Tilt-Wall Panel

Abstract

Embodiments of a panel for use in building a tilt-wall building are disclosed, some of which comprise a plurality of structural studs, each comprising: a baseplate; an exterior-facing sidewall and an interior-facing sidewall connected by the baseplate; and a tab punched out of each of the sidewalls; an exterior concrete surface in which the tabs punched out of the exterior-facing sidewalls are embedded; and an interior concrete surface in which the tabs punched out of the interior-facing sidewalls are embedded; where the exterior and interior concrete surfaces are substantially planar surfaces that are substantially parallel to each other. Methods for forming tilt-wall panels are also disclosed.

1 . A tilt-wall panel comprising:
 a plurality of structural studs, each comprising:
 a baseplate; 
 an exterior-facing sidewall and an interior-facing sidewall connected by the baseplate; and 
 a tab punched out of each of the sidewalls, each tab comprising:
 a tab leg that is substantially planar and is connected to the sidewall at one end of the tab leg, and that projects outwardly from the sidewall at an angle of less than ninety degrees to the sidewall; and 
 a tab foot extending from the tab leg and curving either away from or toward a hole in the sidewall created by the tab punched out of the sidewall; 
 
 where the structural studs are arranged such that their baseplates are substantially parallel to each other and voids are formed between successive structural studs; 
   an exterior concrete surface in which the tabs punched out of the exterior-facing sidewalls are embedded; and   an interior concrete surface in which the tabs punched out of the interior-facing sidewalls are embedded;   where the exterior and interior concrete surfaces are substantially planar surfaces that are substantially parallel to each other.   
   
   
       2 . The tilt-wall panel of  claim 1 , where one or more of the holes is defined by a base side and a top side, the base side has a greater length than the top side, and the tab leg extends from the base side. 
   
   
       3 . The tilt-wall panel of  claim 1 , where one or more of the structural studs comprises a plurality of tabs. 
   
   
       4 . The tilt-wall panel of  claim 3 , where the plurality of tabs is spaced such that the gap between successive tab leg connections to the sidewall is less than about six inches. 
   
   
       5 . The tilt-wall panel of  claim 4 , where the gap between successive tab leg connections to the sidewall is about four inches. 
   
   
       6 . The tilt-wall panel of  claim 1 , further comprising an insulation material in the voids formed between the structural studs. 
   
   
       7 . The tilt-wall panel of  claim 1 , further comprising a rubberized insulation material applied to the tabs punched out of the exterior-facing sidewalls of the structural studs before the tabs were embedded in concrete. 
   
   
       8 . The tilt-wall panel of  claim 1 , further comprising a radiant barrier wrapped over the tabs punched out of the exterior-facing sidewalls of the structural studs before the tabs were embedded in concrete. 
   
   
       9 . The tilt-wall panel of  claim 1 , further comprising wire mesh laid over both sidewalls of the structural studs before the tabs punched out of the sidewalls were embedded in concrete. 
   
   
       10 . The tilt-wall panel of  claim 1 , further comprising lifting anchors laid in the voids formed between the structural studs prior to embedding the tabs in concrete, such that a portion of each lifting anchor is exposed in one or both of the concrete surfaces. 
   
   
       11 . The tilt-wall panel of  claim 1 , further comprising support anchors laid in the voids formed between the structural studs prior to embedding the tabs in concrete, such that a portion of each support anchor is exposed in one or both of the concrete surfaces. 
   
   
       12 . A method of building a tilt-wall panel, comprising:
 obtaining a plurality of structural studs, each stud comprising:
 a baseplate; 
 an exterior-facing sidewall and an interior-facing sidewall connected by the baseplate; and 
 a tab punched out of each of the sidewalls, each tab comprising:
 a tab leg that is substantially planar and is connected to the sidewall at one end of the tab leg, and that projects outwardly from the sidewall at an angle of less than ninety degrees to the sidewall; and 
 a tab foot extending from the tab leg and curving either away from or toward a hole in the sidewall created by the tab punched out of the sidewall; 
 
   arranging the structural studs such that their baseplates are substantially parallel to each other and voids are formed between successive structural studs;   forming an exterior concrete surface in which the tabs punched out of the exterior-facing sidewalls are embedded; and   forming an interior concrete surface in which the tabs punched out of the interior-facing sidewalls are embedded;   where the exterior and interior concrete surfaces are substantially planar surfaces that are substantially parallel to each other.   
   
   
       13 . The method of  claim 12 , further comprising:
 laying lifting anchors in the voids formed between the structural studs prior to embedding the tabs in concrete, such that a portion of each lifting anchor is exposed once the concrete surfaces are formed.   
   
   
       14 . The method of  claim 12 , further comprising:
 laying support anchors in the voids formed between the structural studs prior to embedding the tabs in concrete, such that a portion of each support anchor is exposed once the concrete surfaces are formed.   
   
