AU772991B2 - Integral concrete wall forming system - Google Patents

Description

WO 00/79069 PCT/US00/16652 TITLE: INTEGRAL CONCRETE WALL FORMING SYSTEM CROSS-REFERENCE TO A RELATED APPLICATION This application is a continuation-in-part of pending application serial number 09/334,826 filed on June 17, 1999.

BACKGROUND OF THE INVENTION Precast insulated concrete wall panels are well known in the art and offer a number of advantages for residential and commercial building construction. These advantages include shorter construction schedules, improved thermal resistance, improved quality control, and enhanced durability. However, conventional concrete wall panels are heavy, thus increasing the cost of transporting the panels from the pre-casting plant to the job site. The large weight of the panels often times requires multiple loads to be delivered to the job site, thereby resulting in potential delays during loading, transportation, and unloading. The large weight also requires the use of an expensive, heavy crane for panel installation.

Insulated concrete wall panels with cavities are also known in the art. These wall panels include inner and outer concrete layers, or wythes, with an internal insulation layer and an air gap provided between the concrete layers, so as to be lighter weight than solid walls of the same thickness.

Such hollow insulated wall panels are made by separate castings of the first and second concrete layers, with the first concrete layer being completely cured or hardened before the second concrete layer is poured. This construction method involves long delays and increased costs for the production process.

Similar uninsulated concrete wall panels are also known with an air gap between the concrete layers. Connectors extend into each layer to tie the layers together. The first layer is poured and the connectors installed therein before curing. After the first layer cures, the second layer is poured, and the first layer is flipped over and the protruding connectors are set into the uncured second layer above the second layer.

In addition, the prior art concrete wall panels are constructed using metallic connectors with high thermal conductive and corrosion potential which may cause degradation.

Examples of prior art panels are disclosed in patents: DE 16 83 498 A; FR-A-2 670 523; FR-A-2 360 723; US-A-4 805 366; and US-A-4 348 848.

Accordingly, it is desirable to provide an improved method of forming concrete wall panels.

It is also desirable to provide an improved hollow concrete wall panel.

It is also desirable to provide a lightweight insulated or non-insulated wall panel useful in forming an integral concrete wall structure.

It is also desirable to provide a hollow concrete wall panel wherein the inner and outer concrete layers are cured substantially simultaneously.

It is also desirable to provide precast wall panels which can be loaded, transported, unloaded, and assembled at the construction site using lightweight 20 construction equipment.

It is also desirable to provide an improved wall system that can be quickly and easily assembled at the construction site.

It is also desirable to provide a quick and easy method of a precasting concrete ego• wall panels.

25 It is also desirable to provide an improved concrete wall panel with a high degree of thermal insulation.

It is also desirable to provide an improved concrete wall panel which is economical to manufacture and durable and safe in use.

It is also desirable to provide a completed wall assembly with a monolithic concrete layer over the full perimeter and area of the wall.

It is the object of the present invention to substantially overcome or at least ameliorate one or more of the prior art disadvantages or to achieve at least one of the above desires.

[R:\LIBLL]I 3646.doc:TCW Summary of the Invention In one aspect, the present invention provides a method of making a wall panel, the method comprising: pouring a first concrete layer into a form with a perimeter edge and a bottom; the method including placing an insulation layer having a plurality of connectors with opposite first and second ends extending therethrough with the first end of the connectors extending through the first concrete layer to engage the bottom of the form and thereby support the insulation layer in spaced relation above the first concrete layer; pouring a second concrete layer on top of the insulation layer before the first concrete layer has cured, with the second end of the connectors extending into the second concrete layer; and curing the first and second concrete layers substantially simultaneously.

In another aspect, the present invention provides a wall panel having: a first concrete layer; a second concrete layer cured substantially simultaneously with the first concrete layer; an insulation layer adjacent to the second concrete layer; an air gap between the insulation layer and the first concrete layer; and a plurality of connectors each having a first end extending through the first concrete layer to support the insulation o so o -•layer in spaced relation to the first concrete layer so as to define the air gap, and a second end embedded in the second concrete layer without extending through the second 0concrete layer.

