Jobsite apparatus for horizontal casting and vertical stacking of thick insulated concrete panels

A method for horizontal casting and vertical stacking of thick non-composite insulated concrete panel on a job site comprising the steps of:

• covering the concrete contact surfaces of a mold with a mold release agent;
• heating the bottom of the mold;
• pouring a first layer of concrete into the mold while at the same time pressing and vibrating the concrete into close contact with the heated mold bottom;
• the heated mold bottom causing accelerated curing of the concrete in contact therewith, forming a self sustaining concrete outer shell on the panel;
• putting reinforcing steel in the mold over said first concrete layer;
• then
• pouring a second layer of concrete into the mold while at the same time pressing and vibrating the second concrete layer through the reinforcing steel into close contact with the said first concrete layer;
• placing insulating panel board into the mold over said second concrete layer;
• then
• forcing shear connectors through the insulating panel board, into the still soft concrete below while leaving part of the shear connectors standing above the surface of the insulation board;
• putting further reinforcing steel into the mold on top of the standing shear connectors and said insulating panel board;
• then
• pouring a third layer of concrete into the mold over said further reinforcing steel while pressing and vibrating the concrete through the said further reinforcing steel;
• about the standing shear connectors so as to envelope the same and into close contact with said insulating panel board;
• curing the concrete of the first described concrete layer, the second described concrete layer, and the third described concrete layer, whereby said shear connectors embedded in said second and third layers are operative to firmly mechanically lock said layers together;
• until it sets forming said insulated panel;
• pivoting the mold with its enclosed insulated panel about the mold's longitudinal axis from a horizontal to a vertical position;
• setting the said insulated panel vertically upon a support;
• then
• stripping the mold from said insulated panel.