# US 10,767,369 B2 · Reinforced concrete building structures and methods for making same > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,767,369 B2 - Document ID: US10767369B2 - Status: Granted - Kind: B2 - Application number: 16/053,286 - Filed: 2018-08-02 - Published: 2020-02-06 - Granted: 2020-09-08 - Earliest claimed: 2018-08-02 - Assignees: EnviroBuilt Holdings, LLC - Applicants: EnviroBuilt Holdings, LLC - Inventors: Martin Ekster; Matthew D Rader - Web page: https://patentgrep.com/patent/US10767369B2 ## CPC - E04C 2/384: {with a metal frame} - B32B 3/06: for securing layers together; for attaching the product to another member, e.g. to a support {, or to another product, e.g. groove/tongue, interlocking} - B32B 3/08: characterised by added members at particular parts {(layer formed of separate pieces of material which are juxtaposed side-by-side B32B3/14, B32B3/18)} - B32B 3/266: {characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12} - B32B 3/30: characterised by a layer formed with recesses or projections, e.g. {hollows, grooves, protuberances, ribs (apertured layer B32B3/266; layer with cavities or internal voids B32B3/26)} - B32B 5/028: {Net structure, e.g. spaced apart filaments bonded at the crossing points} - B32B 5/18: characterised by features of a layer {of} foamed material - B32B 5/245: {another layer next to it being a foam layer} - B32B 5/32: {at least two} layers being foamed {and next to each other} - B32B 7/12: using interposed adhesives or interposed materials with bonding properties - B32B 13/02: with fibres or particles {being present as additives in the layer} - B32B 13/045: {of foam} - B32B 15/02: {Layer formed of wires, e.g. mesh} - B32B 15/046: {of foam} - B32B 15/18: comprising iron or steel {(B32B15/011, B32B15/012 and B32B15/013 take precedence)} - B32B 19/047: {of foam} - B32B 21/02: {the layer being formed} of fibres, chips, or particles {, e.g. MDF, HDF, OSB, chipboard, particle board, hardboard} - B32B 21/047: {of foam} - E04B 1/04: the elements consisting of concrete, e.g. reinforced concrete, or other stone-like material - E04B 1/14: the elements being composed of two or more materials (of reinforced concrete E04B1/04) - E04B 7/22: the slabs having insulating properties, e.g. laminated with layers of insulating material - E04C 2/06: reinforced - E04C 2/2885: {with the insulating material being completely surrounded by, or embedded in, a stone-like material, e.g. the insulating material being discontinuous} - E04C 2/523: {for ventilating} - E04D 3/352: {at least one insulating layer being located between non-insulating layers, e.g. double skin slabs or sheets} - B32B 37/15: with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state - B32B 2250/04: 4 layers - B32B 2255/02: on fibrous or filamentary layer - B32B 2255/20: Inorganic coating - B32B 2255/205: Metallic coating - B32B 2255/26: Polymeric coating - B32B 2255/28: Multiple coating on one surface - B32B 2260/021: Fibrous or filamentary layer - B32B 2260/044: Water-setting substance, e.g. concrete, plaster - B32B 2262/067: Wood fibres - B32B 2262/10: Inorganic fibres - B32B 2262/103: Metal fibres - B32B 2262/105: Ceramic fibres - B32B 2264/0235: Aromatic vinyl resin, e.g. styrenic (co)polymers - B32B 2266/0228: Aromatic vinyl resin, e.g. styrenic (co)polymers - B32B 2266/0278: Polyurethane - B32B 2266/049: Water-setting material, e.g. concrete, plaster or asbestos cement - B32B 2305/022: Foam - B32B 2305/07: Parts immersed or impregnated in a matrix - B32B 2305/08: Reinforcements - B32B 2305/38: Meshes, lattices or nets - B32B 2307/102: Insulating - B32B 2307/304: Insulating - B32B 2307/3065: Flame resistant or retardant, fire resistant or retardant - B32B 2307/7145: Rot proof, resistant to bacteria, mildew, mould, fungi - B32B 2307/7246: Water vapor barrier - B32B 2307/73: Hydrophobic - B32B 2311/30: Iron, e.g. steel - B32B 2315/02: Ceramics - B32B 2315/06: Concrete - B32B 2317/16: Wood, e.g. woodboard, fibreboard, woodchips - B32B 2325/00: Polymers of vinyl-aromatic compounds, e.g. polystyrene - B32B 2419/06: Roofs, roof membranes - B32B 2607/00: Walls, panels - E04C: STRUCTURAL ELEMENTS; BUILDING MATERIALS (for bridges E01D; specially designed for insulation or other protection E04B; elements used as building aids E04G; for mining E21; for tunnels E21D; structural elements with broader range of application than for building engineering F16, particularly F16S) - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM - E04B: GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS (border constructions of opening in walls, floors or ceilings E06B1/00; {electromagnetic shielding H05K9/0001}) - E04D: ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS (coverings of outer walls by plaster or other porous material E04F13/00) ## Abstract Reinforced concrete structures and assemblies, building systems, and methods of fabrication. ## Claims ### Claim 1 An insulated reinforced concrete wall panel, comprising: an outer skin coating comprised of at least one of an acrylic resin, ceramic, and titanium; a concrete panel; a mesh mat; at least two fusion bars extending parallel to one another and in a longitudinal direction parallel to the outer skin and interior skin, each comprising a tilt up connection and a steel member at least 20″ in length, wherein each fusion bar is disposed