20 In another aspect, the present invention provides a composite wall structure having a plurality of wall panels according to the above, the wall structure including shims providing a space between the base of the panels and the soil subgrade.

sPrecast concrete wall panels of the present invention include inner and outer concrete layers, and an air gap between the concrete layers. In constructing the wall 25 panels, the first concrete layer is poured into a form. In one embodiment, an insulation layer is supported in a spaced relation above the first concrete layer, and the second concrete layer is poured on top of the insulation layer while the first concrete layer is still ooeoo o wet. Thus, the first and second concrete layers cure substantially simultaneously. A plurality of connectors or rods extend through the foam with opposite ends embedded in the first and second concrete layers. An enlarged flange on each connector supports the insulation layer above the first concrete layer to provide an air gap therebetween. In the insulated embodiment, the [R:ALIBLL] I 3646.doc:TCW WO 00/79069 PCT/US00/16652 thickness of the insulation layer can be determined based upon thermal insulation requirements as well as upon mechanical requirements for the insulation material acting as a concrete form. Where required for mechanical purposes, enhanced insulation material may be used incorporating fiber reinforcement, surface laminations, increased density or combinations thereof.

In a second non-insulated embodiment, connectors are set into the uncured first layer and held in place by locators removably extending across the form. Aggregate or particulate material is placed over the uncured first layer.

The second layer is then poured onto the aggregate or particulate material, and allowed to cure substantially simultaneously with the first layer. After the first and second layers have cured, the connector locators are pulled out of the form. The panel formed by the interconnected first and second layers is then lifted such that the aggregate or particulate material falls out, thereby providing an air gap between the layers.

In a third, insulated embodiment, an insulation layer is installed on the first concrete layer and connectors are installed in the two layers. As with the second embodiment, aggregate or particulate is placed, and a second concrete layer is placed on top of the aggregate or particulate material.

Other embodiments utilize other support structures, such as metal sheeting or air bags, to space the second concrete layer from the first concrete layer and thereby define an air gap therebetween. In each embodiment, the concrete layers cure substantially simultaneously.

WO 00/79069 PCTIUS00/16652 After the concrete layers have hardened in each embodiment, the wall panels can be lifted and installed in a vertical orientation on footings or another base. The edges of the panels may be flat to create a butt joint or may be contoured for an interlocked joint, so as to matingly engage with a corresponding edge on an adjacent panel, thereby providing an interlocking joint between adjacent panels. The panels can be assembled adjacent one another and on top of one another so as to provide a form which becomes an integral part of the wall structure. The assembled panels create a continuous form, with the air gap in the panels being filled with concrete.

The upper edges of the inner concrete layer may include a notch to receive a floor or roof joist. The joists are thus supported by the inner concrete layer of the wall panels without the need for a ledger beam attached to the inside face of the wall panels.

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a perspective view showing a plurality of insulated wall panels according to one embodiment of the present invention assembled so as to create an insulated integral concrete wall forming system.

Figure 2 is a perspective view of a single wall panel according to the present invention.

Figure 3 is a side elevation view of a wall panel according to the present invention.

Figure 4 is an enlarged side elevation view of the wall panel as cast in a concrete casting form.

Figure 5 is an enlarged top plan view of one corner of the wall structure shown in Figure 1.

WO 00/79069 PCT/US00/16652 Figure alternative Figure alternative Figure alternative Figure wall panels alternative receiving a Figure 6 is a view similar to Figure 5, showing an corner construction.

7 is a view similar to Figure 5, showing a second embodiment for a corner construction.

8 is a view similar to Figure 5, showing a third corner construction.

9 is a side elevation view showing a plurality of assembled in multiple tiers and showing an embodiment of the wall panel having a notch for floor or roof joist.

10 is a sectional view taken along lines 10-10 of Figure 9, with floor joists and floor decking installed.

Figures 11-14 are similar to Figures 1-4, but showing a non-insulated integral concrete wall.

Figure 15 is a sectional view taken along lines 15-15 of Figure 14.

Figure 16 is a side elevation view of a further embodiment of the invention.

Figure 17 is an enlarged view showing the embodiment of Figure 16.

Figure 18 is a side elevation view of a panel made by another method of the invention.

Figure 19 is a top plan view of the embodiment shown in Figure 18.

Figure 20 is a side elevation view of a panel made by a further method of the invention.

