108, such as a single-layer steel mesh, an appropriate material is able to be selected, which is typically high-quality steel. This steel is able to be either carbon steel or a type of alloy with properties that make it suitable for reinforcement applications. The steel is then processed through a rolling mill or welding equipment. In the case of rolled mesh, the steel is fed through a series of rollers that shape and form it into the desired grid pattern. For welded mesh, individual steel bars are welded together at their intersections to create the mesh structure. In some embodiments, the mesh then undergoes surface treatment processes such as galvanization to enhance its corrosion resistance. Galvanization involves coating the mesh with a layer of zinc, protecting it from rust and corrosion over time. Once the mesh is formed, it is cut to the required size and shape. This step allows manufacturers to produce mesh rebar in various configurations and dimensions to meet specific project requirements.
The core 104 has a thermally insulating material and is responsible for thermal insulation of the precast concrete panel. These materials have insulating properties and help to minimize heat transfer through the precast concrete panel. Further, as shown in FIG. 1A, the core 104 is able to have a variable thickness throughout the length of the precast concrete panel based on structural, thermal, and/or design requirements. For example, variable thickness in the core 104 is able to be designed to optimize the structural and thermal performance of the precast concrete panel. The variability in thickness allows for strategic placement of insulating materials to enhance the precast concrete panel's overall efficiency. Thicker portions provide better structural support, while thinner sections focus on insulation, resulting in a precast concrete panel that meets both structural and thermal requirements effectively.
Further, the core 104 is able to have different shapes, such as a L-shape, for specific structural and/or functional purposes. Variations in core shapes are able to influence the distribution of materials within the precast concrete panel, optimizing insulation and thermal performance. The choice of a specific core shape is typically based on a combination of structural requirements, architectural considerations, and the desired thermal properties of the precast concrete panel. For example, the L-shape of the core 104 provides added stability and strength, making it suitable for load-bearing applications. In some embodiments, the core 104 is placed and/or poured over the first layer 102 when forming the precast concrete panel.
In some embodiments, the core 104 is made of materials, such as, but not limited to, expanded polystyrene (EPS), polyurethane foam (PUR), or mineral wool. EPS is a lightweight, closed-cell insulation material. EPS cores are known for their good insulation properties and are commonly used in construction for energy-efficient buildings. Polyurethane (PUR) or Polyisocyanurate (PIR) are foam insulation materials with excellent thermal performance. They offer high insulation values, making them effective choices for the insulating core of sandwich wall panels. These materials contribute to energy efficiency and temperature regulation in buildings. Mineral wool is a fibrous insulation material made from natural or synthetic minerals. Mineral wool provides both thermal and acoustic insulation. When used as the core in sandwich wall panels, mineral wool enhances fire resistance and sound absorption properties.
The primary function of the core 104 is to provide thermal insulation to the precast concrete panel 100. This helps regulate indoor temperatures, improving energy efficiency by reducing heating or cooling requirements. By minimizing heat transfer through the wall, the insulating core enhances the overall energy efficiency of the building. This is crucial for maintaining comfortable interior temperatures and reducing reliance on mechanical heating or cooling systems. The core 104 is also able to offer resistance to moisture by helping prevent water infiltration, reducing the risk of mold growth and maintaining the structural integrity of the wall panel. In some embodiments, the core 104 contributes to the fire resistance of the precast concrete panel. This is especially important for meeting building safety standards and providing occupants with additional time for evacuation in case of a fire. Further, in some embodiments, the core 104 contributes to the sound insulation properties of the precast concrete panel. This is beneficial for creating acoustically comfortable indoor environments by reducing noise transmission.
In accordance with some embodiments, the second layer 106 includes concrete reinforced with fiber or fiber reinforced concrete (FRC). That is, concrete is mixed with suitable fibers to increase the toughness and durability of the second layer. Non-reinforced concrete is likely to break down when it fractures and cracks, concrete reinforced with fiber will maintain its structural integrity, as it is held together by the fibers when a crack develops. Fiber reinforced concrete is able to be a composite material comprising mixtures of concrete combined with continuous or discontinuous, uniformly, or non-uniformly dispersed fibers. In some embodiments, the fibers include one or more of metal fibers, glass fibers, synthetic fibers, and natural fibers. Most commonly used metal fibers are steel fibers. These fibers, typically, are in round shape. In some embodiments, the diameter of the fiber is in the range of 0.25 to 0.75 mm. The steel fibers are also able to include round crimped steel fiber, melt-extract stainless steel, hooked-end steel fiber, glued steel fiber, and flat-end fiber. Further, glass fiber is a versatile type of fiber that is widely employed in the composite industry because of its excellent strength-to-weight ratio while being less stiff than other reinforcing fibers. Glass fibers are readily available in the forms of chopped strands, direct draw roving, assembled roving, mats, and so on.
