Insulated tilt-up wall panel

Abstract

A tilt-up wall panel formed on a horizontal support surface within a form comprises an outer foam layer having a top surface, and an outer surface with an outer finish layer applied thereto. An intermediate concrete layer having a bottom surface and a top surface is applied, at the bottom surface thereof, to the top surface of the outer foam layer. An intermediate foam layer having a bottom surface and a top surface is applied, at the bottom surface thereof, to the top surface of the intermediate concrete layer. A concrete inner layer having a bottom surface and a top surface is applied, at the bottom surface thereof, to the top surface of the intermediate foam layer. The tilt-up wall panel is then raised to a vertical position to form part of a wall of a building. Methods of forming the tilt-up wall panel are disclosed.

1 . A tilt-up wall panel assembly comprising:
 a first foam layer comprising:
 a first surface of the first foam layer; and 
 a second surface of the first foam layer; and 
   a first concrete layer comprising:
 a first surface of the first concrete layer; and 
 a second surface of the first concrete layer, 
   wherein the second surface of the first foam layer is disposed opposite to the first surface of the first foam layer;   wherein the second surface of the first concrete layer is disposed opposite to the first surface of the first concrete layer,   wherein the second surface of the first foam layer is disposed adjacent to the first surface of the first concrete layer,   wherein at least one of the first foam layer and the first concrete layer defines a first keyed recess having a narrowed opening, and   wherein another of the at least one of the first foam layer and the first concrete layer comprises a protrusion having a broadened portion that is wider than the narrowed opening and that is disposed in the first keyed recess, beyond the narrowed opening, to resist the first concrete layer separating from the first foam layer.   
     
     
         2 . A tilt-up wall panel comprising:
 a first foam layer comprising:
 a first surface of the first foam layer; and 
 a second surface of the first foam layer, which is disposed opposite to the first surface of the first foam layer; 
   a first concrete layer comprising:
 a first surface of the first concrete layer that is disposed adjacent to the second surface of the first foam layer; and 
 a second surface of the first concrete layer, which is disposed opposite to the first surface of the first concrete layer; and 
   a second foam layer comprising:
 a first surface of the second foam layer that is disposed adjacent to the second surface of the first concrete layer; and 
 a second surface of the second foam layer, which is disposed opposite to the first surface of the second foam layer, 
   wherein at least one of the first foam layer and the first concrete layer defines a first keyed recess having a narrowed opening, and   wherein another of the at least one of the first foam layer and the first concrete layer comprises a protrusion having a broadened portion that is wider than the narrowed opening and that is disposed in the first keyed recess, beyond the narrowed opening, to resist the first concrete layer separating from the first foam layer.