Figure 21 is a side elevation view of a panel made by yet another method of the invention.

WO 00/79069 PCT/US0016652 DETAILED DESCRIPTION OF THE DRAWINGS As seen in Figure 1, a wall structure in accordance with the present invention is generally designated by the reference numeral 10. The wall structure 10 is formed from a plurality of hollow wall panels 12. As best seen in Figures 2 and 3, each wall panel 12 includes a first concrete layer 14, a second concrete layer 16, and an interior insulation layer 18. Concrete layers 14 and 16 may be constructed with reinforcement, such as wire fabric, reinforcing bars, or fiber reinforcing. A plurality of rods or connectors extend through the wall panels 12 to tie together the inner and outer concrete layers 14, 16. As shown in Figure 4, the connectors 20 include opposite ends 21, 22 with a varying dimension so as to provide an anchoring surface to anchor the connectors 20 in the first and second concrete layers 14, 16.

One type of connector 20 is described in detail in applicant's U. S. Patent Nos. 4,829,733 and 4,805,366, which are incorporated herein by reference. The connectors 20 have a low thermal conductivity, thereby enhancing the thermal efficiency of the wall structure 10. The connectors 20 also are corrosion resistant and they have a thermal expansion rate that is compatible with concrete. Other types of connectors may also be used, including metal, plastic, and other materials with various shapes and dimensions.

The insulation layer 18 may include predrilled holes 19 through which the connectors 20 are inserted, or the connectors may be punched through the insulation. The connectors include an upper flange 23, which limits the insertion of the connections through the insulation layer 18.

After insertion, a lower flange or button 24 is slid over the lower end 22 of the connectors and into engagement with the 7 WO 00/79069 PCT/USOO/16652 insulation layer, as best seen in Figure 4. The lower flange 24 is retained in a non-slip position by a snap fit on the ridges 25 formed on the central portion of the connector Alternate methods of attaching the flange 24 include threads or notches. Alternately, upper flange 23 can be eliminated and lower flange 24 can be molded onto connector Insulation layer 18 may comprise any thermally efficient material capable of spanning between connectors 20 without excessive deformation or fracture.

As seen in Figures 11-15, a similar non-insulated wall structure 10A is formed by a plurality of non-insulated panels 12A, each having a first concrete layer 14A and a second concrete layer 16A. The concrete layers 14A, 16A may be reinforced with wire fabric, reinforcing bars, or fiber reinforcing. A plurality of connectors of 20A extend into the concrete layers 14A, 16A so as to tie the layers together so as to form the wall panel 12A. The connectors 20A are similar to the connectors 20, except that the enlarged flange 24 is replaced with a smaller collar 98, and the ribs 25 are eliminated. The ends of the connector 20A have a varying dimension so as to provide an anchoring surface to anchor the connectors 20A in the inner and outer concrete layers 14A, 16A.

Figures 16 through 20 show a further embodiment of the panel of the present invention. In the embodiment of Figures 16 and 17, the wall structure is formed by a plurality of panels 12B, each having a first concrete layer 14B and a second concrete layer 16B. An insulation layer 18B is provided adjacent the first concrete layer 14B. The plurality of connectors 20B extend into the concrete layers 14B, 16B so as to tie the layers together, thereby forming 8 WO 0079069 PCT/US00/16652 the wall panel 12B. Connectors 20B include a flange 23B.

Ribs 25B are provided on the connector 20B so as to retain the flange 23B in a desired position. An air gap 26B exists between the second concrete layer 16B and the insulation layer 18B.

As shown in Figure 17, the form for concrete layer 14B can have indentation or thin-set brick to provide an aesthetically enhanced exterior finish on the concrete layer immediately adjacent to the insulation layer 18B.

Figure 21 shows another form of a panel 12C similar to panel 12A with first and second concrete layers 14C, 16C respectively. Panel 12C does not have an insulation layer.

A plurality of connectors 20C tie the concrete layers 14C, 16C together. The connectors 20C include a flange 23C.

