The present invention relates generally to precast insulated panels, and more particularly to an apparatus for lifting and positioning precast insulated panels.
Precast insulated panels have become popular in construction for variability of design and efficiency of manufacture. Precast insulated panels are typically constructed in molds or formwork by pouring a first concrete panel or wythe, positioning an insulating board, and topping off with a second concrete panel or wythe. Such panels must then be removed from the mold, and as the panels can be quite large, in some cases as large as 12′×60′ and weighing thousands of pounds, positioning and erecting the panels can provide challenges. For this reason, erection lifting inserts are utilized. Cables from lifting devices such as cranes are attached to the erection lifting inserts to provide engagement points for the cables, and to position the panels on the construction site. Such erection lifting inserts must be quite strong, however, due to the dimensions of the panels, where the wythes may be no more than several inches thick, Such erection lifting inserts must also preferably be corrosion resistant.
An erection lifting insert is provided for precast insulated panels having an insulating material layer between opposing wythes. The insulating material layer, wythes, and precast insulated panel have respective widths. The erection lifting insert includes an insert body having opposing sides defining a thickness, opposing lateral sides defining a lateral width and a midpoint of the insert body, and top and bottom sides defining a height. The lateral width of the insert body can be greater than the width of the insulating material layer and less than the width of the precast insulated panel such that penetrating portions of the insert body can penetrate into the wythes. Opposing elongated engagement arms extend outward from the opposing sides of the insert body and downward past the bottom of the insert body. The opposing engagement arms can be provided on each lateral side of the insert body between the midpoint and the side edges. The engagement arms have a width less than the width of the wythes and a length greater than the lateral width of the insert body.
The insert body can include a plate having planar sides and a height less than the width of the plate, and a thickness less than the height of the plate. The engagement arms can be detachable from the plate. The opposing engagement arms can be provided by a single elongated member, and the plate can include holes for receiving the elongated members such that portions of the elongated members extend from opposing sides of the plate to form the opposing engagement arms. The elongated members can be curved and the engagement arms extend outward and downward from the plate. The plate can include three holes arranged in a triangle. Two of the holes can have a first diameter and form a side of the triangle arranged along, and adjacent to, the bottom side of the plate, and the third hole can have a second diameter larger than the first diameter, the third hole being arranged adjacent to the top side of the plate. The elongated engagement arms can include surface protrusions for engaging the wythe. The top of the insert body can have a width less than the bottom of the insert body.
At least one of the insert body and the engagement arms can be comprised of a fiber-reinforced polymer. The fibers of the fiber-reinforced polymer can include at least one selected from the group consisting of continuous and discontinuous fibers. The fiber of the fiber reinforced polymer can comprise at least one selected from the group consisting of carbon fibers, glass fibers, basalt fibers, aramid fibers. The matrix can comprises at least one selected from the group consisting of thermoplastic polyphenylene sulfide, polyethylene terephthalate, polyamide, polyurethane, polysulfone, polyether ketone, polyetherether ketone, thermoset epoxy, phenolic, nylon, vinyl ester and polyester. The fibers can be in a configuration that is at least one selected from the group consisting of non-crimped, multi-directional, woven, knitted, or braided configurations.
A precast insulated panel can include an insulating material layer, opposing wythes on each side of the insulating material layer, the insulating material layer, wythes, and the precast insulated panel having respective widths, and an erection lifting insert. The erection lifting insert can include an insert body having opposing sides defining a thickness, opposing lateral sides defining a lateral width and a midpoint of the insert body, and having top and bottom sides defining a height. The lateral width of the insert body can be greater than the width of the insulating material layer and less than the width of the precast insulated panel such that penetrating portions of the insert body penetrate into the wythes. Opposing elongated engagement arms extend outward from the opposing sides of the insert body and downward past the bottom of the insert body. The opposing engagement arms can be provided on each lateral side of the insert body between the midpoint and the side edges. The engagement arms can have a width less than the width of the wythes and a length greater than the lateral width of the insert body and penetrating into the wythes.
The erection lifting insert can be arranged such that the insert body is orthogonal to the wythes and at a top portion of the precast insulated panel. The erection lifting insert can be configured to sustain an ultimate tension load of 12,000 lbs. and an ultimate shear load of 6,000 lbs. The insulating material layer can include a cutout portion for receiving a portion of the erection lifting insert.
