Concrete wall systems and methods and spacers therefor

Abstract

A concrete wall system includes first and second opposing wall panels and a plurality of spacers disposed between the first and second wall panels. A plurality of reinforcing bars is placed between the first and second wall panels and supported by the spacers, and a concrete core is disposed between the first and second wall panels such that the spacers and the reinforcing bars are embedded in the concrete core. Each one of the spacers has a cup-like body defining a closed first end and an open second end with a flange formed on the second end. The spacer bodies are tapered so that the spacers are stackable.

1 . A spacer for positioning two opposing wall panels relative to one another, said spacer comprising:
 a cup-like body defining a first end and an open second end and having a base piece at said first end and a flange formed on said second end;   wherein said base piece presents a surface that is attachable to a first one of said two wall panels and said flange presents a surface that is attachable to a second one of said two wall panels; and   wherein said body is tapered such that said first end has a smaller cross-sectional area than said second end.   
     
     
         2 . The spacer of  claim 1  wherein said body comprises four side walls arranged in mutually orthogonal fashion, said base piece is rectangular in shape and is connected to said four side walls at said first end of said body, and said flange is rectangular in shape and extends outward from each of said four side walls. 
     
     
         3 . The spacer of  claim 2  further comprising at least one opening formed in each one of said four side walls. 
     
     
         4 . The spacer of  claim 1  wherein said spacer is of a single-piece construction. 
     
     
         5 . The spacer of  claim 1  wherein said spacer is made of injection molded plastic. 
     
     
         6 . A concrete wall system comprising:
 first and second opposing wall panels;   a plurality of spacers disposed between said first and second wall panels, each one of said spacers comprising a cup-like body defining a first end and an open second end and having a base piece at said first end and a flange formed on said second end, said body being tapered such that said first end has a smaller cross-sectional area than said second end;   wherein each base piece is attached to said first wall panel and each flange is attached to said second wall panel;   a plurality of reinforcing bars placed between said first and second wall panels and supported by said spacers; and   a concrete core disposed between said first and second wall panels such that said spacers and said reinforcing bars are embedded in said concrete core.   
     
     
         7 . The concrete wall system of  claim 6  wherein each cup-like body comprises four side walls arranged in mutually orthogonal fashion, said base piece is rectangular in shape and is connected to said four side walls at said first end of said body, and said flange is rectangular in shape and extends outward from each of said four side walls. 
     
     
         8 . The concrete wall system of  claim 7  wherein each cup-like body has at least one opening formed in each one of said four side walls, and wherein said reinforcing bars extend through corresponding openings. 
     
     
         9 . The concrete wall system of  claim 6  wherein each base piece is attached to said first wall panel with an adhesive and each flange is attached to said second wall panel with an adhesive. 
     
     
         10 . The concrete wall system of  claim 6  further comprising a channel attached to a floor, and wherein a bottom portion of said first wall panel abuts and is fastened to one side of said channel and a bottom portion of said second wall panel abuts and is fastened to another side of said channel. 
     
     
         11 . The concrete wall system of  claim 6  wherein one of said first and second wall panels comprises a board of insulating material with an outer finish surface clad thereto. 
     
     
         12 . A method of constructing a concrete wall system comprising:
 providing a shell assembly comprising first and second opposing wall panels in parallel, spaced-apart relation so as to define an inter-panel space therebetween with a plurality of spacers disposed in said inter-panel space, each one of said spacers comprising a cup-like body defining a first end and an open second end and having a base piece at said first end and a flange formed on said second end, said body being tapered such that said first end has a smaller cross-sectional area than said second end;   inserting reinforcing bars through openings formed in said spacers; and   pouring concrete into said inter-panel space.   
     
     
         13 . The method of  claim 12  further comprising:
 attaching a channel to a floor; 
 fitting said shell assembly over said channel with a bottom portion of said first wall panel abutting a first side of said channel and a bottom portion of said second wall panel abutting a second side of said channel; and 
 fastening said first wall panel to said first side of said channel and said second wall panel to said second side of said channel prior to pouring concrete into said inter-panel space. 
 
     
     
         14 . The method of  claim 12  further comprising inserting at least one electrical conduit through openings formed in said spacers prior to pouring concrete into said inter-panel space. 
     
     
         15 . The method of  claim 14  further comprising installing a junction box in said shell assembly prior to pouring concrete into said inter-panel space. 
     
     
         16 . The method of  claim 15  wherein installing a junction box includes:
 cutting an opening in said first wall panel; 
 cutting a gap is said conduit, wherein said gap is aligned with said opening in said first wall panel; and 
 inserting said junction box into said opening in said first wall panel and said gap such that tabs on said junction box abut said first wall panel. 
 
     
     
         17 . A column comprising:
 first, second, third and fourth panels arranged in mutually orthogonal fashion to form a rectangular configuration, wherein said first and third panels are arranged parallel to each other and said second and fourth panels are arranged parallel to each other;   at least one spacer extending between said first and third panels, said spacer comprising a length of pipe having an end cap attached to each and multiple openings formed therein;   a horizontal reinforcing bar inserted lengthwise in said length of pipe;   at least one vertical reinforcing bar inserted through a pair of said openings formed in said length of pipe; and   a concrete core disposed between said first, second, third and fourth panels such that said spacer and said reinforcing bars are embedded in said concrete core.   
     
     
         18 . The column of  claim 17  wherein said length of pipe is PVC pipe. 
     
     
         19 . The column of  claim 17  further comprising a second vertical reinforcing bar inserted through a second pair of said openings formed in said length of pipe. 
     
     
         20 . The column of  claim 17  further comprising:
 a second spacer extending between said first and third panels, said second spacer comprising a second length of pipe having an end cap attached to each and multiple openings formed therein; 
 a second horizontal reinforcing bar inserted lengthwise in second said length of pipe; and 
 a second vertical reinforcing bar inserted through a pair of said openings formed in said second length of pipe. 
 
     
     
         21 . The column of  claim 17  further comprising:
 a second spacer extending between said second and fourth panels, said second spacer comprising a second length of pipe having an end cap attached to each and multiple openings formed therein; and 
 a second horizontal reinforcing bar inserted lengthwise in second said length of pipe. 
 
     
     
         22 . The column of  claim 21  wherein said at least one vertical reinforcing bar is inserted through a pair of said openings formed in said second length of pipe. 
     
     
         23 . The column of  claim 21  further comprising a second vertical reinforcing bar inserted through a pair of said openings formed in said second length of pipe.