Each wall panel 12, 12B is hollow, with an air gap or space 26, 26B between the insulation layer 18, 18B and the first concrete layer 14. Similarly, non-insulated panels 12A, 12C are hollow with an air gap 26A, 26C between the first concrete layer 14A, 14C and the second concrete layer 16A, 16C. When the wall panels 12-12C are assembled into the wall structure 10 or 10A, the panels 12-12C serve as a concrete form, with concrete being poured into the air gap 26-26C so as to form a continuous intermediate concrete layer 27. Accordingly, the panels 12-12C become an integral part of the wall structure 10 or It is apparent that the air gap 26-26C can be partially filled with concrete. It is also apparent that the air gap 26-26C can be filled with bat, granular, or foamed-in-place insulation.

In addition to the wall structure 10 shown in Figure 1 wherein the panels are assembled side by side, the wall 9 WO 00/79069 PCT/US00/16652 panels 12 may also be stacked one on top of one another so as to form a multi-tier wall structure 28, as shown in Figure 9.

The panels may be assembled on top of conventional footings (not shown), or on top of concrete footings or a compacted base material 29, such as limestone, with shims 30 being used to level the panels 12-12C. After placement of the concrete layer 27, the assembled wall panels have continuous bearing on the compacted subgrade. The wall structure 10, 10A can be built below grade, such as basement or foundation walls, or above grade for any type of building structure, including commercial and residential buildings, or as sound barrier walls.

Preferably, the panels 12-12C are rectangular in shape, with major and minor axes. The major axis of each wall panel may be oriented vertically, as shown in the wall structure 10A of Figure 1 and 11, or horizontally as in the wall structure 28 of Figure 9.

It is important to note that a continuous concrete layer 27 will provide an effective barrier against insect, rodent and moisture intrusion, as well as sound penetration. The present invention therefore provides the advantages of a monolithic, cast-in place structure. The common disadvantages of precast concrete, including open joints and welded or bolted connections are, however, avoided. When required to resist large lateral forces, additional reinforcing may be added to concrete layer 27.

To facilitate the assembly of the wall panels 12-12C into the wall structure 10, 10A or 28, the opposite side edges 32, 33 may be flat or contoured, so as to provide a butt joint or an interlocking mating engagement between adjacent panels 12-12C, respectively. Also, the upper edge WO 00/79069 PCT/US00/16652 34 and lower edge 36 may also be flat for a butt joint or contoured so as to matingly engage the corresponding edge of an adjacent panel. Thus, an interlocked joint 38 is provided between the adjacent panels 12-12C with forward and rearward relative movement of the panels being inhibited by the matingly engaged contoured edges 32, 33, 34, 36. The contoured edges of the wall panels 12-12C may take various shapes which provide overlapping mating engagement.

As seen in Figures 9 and 10, the upper edge 34 of the wall panels 12-12C may also be provided with a plurality of notches 40 adapted to receive floor or wall joists 42. The joists 42 are supported by the inner concrete layer 14-14C and may be any known construction. The joists 42 are preferably positioned in the notches 40 of the wall panels 12-12C before the intermediate concrete layer 27 is poured.

The ends of the joists 42 may extend into the air gap 26-26C, as seen in Figure 10. An anchoring surface may extend from the ends of the joists or be formed therein so as to anchor the joints in the intermediate concrete layer 27. For example, the anchoring surface may be a nail or bolt in the end of the joist 42, or may be a varying dimension formed in the end of the joist 42. Decking material 44 may be attached to the joists 42 before the intermediate concrete layer 27 is poured. By installing the floor or roof joists in the notches 40, the need for a ledger beam on the wall is eliminated. By installing the joists and the decking material 44 before concrete layer 27 is poured, the wall panels 12-12C are braced during the pouring process.

Further, the decking material 44 provides a safe work platform at the top of the wall structure 10, 10A or 28.

WO 0079069 PCT/US00/16652 To complete the assembly, the joints between the edges 32, 33, 34, 36 may be filled with a rigid or flexible material that cures in place.

It is understood that either of the concrete layers may be oriented as the exterior wall of a building. Preferably, in an insulated wall, the insulation layer is adjacent the exterior concrete layer.

