Pre-cast concrete wall with truss ledge

In a pre-cast concrete wall panel having a generally horizontal footer beam for positioning below grade, an upper bond beam located vertically above said footer beam and oriented generally parallel thereto, said upper bond beam being positioned above grade, a plurality of generally vertical stud members interconnecting said footer beam and said upper bond beam, and a monolithic concrete shell located on an exterior surface thereof and incorporating said footer beam, said upper bond beam and said stud members, the improvement comprising:

• a truss ledge integrally formed with said monolithic concrete shell and projecting vertically above said upper bond beam to be located above grade and provide an exterior concrete surface for a floor truss system, said concrete shell having foam insulation on an interior side thereof both above and below said upper bond beam such that said truss ledge has insulation placed between said concrete shell and said floor truss system, each said vertical stud member having a monolithic foam channel on said interior side provided with a rigid stud facing member on an outer front face of said foam channel, said facing member including an integral reinforcing bar support member oriented perpendicularly to said front face and projecting through said foam channel to secure said foam channel on said facing member and to provide support for a reinforcing bar within said foam channel above said facing member.

A method of forming a pre-cast concrete wall panel comprising the steps of:

• arranging a form in a size and configuration desired for said wall panel;
• placing freestanding foam channels within said form at locations desired for the formation of stud members said foam channels having exposed outer foam side surfaces and a rigid stud facing member on an outer front face thereof;
• placing insulation sheets on said foam channels to define an interior surface of said wall panel;
• setting insulation members to define cavities for a footer beam and for an upper bond beam;
• positioning an insulation panel to form a truss ledge that projects from said upper bond beam;
• pouring concrete into said form to fill said foam channels, cavities for said footer beam and said upper bond beam, and to fill areas within said form defined by said insulation sheets and said insulation panel, thus creating a monolithic concrete shell that incorporates said footer beam, said upper bond beam, said stud members, and said truss ledge, said insulation panels establishing an insulated interior surface of said concrete shell both above and below said upper bond beam;
• and
• allowing said concrete to cure before removing said form.