A method of making a precast insulated panel includes the step of providing an erection lifting insert with an insert body having opposing sides defining a thickness, opposing lateral sides defining a lateral width and a midpoint of the insert body, and having top and bottom sides defining a height. The lateral width of the insert body can be greater than the width of the insulating material layer and less than the width of the precast insulated panel such that penetrating portions of the insert body penetrate into the wythes. Opposing elongated engagement arms extend outward from the opposing sides of the insert body and downward past the bottom of the insert body. The opposing engagement arms can be provided on each lateral side of the insert body between the midpoint and the side edges. The engagement arms can have a width less than the width of the wythes and a length greater than the lateral width of the insert body and penetrate into the wythes. The erecting lifting insert is fixed in position in a mold. A first concrete wythe is poured into a mold, the first wythe embedding a first pair of opposing engagement arms. An insulating material layer is placed into the mold. A second wythe is poured into the mold, the second wythe embedding a second pair of the opposing engagement arms.
The opposing engagement arms can be provided by a single elongated member. The erection lifting insert can include a first elongated member providing a first pair of opposing engagement arms, and a second elongated member providing a second pair of engagement arms. The insert body can include a plate comprising holes for receiving the elongated members such that portions of the elongated engagement members extend from opposing sides of the plate to form the opposing engagement arms. The method can further include the step of positioning the plate in the mold and inserting a first elongated member into one of the holes and pouring a first wythe embedding the first elongated member. After positioning of the insulating layer the method can continue with the step of inserting a second elongated member into a second of the holes and pouring a second wythe embedding the second elongated member.
A method of erecting a precast insulated panel can include the steps of providing a precast insulated panel comprising an insulating material layer, opposing wythes on each side of the insulating material layer, the insulating material layer, wythes, and precast insulated panel having respective widths, and an erection lifting insert. The erection lifting insert comprises an insert body having opposing sides defining a thickness, opposing lateral sides defining a lateral width and a midpoint of the insert body, and having a top side and a bottom side defining a height. The lateral width of the insert body can be greater than the width of the insulating material layer and less than the width of the precast insulated panel such that penetrating portions of the insert body penetrate into the wythes. Opposing elongated engagement arms extend orthogonally outward from the opposing sides of the insert body and downward past the bottom of the insert body. The opposing engagement arms can be provided on each lateral side of the insert body between the midpoint and the side edges. The engagement arms can have a width less than the width of the wythes and a length greater than the lateral width of the insert body and penetrating into the wythes. A lifting device is engaged to the erecting lifting insert. The precast insulated panel is positioned and the precast insulated panel is secured in its position. The lifting device is disengaged from the erection lifting insert.
There are shown in the drawings embodiments that are presently preferred it being understood that the invention is not limited to the arrangements and instrumentalities shown, wherein:
An erection lifting insert is provided for precast insulated panels having an insulating material layer between opposing wythes, the insulating material layer, wythes, and precast insulated panel having respective widths. The erection lifting insert includes an insert body having opposing sides defining a thickness, opposing lateral sides defining a lateral width and a midpoint of the insert body, and top and bottom sides defining a height. The lateral width of the insert body is greater than the width of the insulating material layer and can be less than or no greater than the width of the precast insulated panel such that penetrating portions of the insert body can penetrate into the wythes. The top of the insert body can have a lateral width less than the lateral width of the bottom of the insert body. The erection lifting insert includes opposing elongated engagement arms extending outward from the opposing sides of the insert body and downward past the bottom of the insert body. The opposing engagement arms are provided on each lateral side of the insert body between the midpoint and the side edges. The engagement arms have a width less than the width of the wythes and a length greater than the lateral width of the insert body.
The insert body can be a plate having planar sides and a height less than the width of the plate, and a thickness less than the height of the plate. The engagement arms can be detachable from the plate. The opposing engagement arms can be provided by single elongated members, and the plate can have holes for receiving the elongated members such that portions of the single elongated member form both opposing engagement arms which extend from opposing sides of the plate. The single elongated member can be semicircular in shape. The single elongated member can be an inverted V in shape. Other shapes are possible. The engagement arms extend outward and downward from the insert body such that in the completed precast insulated panel the engagement arms extend outward and downward into the wythe such that thorough contact is made with the concrete forming the wythe. The length of the engagement arms will depend on the anticipated load that the erection lifting insert must carry, and for example can be from 12″ to 30″.
The insert body can include three holes arranged in a triangle. Two of the holes have a first diameter and form a side of the triangle arranged along, and adjacent to, the bottom side of the plate, and the third hole has a second diameter larger than the first diameter. The third hole can be arranged adjacent to the top side of the plate. The elongated engagement arms can include surface protrusions for engaging the wythe.
The erection lifting insert can be made of strong, light in weight and corrosion resistant materials. At least one of the insert body and the engagement arms comprises a fiber-reinforced polymer. The fiber-reinforced polymer can include at least one of continuous and discontinuous fibers. The fibers can be incorporated into the polymer matrix in different configurations. The configuration can be non-crimped, multi-directional, woven, knitted, or braided configurations, and combinations thereof.