The present invention is also directed towards the method of making the wall panels 12-12C. The panels are precast, using a form, as shown in Figure 4, 14, 17, 20 and 21. More particularly, a lower form section 46 is provided with a bottom, and a perimeter edge 48. An upper form section 50 includes only a perimeter edge 52. An appropriate profile 54 is provided along the perimeter edges 48, 52 of the lower and upper form sections 46, 50 so as to create the contoured edges 32, 33, 34 and 36 of the panels 12-12C. The lower form section 46 may be textured to provide a desired appearance to the exterior of the first concrete layer 14- 14C, such as a brick pattern, as seen in Figures 16-17.

In making the wall panels 12, the first concrete layer 14 is poured into the lower form section 46. A screed may be run across the perimeter edge 48 to smooth and level the surface of the first concrete layer 14, as seen in Figure 4.

The upper form section 50 may then be attached to the lower form section 46 in any conventional manner, such as with side braces 55. The insulation layer 18 with the pre-installed connectors 20 are then set into the upper form section with the lower ends 22 of the connectors 20 extending through the wet concrete layer 14. The lower ends 22 of the connectors 20 rest upon the bottom 47 of the lower form 46, with the lower flange 24 of the connectors 20 supporting the WO 00/79069 PCT/US00/16652 insulation layer in a spaced relation above the first concrete layer 14, thereby defining the air gap 26. The upper form 50 may also have an inwardly extending lip (not shown) to support the insulation layer 18. The insulation layer also serves as the bottom of the upper form section The second concrete layer 16 is then poured into the upper form section 50, before the first concrete layer 14 cures.

Thus, the second concrete layer 16 is poured substantially immediately after the first concrete layer 14 is poured, and both layers 14, 16 cure substantially simultaneously. Accordingly the time required to manufacture the wall panels is minimized, without any delays waiting for the first poured concrete layer to cure before the second layer is poured, as in the prior art. After both concrete layers have cured, the forms 46, 50 can be stripped from the panel 12. Lifting tabs (not shown) may be cast into the second concrete layer 16 for attaching a cable for lifting the finished panel 12. However, in the preferred embodiment, connectors 20 have sufficient strength to be used as attachment points for lifting cables.

As seen in Figure 4, reinforcing fibers 56 may be provided throughout the concrete layers 14, 16.

The wall panel 12A is made in a manner similar to the wall panel 12. The first concrete layer 14A is first poured into the lower form section 46. The upper form section may then be attached to the lower form section 46, in any conventional manner, such as with side braces 55. A plurality of connector locators 96 extend across the forms, and are supported by the side braces 55, as best seen in Figures 14 and 15. A plurality of connectors 20A are then set into the locators, with the lower ends 22A of the 13 WO 00/79069 PCT/US00/16652 connectors 20A extending into the wet inner concrete layer 14A. The lower ends 22A of the connectors 20A may rest upon the bottom 47 of the lower form 46. The connectors 20A have a collar 98 which rests upon the locators 96. Aggregate or particulate material 99 may then be poured onto the exposed surface of the first concrete layer 14A, as seen in Figures 14 and 15. The second concrete layer 16A is then poured into the upper frame section 50, before the first concrete layer 14A cures. The aggregate or particulate material 99 supports the second concrete layer 16A, which is poured as soon as possible after the first concrete layer 14A is poured, such that the layers 14A, 16A cure substantially simultaneously.

Thus, the time required to manufacture the wall panels 12A is minimized, without any delays waiting for the firstpoured concrete layer to cure before the second layer is poured, as in the prior art. After both concrete layers 14A, 16A have cured, the forms 46, 50 can be stripped from the panel 12A. Lifting tabs (not shown) may be cast into the concrete layer 16A for attaching a cable for lifting the finished panel 12A. Upon lifting, the aggregate or particulate material 99 falls out of the panel 12A, thereby providing an air space 26A between the first and second layers 14A, 16A. The locators 96 may be pulled out of the forms 46, 50 before lifting the cured panel 12A, or will fall out with the aggregate or particular material 99 when the panel 12A is lifted.

In the methods depicted in Figures 14-17, it is understood that the aggregate 99 provides a rigid support for the second concrete layer 16A, 16B. The invention allows the concrete layer 14A, 14B to incorporate face brick or specially finished surfaces using the form liners. The rigid WO 00/79069 PCT/US00/16652 support provided by the aggregate allows the second concrete layer 16A, 16B to be provided with a smooth trowelled top surface. The inside surface of the concrete layer 16A, 16B is roughened, so as to allow the layer 16A, 16B to bond with the intermediate concrete 27 that fills the air gap 26A, 26B.