Another example of the fibers that are able to be used are synthetic fibers that are made from synthesized polymers of small molecules. The compounds that are used to make these synthetic fibers come from raw materials such as petroleum-based chemicals or petrochemicals. These materials are polymerized into a chemical that bonds two adjacent carbon atoms. Differing chemical compounds are used to produce different types of synthetic fibers. Some examples of synthetic fibers include, but are not limited to, acrylic, aramid, carbon, nylon, polyester, polyethylene and polypropylene. Typically, they are categorized as micro and macro synthetic fibers for reinforcement of concrete. Micro-fiber concrete with polypropylene fibers is mainly used to reduce plastic shrinkage in fresh concrete. The micro-fiber concrete also improves the fire resistance behavior of concrete structures at very high temperatures. Addition of micro-fibers in the concrete ensures that as these fibers melt, they create open channels in the concrete pore structure which allows the built-up vapors to escape, thereby releasing the internal pressures and preventing the spalling. Macro-fiber concrete with polypropylene fibers is mainly used in lightly loaded applications to improve the concrete in terms of their crack behavior and to improve the resistance against the thermal shrinkage process. Further, macro synthetic fibers do not corrode. Hence, no rusty spots appear at the surface.
Natural fibers are also able to be used to reinforce concrete. For example, wood fibers, jute, hast fibers including hemp, flax, and ramie are able to be used as natural fiber reinforcement to concrete. Other examples that are able to be used are leaf fibers, such as, sisal, seed and fruit fibers, such as, coconut or coir, etc. Natural fibers are also able to be derived from palm trees, bamboo plants, and sugarcane.
In some embodiments, different types of fibers are mixed to form a customized fiber reinforcement for concrete. For example, blends of both steel and polymeric fibers are able to be used in order to combine the benefits of both products. Further, the distribution, orientation, and density of these fibers impact the properties of the resulting concrete. The amount of fibers added, measured as a percentage of the total volume, termed volume fraction (Vf), is able to range depending on the required tensile strength of the precast structure and/or building design requirements. The aspect ratio (l/d) of the fiber influences the flexural strength and toughness of the matrix. For example, microfibers exhibit better impact resistance compared to longer fibers.
Thus, concrete reinforced with fiber increases tensile strength, reduces voids, enhances durability, resists creep, ensures compatibility under thermal stresses, and acts as a crack arrester, substantially improving static and dynamic properties of the second layer 106 of the precast concrete panel 100, without having to incorporate a rebar or any reinforcement structure. This makes the second layer 106 substantially less thick than the first layer 102, thereby maximizing overall room space in a building. For example, in a scenario, the first layer 102 is able to be 4 inches thick including the single-layer metal mesh as the reinforcement structure, and the second layer 106 is able to be 2 inches thick with fiber reinforced concrete.
As shown in FIG. 1A, in some embodiments, the precast concrete panel 100 further includes a load bearing element 110. In some embodiments, the load bearing element 110 traverses, at least in part, through the first layer 102, the core 104, and the second layer 106, as shown. Thus, the load bearing element 110 is able to also assist in joining and/or bonding the three layers of the precast concrete panel 100 together. In some embodiments, the load bearing element 110 includes a lattice girder having an upper bar and two lower bars coupled through a triangulated framework of lacing. This will be discussed further with reference to FIG. 2B.
In some embodiments, the precast concrete panel 100 also includes a connecting member for interconnecting the precast concrete panel to an adjacent precast concrete panel. As shown in FIG. 1A, in some embodiments, the connecting member is a wire loop 112 extending from an edge of the precast concrete panel. In some embodiments, a plurality of such connecting members are able to be mounted along an edge of the precast concrete panel depending on the size and/or weight of the interlocking concrete panels. In some embodiments, the wire loop 112 overlaps with another wire loop of the adjacent precast concrete panel to create a hook, and a metal rod passes through the hook locking the precast concrete panel to the adjacent precast concrete panel. This will be discussed further with reference to FIG. 3 .