within the insulated reinforced concrete wall panel at about 2′ on center intervals; a rebar rod; one or more wall panel weld plates; a foam panel; and an interior skin. ### Claim 2 (depends on 1) The insulated reinforced concrete wall panel of claim 1 wherein the outer skin coating further comprises a hydrophobic element. ### Claim 3 (depends on 1) The insulated reinforced concrete wall panel of claim 1 wherein the outer skin coating is 10 to 16 millimeters thick. ### Claim 4 (depends on 1) The insulated reinforced concrete wall panel of claim 1 wherein the outer skin coating further comprises an acrylic architectural coating formulated with microscopic ceramic spheres. ### Claim 5 (depends on 1) The insulated reinforced concrete wall panel of claim 1 wherein the outer skin coating is mildew and algae resistant. ### Claim 6 (depends on 1) The insulated reinforced concrete wall panel of claim 1 wherein the concrete panel is aerated. ### Claim 7 (depends on 1) The insulated reinforced concrete wall panel of claim 1 wherein the mesh mat further comprises wire welded together in a grid pattern. ### Claim 8 (depends on 1) The insulated reinforced concrete wall panel of claim 1 wherein the mesh mat further comprises welded rebar. ### Claim 9 (depends on 1) The insulated reinforced concrete wall panel of claim 1 wherein the mesh mat further comprises basalt fiber. ### Claim 10 (depends on 1) The insulated reinforced concrete wall panel of claim 1 wherein the mesh mat further comprises steel. ### Claim 11 (depends on 1) The insulated reinforced concrete wall panel of claim 1 wherein the mesh mat further comprises ASTM A185 plain steel welded wire fabric. ### Claim 12 (depends on 1) The insulated reinforced concrete wall panel of claim 1 wherein the mesh mat further comprises rebar arranged in a 6″×6″ grid pattern. ### Claim 13 (depends on 1) The insulated reinforced concrete wall panel of claim 1 further comprising one or more furring elements. ### Claim 14 (depends on 1) The insulated reinforced concrete wall panel of claim 1 further comprising one or more spacing elements. ### Claim 15 (depends on 14) The insulated reinforced concrete wall panel of claim 14 wherein the one or more spacing elements are attached to the mesh mat about every 24″ on center. ### Claim 16 (depends on 14) The insulated reinforced concrete wall panel of claim 14 wherein the one or more spacing elements are attached to the mesh mat a minimum 2″ between surfaces desired to be spaced. ### Claim 17 (depends on 14) The insulated reinforced concrete wall panel of claim 14 wherein the one or more spacing elements are attached to the mesh mat by one or more of a weld, clip, and tie. ### Claim 18 (depends on 1) The insulated reinforced concrete wall panel of claim 1 wherein the mesh mat is embedded in the concrete panel. ### Claim 19 (depends on 1) The insulated reinforced concrete wall panel of claim 1 wherein the mesh mat is attached to at least one fusion bar by threaded spacer bolts. ### Claim 20 (depends on 1) The insulated reinforced concrete wall panel of claim 1 wherein the one or more fusion bars is substantially rectangular. ### Claim 21 (depends on 1) The insulated reinforced concrete wall panel of claim 1 wherein the one or more fusion bars is up to 2″ thick. ### Claim 22 (depends on 1) The insulated reinforced concrete wall panel of claim 1 wherein the height of the one or more fusion bars exceeds the height of the concrete panel by about 6″. ### Claim 23 (depends on 1) The insulated reinforced concrete wall panel of claim 1 wherein the one or more fusion bars further comprises a steel member that is substantially rectangular and about 318th inch gauge thick. ### Claim 24 (depends on 1) The insulated reinforced concrete wall panel of claim 1 wherein the one or more wall panel weld plates attach the insulated reinforced concrete wall panel to one or more footers. ### Claim 25 (depends on 24) The insulated reinforced concrete wall panel of claim 24 wherein the fusion bars are attached to the one or more wall panel weld plates. ### Claim 26 (depends on 1) The insulated reinforced concrete wall panel of claim 1 wherein the one or more wall panel weld plates are attached to one or more weld plates attached to footers. ### Claim 27 (depends on 1) The insulated reinforced concrete wall panel of claim 1 wherein the fusion bars further comprise one or more steel members substantially shaped, when viewed on-edge, in a “t”, “+” or “x” shape. ### Claim 28 (depends on 1) The insulated reinforced concrete wall panel of claim 1 wherein the fusion bars further comprise one or more prefabricated holes. ### Claim 29 (depends on 28) The insulated reinforced concrete wall panel of claim 28 wherein the one or more prefabricated holes is between about 0.5-2″ in diameter. ### Claim 30 (depends on 28) The insulated reinforced concrete wall panel of claim 28 wherein one of the one or more prefabricated holes is disposed about 6″ from one end of one of the fusion bars. ### Claim 31 (depends on 28) The insulated reinforced concrete wall panel of claim 28 wherein the prefabricated holes are disposed about every 4″ along the length of the fusion bars. ### Claim 32 (depends on 1) The insulated reinforced concrete wall panel of claim 1 wherein the fusion bars are comprised of at least one of aluminum, titanium, and plastic. ### Claim 