The method of making the wall panel 12B of Figure 16-17 is similar to that used to make the panels 12A, except that an insulation layer 18B is placed adjacent the first concrete layer 14B before the aggregate 99 is added. The flange 23B on the connector 20B limits the downward movement of the connector 20B relative to the insulation layer 18B.

The casting method illustrated in Figures 18 and 19 eliminates the use of the aggregate 99 by utilizing the plurality of cross braces 102 which support a strippable film or sheet 104. After the concrete layers 14B, 16B have cured, the sheet 104 and cross braces 102 are removed from the form, leaving the air gap 26B, which is adapted to receive the intermediate concrete layer, as described above with respect to panel 12.

The method illustrated by Figure 20 for the panel 12B replaces the aggregate 99 with a plurality of air bags 106.

The air bags 106 may have a textured or deformed upper surface so as to leave a roughened texture on the inside of the outer concrete layer 16B. After the concrete layers 14B, 16B have cured, the air bags 106 are removed to leave the air gap 26B. The individual air bags conform to the connectors so as to prevent concrete from filling a portion of the air gap 26B. It is noted that the air bags 106 may also be utilized in forming a non-insulated panel wherein the insulation layer 18B is eliminated. In such a non-insulated panel, the air bag or bladder 106 may have a textured or WO 00/79069 PCT/US00O/16652 deformed surface on each side adjacent the inner surfaces of the concrete layers 14B, 16B.

In the method depicted in Figure 21, a non-insulated panel 12C is created by supporting one or more light-gage corrugated or dimpled sheets 108 on the flange of the connectors 20C. Preferably, the sheets 108 are made of steel, and may be left in place after the concrete layers 14C, 16C have been cured, so as to define the air gap 26C therebetween.

It is understood that in all the methods of the present invention, the first concrete layers 14-14C and second concrete layers 16-16C are poured one after the other so as to cure substantially simultaneously, thereby minimizing the time required to make the wall panels 12-12C.

Figures 5-8 show various alternatives for the corners of the wall structure 10, 10A. In Figure 5, the corner panels 58, 60 are formed with 45-degree edges 62, 64, each of which are contoured to provide an interlocking miter joint. As an alternative shown in Figure 6, one corner panel 66 is formed with a contoured edge 68 while the adjacent corner panel is formed with a contoured surface 72 for interlocking mating engagement with the edge 68. As another alternative shown in Figure 7, the corner panels 74, 76 are provided with contoured interlocking edges 78, 80, respectively.

In each of the corner panels shown in Figures 5-7, the mating edges will tend to separate by the pressure of the intermediate concrete layer 27 when the intermediate layer is poured into the air gap 26-26C. Accordingly, the corner panels 58, 60, 66, 70 and 74, 76 are clamped or tied together in a convenient fashion. For example, as seen in Figure 5, a recess or hole 82 is provided in the outer concrete layer 16- WO 00/79069 PCT/US00/16652 16C for receiving a clamp 84, or a bolt or tie (not shown) extending through the hole 82. A plurality of spaced apart recesses or holes 82 are provided along the height of the panel for multiple clamps, bolts, or ties.

As a further alternative, as shown in Figure 8, a corner panel 86 may be used at the corners of the wall structure The corner panel 86 is similar to the flat panels 12- 12C, except that the inner and outer concrete layers 88, are formed with angled sections.

It is understood that corner panels can be used to form interior 90' corners as well as 450 and other angles.

It is understood that the present invention contemplates use of the wall panels in both insulated and non-insulated building structures, such as shown in Figures 1 and 11, respectively. Also, the wall panels can be used for other applications, such as a sound barrier wall between a highway and residential housing. Such a sound barrier wall may include sound proofing foam, or may be non-insulated. It is also understood that the insulation layer 18-18C may be laminated or non-laminated.

As shown in Figure 9, the panels may be assembled on blocks or shims. As shown in Figures 9 and 10, this allows the creation of an open volume into which footing concrete 29 may be installed. Footing concrete 29 may be installed by a separate placement operation or as a consequence of the placement of intermediate concrete layer 27. Footing concrete 29 may be confined using a trench in the subgrade (shown) or using temporary or permanent side and/or top forms (not shown). Footing concrete 29 may be reinforced by steel bars projecting through and supported by the shims 30. The 21-02-2001gent's Ref. No. P4047 334826 US 000016652 shims 30 can be constructed of precast concrete or other durable material.