FIG. 1B is a three-dimensional perspective view of the precast concrete panel 100, in accordance with some embodiments. As shown in FIG. 1B, the precast concrete panel 100 includes a first layer 102 and a second layer 106, such that the first layer 102, the core (not shown), and the second layer 106 are coupled together to form the precast concrete panel 100. The precast concrete panel 100 also includes a plurality of connecting members, such as, wire loops 112, along an edge of the precast concrete panel 100. Further, in some embodiments, extended bars 114 are provided for lifting the precast concrete panel 100 using lifting mechanisms, such as, cranes, without damaging the concrete layers.
FIG. 2A is another detailed view of precast concrete panel 100, in accordance with some embodiments. As shown in FIG. 2A, the precast concrete panel 100 includes the first layer 102, the core 104, and the second layer 106. The first layer 102 also includes the reinforcement structure 108.
Further, in some embodiments, the precast concrete panel 100 is installed as a wall panel in a building. The wall panel is coupled to adjacent wall panels and to a foundation underneath. In some embodiments, the foundation corresponds to a monolithic cast-in-place foundation structure. The foundation is the lowest part of a building that is in direct contact with the ground which transfers loads from the building to the ground safely. To construct the foundation, trenches are dug deeper into the soil until a hard stratum is reached. Reinforcement cages are incorporated, and concrete is poured. A wall panel is typically installed directly on the foundation. Thus, in some embodiments, the precast concrete panel 100 includes a first recessed section 116 at a bottom side 118 of the precast concrete panel 100 for coupling to the foundation. In some embodiments, there is able to be a bolted connection between the precast concrete panel 100 and the foundation such that the bolted connector and/or a portion of the foundation fits into the first recessed section 116. Other methods of coupling the precast concrete panel 100 and the foundation are also able to be used.
Further, the building is able to have multiple floors and/or levels. Thus, the precast concrete panel 100, installed as a level-1 wall panel in the building, is also able to have a second recessed section 120 at a top side 122 of the precast concrete panel 100 for coupling to another precast concrete panel, such as, a level-2 wall panel, disposed on top of the precast concrete panel 100. In some embodiments, a wall-to-wall connector is able to be used to couple the precast concrete panel 100 to the other wall panel, directly or through a roof slab, such that the wall-to-wall connector and/or portion of the wall panel or the roof slab is able to fit into the second recessed section 120. Other methods of coupling the precast concrete panel 100 and the other wall panel are also able to be used.
FIG. 2B is a perspective view of the load bearing element 110 as shown in FIG. 1A. In accordance with some embodiments, the load bearing element 110 is able to be a lattice girder 200. In some embodiments, the lattice girder 200 is able to traverse, at least in part, through the first layer, the core, and the second layer of the precast concrete panel. As shown in FIG. 2B, in some embodiments, the lattice girder 200 includes an upper bar 202 and two lower bars 204 and 206 coupled through a triangulated framework of lacing members 208.
The lattice girder 200 includes a framework of intersecting diagonal lacing members 208 arranged in a grid-like pattern. The lacing members 208 are inclined at angles and form a lattice pattern throughout the lattice girder 200. The lacing members 208 contribute to the structural integrity by distributing loads efficiently. Further, the lacing members 208 intersect with the upper bar 202 and two lower bars 204 and 206 at points known as nodes 210. Nodes 210 play a crucial role in transferring forces and maintaining stability throughout the structure. Further, the lacing members 208 at the nodes 210 are often coupled through welded or bolted joints, ensuring the overall stability and strength of the lattice girder 200.
The open grid-like structure of the lattice girder 200 allows for efficient load distribution while minimizing the overall weight of the lattice girder 200. The grid pattern is typically repeated along the length of the lattice girder 200, as shown in FIG. 2B, contributing to its strength and uniformity. The lattice girder 200 is able to be constructed using materials like steel or reinforced concrete, depending on the structural requirements of the project. The lattice structure inherently provides strength while keeping the girder relatively lightweight. Further, the lattice girders are able to be designed and customized based on specific structural needs, allowing for versatility in various construction projects. In precast construction, where elements are cast and cured off-site before being transported to the construction site, lattice girders are a preferred choice due to their ability to be manufactured with precision and quality control. This helps ensure consistency in the structural elements and speeds up the on-site construction process.
