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US 2006/0218870 A1Published application
Prestressed concrete building panel and method of fabricating the same
OwnerHarold Messenger, Thomas Harmoninventors
Life of this patent
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Abstract
A low density concrete building panel and method of manufacturing is provided with one or more carbon fiber or steel reinforcements which may include window and door openings which can be easily transported and erected at a building site.
Claims30
A carbon fiber reinforced concrete building panel, comprising:
- an inner surface, an outer surface, a first end and a second end, and a substantially longitudinal axis defined between said first end and said second end;
- a tensioned first carbon fiber grid positioned within an exterior concrete layer between said first end and said second end;
- a plurality of foam core panels positioned substantially adjacent to said exterior concrete layer and defining a plurality of rib channels between said plurality of foam core panels which are substantially filled with a concrete material;
- at least one carbon fiber shear strip positioned within said plurality of rib channels and extending into said exterior concrete layer;
- and
- at least one reinforcing bar positioned proximate to said at least one carbon fiber shear strip and positioned within said plurality of rib channels.
3 more elements
A method for fabricating a low density concrete building panel, comprising:
- a) providing a form having a first end, a second end, and lateral edges extending therebetween;
- b) positioning a plurality of metal strands in said form;
- c) applying tension to said plurality of metal strands;
- d) positioning a first grid of carbon fiber material in said form;
- e) applying tension to said first grid of carbon fiber material;
- f) pouring a first layer of concrete material into said form;
- g) positioning a layer of insulative material onto said first layer of concrete material, said insulative material having a plurality of reinforcing rib channels extending substantially between at least one of said first end and said second end or said lateral edges;
- h) positioning a first reinforcing material in said plurality of rib channels;
- i) pouring a second layer of concrete into said plurality of reinforcing rib channels;
- j) allowing said first layer and said second layer of concrete to cure;
- and
- k) removing said concrete building panel from said form, wherein said lightweight concrete building panel is available for transportation and use.
9 more elements
A method for fabricating a low density concrete building panel having a window or door opening, comprising:
- a) providing a casting form having a first end, a second end, and lateral edges extending therebetween;
- b) positioning a negative to a bottom portion of the casting forms in a predetermined position which defines a window opening or a door opening;
- c) positioning a plurality of metal strands in said form;
- d) applying tension to said plurality of metal strands;
- e) positioning a first grid of carbon fiber material in said form;
- f) applying tension to said first grid of carbon fiber material;
- g) positioning a framing material on or proximate to said negative;
- h) pouring a first layer of concrete material into said form;
- i) positioning a layer of foam core onto said first layer of concrete material, said layer of foam core having a plurality of reinforcing rib channels extending substantially between at least one of said first end and said second end or between said lateral edges;
- j) positioning a first reinforcing material in said plurality of reinforcing rib channels;
- k) pouring a second layer of concrete into said plurality of rib channels;
- l) allowing said first layer and said second layer of concrete to cure;
- and
- m) removing said concrete building panel from said form, wherein said lightweight concrete building panel is available for transportation and use.
11 more elements
Dependencies are inferred from the claim text.