Abstract: A through-insulation connector assembly for use in the construction of insulated concrete sandwich wall. The connector assembly includes a spool-shaped connector body comprised of two, interconnecting pieces and a tie that engages the connector body. The two pieces of the connector body are installed at the place of manufacture in a sheet of foam insulation board that will be used as the insulation layer in the construction of an insulated concrete sandwich wall.

Abstract: A concrete sandwich panel is provided with a first dry-cast hollowcore concrete layer having pre-stressing strands, and a second concrete layer, and an insulation layer sandwiched therebetween. The insulation layer includes pre-formed holes. A tool is used to form holes in the first concrete layer aligned with the insulation holes. Adhesive is injected into the concrete holes, with connectors extending through the insulation layer and into the concrete holes. The adhesive, when cured, locks the connector in the hollowcore concrete layer. The upper concrete layer is cast over the insulation layer so as to embed the upper ends of the connectors. The plasticity of the upper concrete layer, which may result from vibration energy input to low-slump concrete, allows the concrete to consolidate around the upper ends of the connectors. When the concrete layers cure, the connectors tie the layers together to preclude excessive shear displacement between the concrete.

Abstract: A through-insulation connector assembly for use in the construction of insulated concrete sandwich wall. The connector assembly includes a spool-shaped connector body comprised of two, interconnecting pieces and a tie that engages the connector body. The two pieces of the connector body are installed at the place of manufacture in a sheet of foam insulation board that will be used as the insulation layer in the construction of an insulated concrete sandwich wall.

Abstract: Wide-body connectors are provided for concrete sandwich walls. Each connector includes a body with longitudinally thickened portions defining flanges and a thinner inner connecting web extending between the flanges. The flanges provide increased bending stiffness for the connector, while the web provides enhanced shear transfer between the concrete layers of the wall. Anchoring surfaces are formed into or overmolded onto the body to anchor the ends of the connector in the concrete layers of the wall and assist in the creation of end moments ofr the transfer of forces between the concrete layers. Preferably, a lip is provided on the connector to limit the penetration of the connector through the insulation layer of the wall. The connectors transfer forces between the concrete layers, without thermal bridging, such that the wall has a substantially composite character.

Abstract: By using a thermal insulation foam/film laminate wherein each major planar surface of a foam panel has a facer film bonded thereto that meets certain performance criteria rather than a foam panel by itself, composite walls that have a foam panel sandwiched between concrete layers can be made with fewer steps.

Abstract: Precast insulated concrete wall panels are made by pouring a first concrete layer into a form. An insulation layer is then supported above the first concrete layer so as to create a space therebetween. The second concrete layer is then poured on top of the insulation layer before the first concrete layer has cured. Connectors are anchored in the first and second concrete layers so as to tie the layers together. After the first and second concrete layers have cured, the wall panels can be lifted, transported, and assembled into a wall structure. An intermediate layer of concrete can be poured into the air gap of the wall panels such that the panels define the form for the intermediate concrete layer and become an integral part of the wall structure. The wall structure may extend below or above grade and may be multi-tiered. The edges of the wall panels are contoured so as to interlockingly matingly engage when assembled into the wall structure.

Abstract: An insulated wall includes first and second spaced apart layers of concrete having a layer of insulating material sandwiched therebetween. Extending through the insulative layer are a plurality of spike connectors having their opposite ends protruding into the two concrete layers and having their central portions extending through the insulating material. On of the opposite ends of the spike connectors is pointed so as to permit it to be punched through the insulative layer. The opposite ends of the spikes each include a holding surface facing at least partially toward the central insulative layer and holding the concrete layers against movement away from the insulative layer. C-shaped connectors may also be used in a similar fashion with hook ends hooked over elongated cables extending within the two concrete layers so as to tie them together.

Abstract: An improved concrete wall structure is provided with an insulation layer sandwiched between concrete layers. The insulation layer includes a vapor film on at least one side. An extruded channel member is fit onto the edge of a sheet of insulation and has a vapor film fit into a longitudinal groove extending along the channel member. The vapor films on the channel members of adjacent wall panels cooperate to bridge the gap between adjacent panels and thereby provide a vapor seal in the space between the adjacent panels.

Abstract: An apparatus and method is provided for producing composite reinforcement elements having high tensile strength and anchoring points for retaining the elements in concrete or masonry. The apparatus includes a creel station having a plurality of fibers, and a placement station for arranging the fibers into a multi-fiber roving. The roving is passed through a resin bath for coating the roving with a corrosion resistant material. The coated roving is heated so as to partially cure the coating material. The roving is then continuously pulled through a rotary die station which imparts a desired shape or profile to the composite element. The element is also heated in the rotary die station so as to complete the curing process.

Abstract: An insulated wall includes first and second spaced apart layers of concrete having a layer of insulating material sandwiched therebetween. Extending through the insulative layer are a plurality of spike connectors having their opposite ends protruding into the two concrete layers and having their central portions extending through the insulating material. One of the opposite ends of the spike connectors is pointed so as to permit it to be punched through the insulative layer. The opposite ends of the spikes each include a holding surface facing at least partially toward the central insulative layer and holding the concrete layers against movement away from the insulative layer. C-shaped connectors may also be used in a similar fashion with hook ends hooked over elongated cables extending within the two concrete layers so as to tie them together.

Abstract: A plastic shear connector for forming an insulated wall having an improved fiber composite or plastic shear connector which is used to form a composite wall formed of an insulating sheet and one or more concrete layers wherein the shear connectors are formed with tapered ends and have a holding portion injection molded and mounted on the center portion of the shear connector and which is inserted through the insulating board as the composite wall is formed.

Abstract: An improved snap lock retainer mechanism for insulated wall construction apparatus for pouring a composite wall structure which includes a pair of outer poured concrete layers separated by a high density foam insulating panel mounted between the concrete layers and which includes a number of tying mechanisms for holding the insulated layer in place while the concrete is being poured and hardened wherein the holding means are formed of plastic rods upon which two plastic receivers are directly injection molded onto the rod. One of the receivers has a single notch and the other receiver has multiple notches. One of two snap rings which are identical goes first over the single notch receiver and is locked in place and then the rod is extended through the insulating panel and a second snap ring is attached to the multiple notches in a ratchet effect on the multiple notches plastic receivers so as to lock the board in place so that the concrete can be poured.

Abstract: The present invention comprises an improved composite wall structure which includes a pair of outer poured concrete layers which are separated by a high density foam insulating panel which is mounted between the concrete layers and includes a plurality of time mechanisms for holding the insulated layer in place while the concrete is being poured and hardened, wherein the holding means comprises metal rods and are low heat conductive rods such as polyglass impregnated plastic rods upon which a pair of holding spools are mounted which engage opposite sides of the insulating panel so as to hold it in a predetermined position.Also disclosed is a novel corner form arrangement.

Abstract: A composite insulated wall includes a pair of outer poured concrete layers cured in a form and an organic or inorganic insulating panel or panels disposed between the concrete layers and retained in place by a number of lateral tie-rods extending through the insulating panel and into the concrete.