18 AMENDED SHEET

Claims (18)

1. A method of making a wall panel, the method comprising: pouring a first concrete layer into a form with a perimeter edge and a bottom; the method including placing an insulation layer having a plurality of connectors with opposite first and second ends extending therethrough with the first end of the connectors extending through the first concrete layer to engage the bottom of the form and thereby support the insulation layer in spaced relation above the first concrete layer; pouring a second concrete layer on top of the insulation layer before the first concrete layer has cured, with the second end of the connectors extending into the second concrete layer; and curing the first and second concrete layers substantially simultaneously.

2. The method of claim 1, wherein the concrete layers are poured in a horizontal orientation.

3. The method of claim 1, further including forming a contoured edge on at least one of the first and second concrete layers.

4. The method of claim 1, wherein the connectors are installed in the insulation layer and then the insulation layer is placed in the form to support the o insulation layer above the first concrete layer.

5. The method of claim 1, further including forming at least one notch in an edge of the panel, the notch being adapted to receive one end of the joist. 20 6. A wall panel constructed in accordance with the method of any one of claims 1 to

7. A wall panel having: a first concrete layer; a second concrete layer 0% "cured substantially simultaneously with the first concrete layer; an insulation layer adjacent to the second concrete layer; an air gap between the insulation layer and the first concrete layer; and a plurality of connectors each having a first end extending through the first concrete layer to support the insulation layer in spaced relation to the first concrete layer so as to define the air gap, and a second end embedded in the second concrete layer ooooe without extending through the second concrete layer.

8. The wall panel of claim 7, wherein each connector has opposite ends, and each end has an anchoring surface for anchoring the connector ends in the respective concrete layers.

9. The wall panel of claim 7, wherein at least one of the concrete layers has a contoured edge adapted to matingly engage with a corresponding contoured edge of an adjacent wall panel. [RA:LIBTr]03600.doc:hxa The wall panel of claim 9, wherein the adjacent panels are co-linear to one another.

11. The wall panel of claim 9, wherein the adjacent panels are angularly disposed with respect to one another so as to form a corner of a wall structure.

12. The wall panel of claim 9, wherein the mating edges of adjacent panels interlock.

13. The wall panel of claim 7, wherein the first concrete layer has an upper edge with at least one notch adapted to receive a structural floor or roof element for support on the first concrete layer.

14. The wall panel of claim 7, wherein the concrete layers are formed with portions oriented at angles relative to each other so as to form a corner for a wall structure. The wall panel of claim 5, wherein each connector includes a flange for supporting the insulation layer in spaced relation to the first concrete layer.

16. The wall panel of claim 7, wherein the first concrete layer has opposite inner and outer sides, with the first end of each of the connectors extending through the first concrete layer from the inner side to the outside thereof. o 17. A composite wall structure having a plurality of wall panels according to any one of claims 7 to 16, the wall structure including shims providing a space between .00% 20 the base of the panels and the soil subgrade.

18. The wall structure of claim 17, wherein a continuous concrete foundation is placed in the space created below the panels such that the foundation contacts the first and second concrete layers in the panels.

19. The wall structure of claim 18, wherein the continuous concrete S" 25 foundation is placed concurrently with a layer of concrete field-cast between the spaced .0 apart first and second concrete layers of the panels.

20. A method of making a wall panel, the method substantially as ooo.oi hereinbefore described with reference to any one of the embodiments of the invention shown in the accompanying drawings.

21. A wall panel substantially as hereinbefore described with reference to any one of the embodiments of the invention shown in the accompanying drawings. [RALIBTr]03600.doc:hxa

22. A composite wall structure substantially as hereinbefore described with reference to any one of the embodiments of the invention shown in the accompanying drawings. Dated 16 March, 2004 Composite Technologies Corporation Patent Attorneys for the Applicant/Nominated Person SPRUSON FERGUSON go *S* .oe.o •gee [R:\LIBTT]03600.doc:hxa