Further, as discussed above, other than the load bearing and load distribution function of the lattice girder 200, it also holds the three layers of the precast concrete panel 100, that is, the first layer 102, the core 104, and the second layer 106, together. In some embodiments, the lattice girder 200 is precast into the first layer 102 along with the reinforcement structure 108, such that at least a portion of the lattice girder 200 traverses into the core 104 and the second layer 106.
FIG. 3 is a perspective view 300 of a connecting member interconnecting the precast concrete panel to an adjacent precast concrete panel, in accordance with some embodiments.
As shown in FIG. 3 , the precast concrete panel 100 is able to be placed next to an adjacent precast concrete panel 302. In some embodiments, the precast concrete panel 100 has a connecting member 112 extending from an edge of the precast concrete panel 100. Similarly, in some embodiments, the adjacent precast concrete panel 302 has a connecting member 304 extending from an edge of the adjacent precast concrete panel 302. In some embodiments, the connecting members 112 and 304 are able to be wire loops that overlap with each other. Once overlapped, in some embodiments, the connecting members 112 and 304 interlock with each other to form a hook 306, as shown in FIG. 3 . Further, in some embodiments, a metal rod 308 is able to pass through the hook 306 to securely couple the precast concrete panel 100 to the adjacent precast concrete panel 302.
As discussed above, in some embodiments, the precast concrete panel 100 has a plurality of connecting members 112 along an edge of the precast concrete panel 100, such that, the plurality of connecting members 112 overlap with a plurality of connecting members 304 of the adjacent precast concrete panel 302. In some embodiments, the metal rod 308 is able to pass through all the overlapped wire loops to interlock the two precast concrete panels together. Further, a sealant or grout, such as, non-shrink grout, is then able to be used to completely fill any gaps between the two precast concrete panels to ensure contact and proper adhesion.
FIG. 4 is a perspective view of a building structure 400 employing the precast concrete panel 100, in accordance with some embodiments.
In some embodiments, the building structure 400 includes a foundation, precast concrete panel as wall panels, a slab structure, a beam structure, and a roof slab. The precast structures are able to be prefabricated at an offsite location away from a construction site and installed on-site at the construction site.
In some embodiments, the slab structure corresponds to a precast structure that includes a concrete base and a structural topping. The structural topping is able to be specialized materials applied to existing concrete base of the slab structure to enhance performance, durability, and aesthetic. In some embodiments, the beam structure corresponds to a precast horizontal structure that is able to withstand vertical loads, shear forces, and bending moments. The beam structure is able to transfer loads that are imposed along their length to their endpoints, such as the foundation structure, the wall panels, and the like. The beam structure is able to be used for both load-bearing and non-load bearing applications and is also able to be made in a variety of shapes and sizes.
Once the aforesaid precast structures, such as the precast concrete panel 100, which are prefabricated, reinforced, and layered concrete elements, are ready in a factory setting, they are subsequently transported to the construction site where the foundation is already in place and hardened. At the construction site, the precast structures, such as, the precast concrete panel 100, are mechanically positioned in accordance with a pre-designed layout for the building structure 400 and interconnected with the foundation using one or more connection assemblies.
Further, the precast concrete panels 100 are also able to couple to adjacent precast concrete panels or wall panels using connecting means as described above with reference to FIG. 3 . The precast concrete panels 100 are also able to couple to one or more of the slab structures, beam structures, roof, and/or other precast concrete panels disposed on top of the precast concrete panel 100 in case of a multi-level building. Further, the precast concrete panels 100 and/or the wall panels are able to be with or without door or window opening based on the design of the building structure 400.
FIG. 5 illustrates the steps of a method 500 of forming precast concrete panels, in accordance with some embodiments of the present disclosure. Although specific operations are disclosed in FIG. 5 , such operations are examples and are non-limiting. In different embodiments, to name only a few examples, the method 500 includes other steps, the sequence of the steps is modified, some steps are omitted, or any combination of these variations are able to be incorporated. The steps of method 500 are able to be automated or semi-automated. In various embodiments, one or more of the operations of the method 500 are able to be controlled or managed by software, by firmware, by hardware, or by any combination thereof. FIG. 5 will be explained in conjunction with the descriptions of FIGS. 1-4 .
