Insulated cast concrete wall system and insulation tie

Abstract

Disclosed is a tie for securing insulation to a cast concrete wall comprising: a head; a shaft attached to the head and having a longitudinal axis, the shaft comprising a series of barbs positioned at pre-determined longitudinal positions along the longitudinal axis, each successive barb being rotated about the longitudinal axis by a pre-determined rotational increment from the immediately preceding barb; and, a tip on the shaft. There is also disclosed a system for constructing an insulated concrete wall comprising: a set of concrete forms comprising two opposing partitions set apart a pre-determined distance; a sheet of insulation secured between the partitions adjacent one of the partitions; and, at least one tie consisting essentially of a head, a shaft attached to the head and a pointed or wedge-shaped tip on the shaft, the tie being inserted through the sheet of insulation such that the tip elastically deforms the insulation to permit passage of the shaft through the insulation and a portion of the shaft extends beyond the insulation into a cavity defined within the forms for securing the insulation to the concrete once the concrete has been poured and cured. A method of constructing an insulated cast concrete wall and a process for making an insulation tie are also disclosed. Inserting the tie into the insulation can be done on-site without any prior preparation of the insulation and can be inserted in any desired pattern greatly facilitating the construction of custom cast concrete walls. Insulation of both sides of the concrete wall can be conveniently done without significant additional labor. A veneer may be applied to one or both insulated surfaces of the cast concrete wall by fastening the veneer to the tie.

1 . A tie for securing insulation to a cast concrete wall comprising: 
 (a) a head;    (b) a shaft attached to the head and having a longitudinal axis, the shaft comprising a series of barbs positioned at pre-determined longitudinal positions along the longitudinal axis, each successive barb being rotated about the longitudinal axis by a predetermined rotational increment from the immediately preceding barb; and,    (c) a tip on the shaft.    
     
     
         2 . The tie according to  claim 1 , wherein the tip is pointed or wedge-shaped.  
     
     
         3 . The tie according to  claim 2 , wherein each successive rotational increment is 90 degrees.  
     
     
         4 . The tie according to  claim 3 , wherein the shaft is of uniform thickness.  
     
     
         5 . The tie according to  claim 4  wherein the barbs are triangular in cross-section.  
     
     
         6 . The tie according to  claim 5 , wherein each barb extends a pre-determined uniform distance transversely from the longitudinal axis.  
     
     
         7 . The tie according to  claim 6 , wherein at least one of the pre-determined longitudinal positions is pre-determined according to insulation thickness.  
     
     
         8 . The tie according to  claim 7 , wherein the series of barbs further comprises counterpart barbs juxtaposed 180 degrees about the longitudinal axis.  
     
     
         9 . A process for producing an insulation tie comprising: 
 (a) providing a mold having a mold cavity having a shape complementary to the tie as defined in  claim 1;     (b) introducing a plastic into the mold; and,    (c) forming the tie.    
     
     
         10 . A process for producing an insulation tie comprising: 
 (a) providing a mold having a mold cavity having a shape complementary to the tie as defined in  claim 8;     (b) introducing a plastic into the mold; and,    (c) forming the tie.    
     
     
         11 . A system for constructing an insulated cast concrete wall comprising: 
 (a) a set of concrete forms comprising two opposing partitions set apart a pre-determined distance;    (b) a sheet of insulation secured between the partitions adjacent one of the partitions; and,    (c) at least one tie consisting essentially of a head, a shaft attached to the head and a pointed or wedge-shaped tip on the shaft, the tie being inserted through the sheet of insulation such that the tip elastically deforms the insulation to permit passage of the shaft through the insulation and a portion of the shaft extends beyond the insulation into a cavity defined within the forms for securing the insulation to the concrete once the concrete has been poured and cured.    
     
     
         12 . The system according to  claim 11 , wherein the shaft has a longitudinal axis and comprises a series of barbs positioned at pre-determined longitudinal positions along the longitudinal axis, each successive barb being rotated about the longitudinal axis by a predetermined rotational increment from the immediately preceding barb.  
     
     
         13 . The system according to  claim 12 , wherein the tip of the tie inserted through the sheet of insulation terminates within the cavity.  
     
     
         14 . The system according to  claim 13 , wherein the partitions are secured together by connecting rods between which the sheets of insulation are wedged to secure the insulation between the partitions before the concrete is poured.  
     
     
         15 . The system according to  claim 14 , wherein the pre-determined rotational increment is 90 degrees, the shaft is of uniform thickness, the series of barbs further comprises counterpart barbs juxtaposed 180 degrees about the longitudinal axis, the barbs are triangular in cross-section and extend a pre-determined uniform distance transversely from the longitudinal axis, and at least one of the pre-determined longitudinal positions is pre-determined according to insulation thickness.  
     
     
         16 . The system according to  claim 15 , wherein a sheet of insulation is secured adjacent each of the partitions between the partitions and each sheet of insulation is provided with at least one tie inserted through the sheet.  
     
     
         17 . A method for constructing an insulated cast concrete wall comprising the steps of: 
 (a) providing a set of concrete forms having opposing partitions set apart a pre-determined distance;    (b) providing at least one tie consisting essentially of a head, a shaft attached to the head and a pointed or wedge-shaped tip on the shaft;    (c) inserting at least one tie provided in step (b) through a sheet of insulation such that the tip elastically deforms the insulation to permit passage of the shaft through the insulation until a portion of the shaft extends beyond the insulation;    (d) securing the sheet of insulation between the partitions adjacent one of the partitions such that the portion of the shaft extending beyond the insulation extends into a cavity defined within the forms; and,    (e) pouring concrete into the cavity and curing the concrete.    
     
     
         18 . The method according to  claim 17 , wherein the shaft has a longitudinal axis and comprises a series of barbs positioned at pre-determined longitudinal positions along the longitudinal axis, each successive barb being rotated about the longitudinal axis by a pre-determined rotational increment from the immediately preceding barb.  
     
     
         19 . The method according to  claim 18 , wherein the tip of the tie inserted through the sheet of insulation terminates within the cavity.  
     
     
         20 . The method according to  claim 19 , wherein the partitions are secured together by connecting rods between which the sheets of insulation are wedged to secure the insulation between the partitions before the concrete is poured.  
     
     
         21 . The method according to  claim 20 , wherein the pre-determined rotational increment is 90 degrees, the shaft is of uniform thickness, the series of barbs further comprises counterpart barbs juxtaposed 180 degrees about the longitudinal axis, the barbs are triangular in cross-section and extend a pre-determined uniform distance transversely from the longitudinal axis, and at least one of the pre-determined longitudinal positions is pre-determined according to insulation thickness.  
     
     
         22 . The method according to  claim 21 , wherein a sheet of insulation is secured adjacent each of the partitions between the partitions and each sheet of insulation is provided with at least one tie inserted through the sheet.  
     
     
         23 . The method according to  claim 22 , further comprising removing the forms and attaching a veneer to the head of at least one of the ties of the insulated cast concrete wall.