Precast insulated concrete wall assembly

Abstract

A prefabricated concrete wall panel may include a concrete top beam, a concrete bottom beam, studs interposed between the top and bottom beams and a concrete exterior interposed between the top and bottom beams. Water-impervious protective end caps may be placed on ends of the studs to preclude contact between the studs and the concrete of the beams.

1 . A prefabricated concrete wall panel comprising:
 a concrete top beam;   a concrete bottom beam;   studs interposed between the top and bottom beams;   a concrete exterior interposed between the top and bottom beams; and   protective end caps on one or more of the studs interposed between the studs and the top and bottom beams.   
     
     
         2 . The wall panel of  claim 1  wherein the end caps comprise:
 a water impervious body configured to enclose an end of the stud; 
 fins attached to exterior surfaces of the body; and 
 one or more rebar supports formed in one or more of the fins. 
 
     
     
         3 . The wall panel of  claim 1  wherein the protective end caps are plastic. 
     
     
         4 . The wall panel of  claim 1  further comprising rebar supported by the protective end caps. 
     
     
         5 . Protective end caps for studs of a precast concrete wall panel with integral concrete beams, the end caps comprising a water impervious body configured to enclose an end of the stud and preclude direct contact between concrete and the stud within the integral concrete beams. 
     
     
         6 . The protective end cap of  claim 5  further comprising a tab configured to engage with a groove in the stud, the tab being oriented to be not orthogonal to an axis of the stud so that interaction of the tab and the groove in the stud lock the stud into the wall panel when the end cap is encased in the concrete beam. 
     
     
         7 . The protective end cap of  claim 5  further comprising a bottom having a chamfer, the chamfer being engageable with a portion of the concrete beam to lock the stud into the wall panel when the end cap is encased in the concrete beam. 
     
     
         8 . The protective end cap of  claim 5  further comprising:
 fins attached to exterior surfaces of the body; and 
 one or more rebar supports formed in one or more of the fins. 
 
     
     
         9 . A method for producing precast wall panels comprising the steps of:
 applying protective end caps to end portions of studs, leaving mid portions of the studs unenclosed by the end caps;   placing the studs in a pouring jig with spaces between the studs;   applying covering over the mid potions of the studs and mid portions of the spaces between the studs; and   pouring concrete onto the covering and around the protective end caps.   
     
     
         10 . The method of  claim 9  further comprising the step of:
 attaching rebar to the protective end caps prior to pouring the concrete, 
 wherein the step of pouring concrete includes pouring concrete around the rebar so that reinforced beams are produced in the wall.