In some embodiments, the method 500 includes processes in accordance with the present disclosure which are able to be controlled or managed by a processor(s) and electrical components under the control of a computer or computing device including computer-readable media containing computer-executable instructions or code. The readable and executable instructions (or code) are able to reside, for example, in data storage such as volatile memory, non-volatile memory, and/or mass data storage, as only some examples.
At step 502, the method 500 includes forming a first layer 102 of the precast concrete panel 100 using concrete reinforced with a reinforcement structure 108. In some embodiments, the first layer 102 forms a rear-side of the precast concrete panel 100. In some embodiments, the reinforcement structure, such as, a single-layer metal mesh, is able to be placed on a surface of a manufacturing workstation in a precast factory. Then concrete is able to be poured over the reinforcement structure in a controlled manner forming a first layer of the precast concrete panel. The wet concrete of the first layer 102 is able to be allowed to set for a predefined period of time.
At step 504, the method 500 includes placing a core 104 comprising thermally insulating material on the first layer 102. In some embodiments, the core 104 includes one or more of polystyrene (EPS), polyurethane foam (PUR), and mineral wool, which are able to be placed evenly or in a variable thickness, over the first layer 102.
At step 506, the method 500 includes forming a second layer 106 of the precast concrete panel 100 using fiber reinforced concrete. The second layer 106 forms a front-side of the precast concrete panel 100. In some embodiments, fiber reinforced concrete is poured over the core 104 forming the second layer 106 of the precast concrete panel 100. The wet concrete of the second layer 106 is able to be allowed to set for a predefined period of time. Thus, in some embodiments, the first layer 102, the core 104, and the second layer 106 are coupled to each other to form the precast concrete panel 100.
In some embodiments, a load bearing member is also able to be precast into the first layer 102 along with the reinforcement structure, as described above. Further, in some embodiments, one or more connecting members are able to be coupled to an edge of the precast concrete panel for coupling the precast concrete panel 100 to an adjacent precast concrete panel during installation. Further, in some embodiments, a first recessed section at a bottom side of the precast concrete panel and a second recessed section at a top side of the precast concrete panel is also able to be formed for coupling to a foundation and another precast concrete panel, respectively.
The terms “comprising,” “including,” and “having,” as used in the specification herein, shall be considered as indicating an open group that is able to include other elements not specified. The terms “a,” “an,” and the singular forms of words shall be taken to include the plural form of the same words, such that the terms mean that one or more of something is provided. The term “one” or “single” may be used to indicate that one and only one of something is intended. Similarly, other specific integer values, such as “two,” are able to be used when a specific number of things is intended. The terms “preferably,” “preferred,” “prefer,” “optionally,” “may,” and similar terms are used to indicate that an item, condition, or step being referred to is an optional (not required) feature of the disclosure. The term “connecting” includes connecting, either directly or indirectly, and “coupling,” including through intermediate elements.
The disclosure has been described with reference to various specific and preferred embodiments and techniques. However, it should be understood that many variations and modifications may be made while remaining within the spirit and scope of the disclosure. It will be apparent to one of ordinary skill in the art that methods, devices, device elements, materials, procedures, and techniques other than those specifically described herein may be applied to the practice of the disclosure as broadly disclosed herein without resort to undue experimentation. All art-known functional equivalents of methods, devices, device elements, materials, procedures, and techniques described herein are intended to be encompassed by this disclosure. Whenever a range is disclosed, all subranges and individual values are intended to be encompassed. This disclosure is not to be limited by the embodiments disclosed, including any shown in the drawings or exemplified in the specification, which are given by way of example and not of limitation. Additionally, it should be understood that the various embodiments of the building blocks described herein contain optional features that may be individually or together applied to any other embodiment shown or contemplated here to be mixed and matched with the features of that building block.
While the disclosure has been described with respect to a limited number of embodiments, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments may be devised which do not depart from the spirit and scope of the disclosure as disclosed herein.

Claims

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,

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.