   
       15 . The method of  claim 12 , further comprising placing an insulation material in the voids formed between the structural studs. 
   
   
       16 . The method of  claim 12 , further comprising applying a rubberized insulation material to the tabs punched out of the exterior-facing sidewalls of the structural studs prior to embedding the tabs in concrete. 
   
   
       17 . The method of  claim 12 , further comprising wrapping a radiant barrier over the tabs punched out of the exterior-facing sidewalls of the structural studs prior to embedding the tabs in concrete. 
   
   
       18 . The method of  claim 12 , further comprising laying wire mesh over both sidewalls of the structural studs prior to embedding the tabs punched out of the sidewalls in concrete. 
   
   
       19 . A tilt-wall panel comprising:
 a plurality of structural studs, each comprising:
 a baseplate; 
 an exterior-facing sidewall and an interior-facing sidewall connected by the baseplate; 
 a vertical tab punched out of each of the sidewalls and a vertical hole resulting from the vertical tab, the tab comprising:
 a tab leg that is substantially planar and is connected to the sidewall at one end of the tab leg, and that projects outwardly from the sidewall at an angle of less than ninety degrees to the sidewall; and 
 a tab foot extending from the tab leg of the vertical tab punched out of the sidewall and curving either away from or toward the vertical hole in the sidewall resulting from the vertical tab punched out of the sidewall; and 
 
 a horizontal tab punched out of each of the sidewalls and a horizontal hole resulting from the horizontal tab, the tab comprising:
 a tab leg that is substantially planar and is connected to the sidewall at one end of the tab leg, and that projects outwardly from the sidewall at an angle of less than ninety degrees to the sidewall; and 
 a tab foot extending from the tab leg of the horizontal tab punched out of the sidewall and curving either away from or toward the horizontal hole in the sidewall resulting from the horizontal tab punched out of the sidewall; 
 
 where the end of vertical tab leg that is connected to the sidewall is substantially perpendicular to the end of the horizontal tab leg that is connected to the sidewall; and 
 where the structural studs are arranged such that their baseplates are substantially parallel to each other and voids are formed between successive structural studs; 
   an exterior concrete surface in which the tabs punched out of the exterior-facing sidewalls are embedded; and   an interior concrete surface in which the tabs punched out of the interior-facing sidewalls are embedded;   where the exterior and interior concrete surfaces are substantially planar surfaces that are substantially parallel to each other.   
   
   
       20 . The tilt-wall panel of  claim 19 , where:
 one or more of the vertical holes is defined by a base side and a top side, the base side has a greater length than the top side, and the vertical tab leg the extends from the base side; and   one or more of the horizontal holes is defined by a base side and a top side, the base side has a greater length than the top side, and the horizontal tab leg the extends from the base side.   
   
   
       21 . The tilt-wall panel  claim 19 , where one or more of the structural studs comprises a plurality of vertical tabs and resulting vertical holes and horizontal tabs and resulting horizontal holes. 
   
   
       22 . The tilt-wall panel of  claim 21 , where the vertical tabs and vertical holes and the horizontal tabs and horizontal holes are positioned in an alternating arrangement on the sidewall such that there is a horizontal tab and horizontal hole between each vertical tab and vertical hole. 
   
   
       23 . The tilt-wall panel of  claim 22 , where the horizontal holes and the vertical holes are spaced such that the distance between the centers of successive vertical and horizontal holes is less than about 6 inches. 
   
   
       24 . The tilt-wall panel of  claim 23 , where the horizontal holes and the vertical holes are spaced such that the distance between the centers of successive vertical and horizontal holes is about 4 inches. 
   
   
       25 . The tilt-wall panel of  claim 19 , further comprising an insulation material in the voids formed between the structural studs. 
   
   
       26 . The tilt-wall panel of  claim 19 , further comprising a rubberized insulation material applied to the tabs punched out of the exterior-facing sidewalls of the structural studs before the tabs were embedded in concrete. 
   
   
       27 . The tilt-wall panel of  claim 19 , further comprising a radiant barrier wrapped over the tabs punched out of the exterior-facing sidewalls of the structural studs before the tabs were embedded in concrete. 
   
   
       28 . The tilt-wall panel of  claim 19 , further comprising wire mesh laid over both sidewalls of the structural studs before the tabs punched out of the sidewalls were embedded in concrete. 
   
   
       29 . The tilt-wall panel of  claim 19 , further comprising lifting anchors laid in the voids formed between the structural studs prior to embedding the tabs in concrete, such that a portion of each lifting anchor is exposed in one or both of the concrete surfaces. 
   
   
       30 . The tilt-wall panel of  claim 19 , further comprising support anchors laid in the voids formed between the structural studs prior to embedding the tabs in concrete, such that a portion of each support anchor is exposed in one or both of the concrete surfaces.