Panel production kits, methods, and systems

Abstract

A method of forming a concrete panel that includes forming a concrete base with a plurality of holes, where the plurality of holes are distributed proximate to a perimeter of a casting surface of the concrete base, and securing casting rails along the casting surface of the concrete base to form a concrete panel form with a closed perimeter. The casting rails are secured using a plurality of anchors through the plurality of holes in the concrete base to couple the casting rails to the concrete base. A reinforcement device and/or an attachment device is introduced within the concrete panel form, and concrete is poured into the concrete panel form. After the poured concrete has solidified into a concrete panel, the concrete panel is removed.

1 - 20 . (canceled) 
     
     
         21 . A concrete panel casting system, comprising:
 a concrete base casting form having a plurality of side walls, a casting surface skin, and a frame supporting the plurality of side walls and the casting surface skin, wherein the plurality of side walls and the casting surface skin are removably attached to the frame;   a plurality of casting rails removably attachable to a casting surface of a formed concrete base; and   a plurality of anchors, wherein the anchors are removably attachable to the plurality of casting rails,   wherein the plurality of casting rails form a concrete panel form configured to receive concrete to form a concrete panel, wherein the plurality of casting rails are configured to form a closed perimeter on the formed concrete base with an opening to receive concrete to form the concrete panel.   
     
     
         22 . The system of  claim 21 , further comprising:
 one or more temperature regulating elements configured to be positioned on or within a casting base formed by the concrete base casting form.   
     
     
         23 . The system of  claim 22 , wherein the one or more temperature regulating elements includes one or more hollow tubes. 
     
     
         24 . The system of  claim 22 , wherein the one or more temperature regulating elements includes one or more conductive heating elements. 
     
     
         25 . The system of  claim 22 , wherein the one or more temperature regulating elements includes a reactive chemical layer applied to the casting surface skin. 
     
     
         26 . The system of  claim 22 , wherein the one or more temperature regulating elements is coupled to a processing module. 
     
     
         27 . The system of  claim 21 , further comprising a steel reinforcing mesh. 
     
     
         28 . The system of  claim 27 , wherein the steel reinforcing mesh includes a hollow interior. 
     
     
         29 . The system of  claim 21 , further comprising a cover,
 wherein the casting surface, the plurality of casting rails, and the cover define a sealed volume.   
     
     
         30 . The system of  claim 29 , further including reinforcing and/or attachment hardware that is attachable to the plurality of casting rails. 
     
     
         31 . The system of  claim 30 , further comprising a plurality of reinforcement members, a plurality of attachment devices, and an overhead hanging rail system, wherein the reinforcement members and the attachment devices are removably coupled to the casting rails via the overhead hanging rail system,
 wherein each casting rail is decoupled from any adjacent casting rail, and individually and removably coupled to and removable from the casting surface of the concrete base by fastening through at least one hole in one of the plurality of casting rails and one of the plurality of holes extending through a thickness of the concrete base.   
     
     
         32 . A method of forming a concrete panel, comprising:
 forming a concrete base having a plurality of holes, wherein the plurality of holes are distributed proximate to a perimeter of a casting surface of the concrete base;   removably securing casting rails along the casting surface of the concrete base to form a concrete panel form with a closed perimeter;
 wherein the casting rails are removably secured using a plurality of anchors through the plurality of holes in the concrete base to couple the casting rails to the concrete base; 
   introducing a reinforcement device and/or an attachment device within the concrete panel form;   pouring concrete into the concrete panel form;   allowing the poured concrete to solidify into a concrete panel; and   removing the concrete panel.   
     
     
         33 . The method of  claim 32 , wherein forming the concrete panel includes positioning one or more temperature regulating elements on or within a casting base formed by the concrete base casting form. 
     
     
         34 . The method of  claim 33 , wherein the one or more temperature regulating elements includes one or more hollow tubes, one or more conductive heating elements, or a reactive chemical layer applied to a casting surface skin. 
     
     
         35 . The method of  claim 34 , wherein the method includes coupling the one or more temperature regulating elements to a processing module. 
     
     
         36 . The method of  claim 32 , wherein forming the concrete panel includes positioning a steel reinforcing mesh on or within a casting base formed by the concrete base casting form. 
     
     
         37 . The method of  claim 36 , wherein the steel reinforcing mesh includes a hollow interior. 
     
     
         38 . A system, comprising:
 a concrete base casting form having a plurality of side walls, a casting surface skin, and a frame supporting the plurality of side walls and the casting surface skin;
 wherein the plurality of side walls and the casting surface skin are removably attachable to the frame; 
   a supply of concrete to pour into and harden within the concrete base casting form to form a concrete base, wherein the concrete base includes a casting surface formed by the casting surface skin, and one or more temperature regulating elements;   a plurality of casting rails removably attachable to the casting surface of the formed concrete base, wherein the plurality of casting rails form a concrete panel form configured to receive additional concrete to form a concrete panel, wherein the plurality of casting rails form a closed perimeter on the concrete base with an opening to receive concrete to form the concrete panel; and   a plurality of anchors, wherein the anchors removably attach the plurality of casting rails to a plurality of holes in the formed concrete base.   
     
     
         39 . The system of  claim 38 , wherein the one or more temperature regulating elements includes one or more hollow tubes, one or more conductive heating elements, or a reactive chemical layer applied to the casting surface skin. 
     
     
         40 . The system of  claim 38 , further comprising:
 a suspended framework coupled to the plurality of side walls, wherein the suspended framework includes a plurality of forming rods extending toward the concrete base casting form,   wherein the plurality of forming rods of the suspended framework are evenly spaced,   wherein the frame is steel,   wherein the concrete base casting form includes a plurality of cylindrical hollow sections,   wherein casting rails on a first side and a second side of the panel form each include an extension on an inwardly facing surface extending toward the opening, and wherein casting rails on a third side and a fourth side of the panel form each include an indentation on an inwardly facing surface extending away from the opening, and   wherein each casting rail is decoupled from any adjacent casting rail, and individually and removably coupled to and removable from the casting surface of the concrete base by fastening through at least one hole in one of the plurality of casting rails and one of the plurality of holes extending through a thickness of the concrete base.