The fibers of the fiber reinforced polymer can be any suitable material. The fibers can be carbon fibers, glass fibers, basalt fibers, aramid fibers, and combinations thereof. Other fiber materials are possible.
The matrix material can be any suitable material. The matrix material can be thermoplastic polyphenylene sulfide, polyethylene terephthalate, polyamide, polyurethane, polysulfone, polyether ketone, polyetherether ketone, thermoset epoxy, phenolic, nylon, vinyl ester and polyester, and combinations thereof. Other matrix materials are possible.
A precast insulated panel according to the invention includes an insulating material layer and opposing wythes on each side of the insulating material layer, and an erection lifting insert. The insulating material layer, wythes, and the precast insulated panel having respective widths. The erection lifting insert includes an insert body and opposing engagement arms. The insert body has opposing sides defining a thickness, opposing lateral sides defining a lateral width and a midpoint of the insert body, and having top and bottom sides defining a height. The lateral width of the insert body is greater than the width of the insulating material layer and can be less than the width of the precast insulated panel such that penetrating portions on lateral sides of the insert body penetrate into the wythes. The opposing elongated engagement arms extend outward from the opposing sides of the penetrating portions of the insert body and downward past the bottom of the insert body. The opposing engagement arms can be provided on each lateral side of the insert body between the midpoint and the lateral sides of the insert body. The engagement arms have a width less than the width of the wythes and a length greater than the lateral width of the insert body and penetrating into the wythes. The insulating layer comprises a cutout portion for receiving a portion of the erection lifting insert.
The erection lifting insert can be arranged such that the insert body is orthogonal to the wythes and at a top portion of the precast insulated panel. The erection lifting insert can be configured to sustain an ultimate tension load of 12,000 lbs. and an ultimate shear load of 6,000 lbs.
A method of making a precast insulated panel includes a step of providing an erection lifting insert according to the invention as previously described. The erecting lifting insert is fixed into a mold. A first concrete wythe is poured into the mold. The first wythe embeds a first pair of opposing engagement arms of the erection lifting insert. An insulating layer is then placed into the mold. A second wythe is poured into the mold. The second wythe embeds a second pair of the opposing engagement arms.
The method can include the step of providing a first elongated member providing a first pair of opposing engagement arms, and a second elongated member providing a second pair of engagement arms. The insert body can be a plate comprising holes for receiving the elongated members such that portions of the elongated engagement members extend from opposing sides of the plate to form the opposing engagement arms. The method further can include the step of positioning the plate in the mold and inserting a first elongated member into one of the holes and pouring a first wythe embedding the first elongated member. After positioning of the insulating layer, the method can include inserting a second elongated member into a second of the holes and pouring a second wythe embedding the second elongated member.
A method of erecting a precast insulated panel can include the step of providing a precast insulated panel with an erection lifting insert according to the invention. A suitable lifting device is engaged to the erecting lifting insert. The lifting device can be any such device, for example a crane or forklift. Other lifting devices and machinery are possible. The precast insulated panel is positioned and secured in a desired location. The lifting device is then disengaged from the erection lifting insert.
There is shown in
A recess plug 50 is provided to position the erection lifting insert 10 in a mold or formwork during construction of the precast insulated panel and to provide a recess for the lifting device. As shown in
As shown in
A first concrete wythe portion 70 is then poured into the mold 60 (
A layer 74 of insulation is then placed into the mold 60 over the first wythe 70 (
A second wythe layer 80 is then poured into the mold 60 (
The completed precast insulated panel 100 can then be removed from the mold 60 (
The precast insulated panel of the invention can be positioned by erection lifting devices that are currently in use, for example cranes. There is shown in
The invention as shown in the drawings and described in detail herein disclose arrangements of elements of particular construction and configuration for illustrating preferred embodiments of structure and method of operation of the present invention. It is to be understood however, that elements of different construction and configuration and other arrangements thereof, other than those illustrated and described may be employed in accordance with the spirit of the invention, and such changes, alternations and modifications as would occur to those skilled in the art are considered to be within the scope of this invention as broadly defined in the appended claims. In addition, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
This application claims priority to U.S. Provisional Patent Application No. 62/981,685 filed on Feb. 26, 2020, entitled “NON-CORRODING ERECTION LIFTING INSERTS FOR PRECAST CONCRETE”, the entire disclosure of which incorporated herein by reference.
This invention was made with government support under Contract No. DE-AC05-00OR22725 awarded by the U.S. Department of Energy. The government has certain rights in this invention.
Number | Date | Country | |
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62981685 | Feb 2020 | US |