33 (depends on 1) The insulated reinforced concrete wall panel of claim 1 further comprising a plurality of fusion bars positioned within the wall panel such that the distance between each fusion bar, measuring horizontally, is at least about 15″. ### Claim 34 (depends on 1) The insulated reinforced concrete wall panel of claim 1 wherein the foam panel is comprised of extruded polystyrene or expanded polystyrene. ### Claim 35 (depends on 1) The insulated reinforced concrete wall panel of claim 1 wherein the foam panel comprises at least one of polyurethane foam, cement-bonded wood fiber, cement-bonded polystyrene beads, cellular concrete, plastic foam, and cementitious binder. ### Claim 36 (depends on 1) The insulated reinforced concrete wall panel of claim 1 wherein the foam panel comprises an interconnection means for interconnecting with foam panels. ### Claim 37 (depends on 1) The insulated reinforced concrete wall panel of claim 1 wherein the foam panel further comprises a plurality of groove spaces in which the fusion bars may be disposed. ### Claim 38 (depends on 1) The insulated reinforced concrete wall panel of claim 1 wherein the interior skin is comprised of at least one of cement, fiberboard, and gypsum board. ### Claim 39 (depends on 1) The insulated reinforced concrete wall panel of claim 1 wherein the interior skin is attached to the foam panel by one or more of glue, screws, nuts, bolts, and fasteners. ### Claim 40 An insulated reinforced concrete wall panel, comprising: an outer skin coating comprised of at least one of an acrylic resin, ceramic, and titanium; a concrete panel; a mesh mat; a plurality of alternating rebar rods and fusion bars extending parallel to one another and in a longitudinal direction parallel to the outer skin and interior skin, and positioned within the wall panel at about 2′ on center intervals, wherein each fusion bar further comprises a tilt up connection and a steel member at least 20″ in length; one or more wall panel weld plates; a foam panel; and an interior skin. ### Claim 41 (depends on 40) The insulated reinforced concrete wall panel of claim 40 wherein each rebar rod is connected to a plurality of spacers or rebar chairs substantially in contact with the foam panel such that the plurality of spacers or rebar chairs maintains space between the rebar and the foam panel so that the concrete panel adequately encapsulate the rebar rods. ### Claim 42 (depends on 40) The insulated reinforced concrete wall panel of claim 40 further comprising rebar stirrups comprising high-strength steel wire arranged in a column. ### Claim 43 An insulated reinforced concrete wall panel assembly, comprising: a plurality of insulated reinforced concrete wall panels, each comprising an outer skin coating comprised of at least one of an acrylic resin, ceramic, and titanium, a concrete panel, a mesh mat, at least two fusion bars extending parallel to one another and in a longitudinal direction parallel to the outer skin and interior skin, each comprising a tilt up connection and a steel member at least 20″ in length, wherein each fusion bar is disposed within the insulated reinforced concrete wall panel at about 2′ on center intervals, a rebar rod, one or more wall panel weld plates, a foam panel, an interior skin and interconnections for mating each insulated reinforced concrete wall panel to one another. ### Claim 44 (depends on 43) The assembly of claim 43 wherein each insulated reinforced concrete wall panel further comprises threaded bolt holes for receiving bolts to achieve interconnection. ### Claim 45 (depends on 43) The assembly of claim 43 further comprising a footer. ### Claim 46 (depends on 43) The assembly of claim 43 further comprising a door frame perforation in at least one concrete panel, wherein the perforation is surrounded by rebar. ### Claim 47 (depends on 43) The assembly of claim 43 further comprising a window frame perforation in at least one concrete panel, wherein the perforation is surrounded by rebar. ### Claim 48 (depends on 43) The assembly of claim 43 further comprising a concrete blind stop. ### Claim 49 A method of fabricating an insulated reinforced concrete wall panel, comprising the steps of: fabricating a plurality of footers; fabricating a form in the shape of a wall of desired dimensions on a flat surface; fabricating one or more insulated foam panels comprising a plurality of groove spaces in which fusion bars may be disposed; arranging the one or more foam panels inside the form; assembling, on top of the one or more foam panels, at least two fusion bars extending parallel to one another and in a longitudinal direction parallel to the outer skin and interior skin, each comprising a tilt up connection and a steel member at least 20″ in length, wherein each fusion bar is disposed at about 2 on center intervals; arranging a mesh mat; aligning weld plates to connect the wall panel to the footer; pumping concrete into the form until it fills the form to substantially the top of the form; curing the concrete; removing the forms, elevating the cured panel, and positioning a desired location; welding the cured panel to the plurality of footers; applying an interior skin comprising at least one of cement, fiberboard and sheetrock; and applying an outer skin comprised of at least one of an acrylic resin, ceramic, and titanium.