Insulated Wall System

1 . A prefabricated wall panel comprising

a. At least one foam section designed with vertical voids into which concrete is later poured, each foam section having an inner and outer surface, two sides and top and bottom sections with horizontal voids into which concrete is poured to form horizontal studs, the inner and outer surfaces having at least one slot per void, the slot connecting the vertical voids with the surface; and

b. a plurality of metal strips, the metal strips comprising

i. a longitudinal metal strip being situated within a slot,

ii. two longitudinal fastening strips projecting perpendicularly from a longitudinal metal strip, the fastening strips being adjacent to the outer surface of the two foam sections;

iii. a plurality of clearance holes in the longitudinal metal strip;

iv. a plurality of embed tabs projecting from the edge opposite the fastening strips;

v. each embed tab having at least one hole;

vi. between each pair of embed tabs, a foam tab that grips the inside wall of the outer foam accurately positioning and securing the fastener strips in place within the foam.

2 . A partially prefabricated wall system comprising:

a. A plurality of wall panels, each panel comprising

i. a plurality of foam sections sized to leave voids into which concrete is later poured, each foam section having an inner and outer surface and two sides;

ii. a plurality of metal strips, the metal strips comprising

a) a longitudinal metal strip being situated between the sides of two foam sections,

b) two longitudinal fastening strips attached perpendicularly to a longitudinal metal strip, the fastening strips being adjacent to the outer surface of the two foam sections;

c) a plurality of clearance holes in the longitudinal metal strip;

d) a plurality of embed tabs projecting from the edge opposite the fastening strips;

e) each embed tab having at least one hole;

f) between each pair of embed tabs, a foam tab to hold the two inner foam section in place and partially separate the foam from the concrete to be poured into a form.

b. a track into which one end of the wall panels is placed;

c. a cap which fits over the upper ends of a plurality wall panels; and

d. concrete poured into the top of the panels to fill the voids in the panels.

3 . An insulated wall system comprising:

a) a plurality of prefabricated panels comprised of one or more pieces of foam material and one or more fastening strips, the foam material having an upper end, a lower end, an internal surface, an external surface, the two sections of foam material being spaced apart and parallel to each other to form at least one longitudinal channel disposed within the adjacent internal surfaces of the foam material, the fastening strip being longitudinally disposed on a side edge of one of the pieces of foam material, each piece of foam material further including at least one notch that functions to hold two pieces of foam materials together, each fastening strip comprising a first flange and a second flange disposed generally parallel to each other and connected by a connecting flange disposed generally perpendicularly to the first and second flanges, the first, connecting and second flanges forming two adjacent generally C-shaped channels, each C-shaped channel having a piece of foam material disposed therein, the fastening strip further including one or more embed tabs that extend generally perpendicularly from the second flange, and one or more rigid channels disposed on the upper end the foam material and encasing both the foam material and fastening strip;

b) one or more retaining tracks secured to a floor slab or footing and sized to retain a bottom end of one or more of the prefabricated panels; and

c) one or more concrete columns disposed within the longitudinal channel in the prefabricated panels wherein the embed tab is embedded within the concrete column and at least the second flange and the adjacent internal surfaces of foam material are in physical contact with the concrete column.

4 . The insulated wall system of claim 3 further including additional foam disposed between the internal surfaces of the foam material to form a longitudinal channel that is centered around the embed tab of the fastening strip.

4 . The insulated wall system of claim 4 further including additional foam disposed between the internal surfaces of the foam material to form a horizontal channel located at the top end of the foam material and a horizontal channel located at the bottom of the foam materials, both the top channel and bottom channel being in fluid communication with the longitudinal channel, wherein a upper concrete beam is disposed within the top channel and a lower concrete beam is disposed within the bottom channel.

6 . The insulated wall system of claim 5 wherein the concrete column, upper concrete beam and lower concrete beam are formed in situ by pouring a concrete slurry into the longitudinal channel, upper channel and lower channel.

7 . The insulated wall system of claim 1 wherein the second flange is comprised of two or more a flat panels disposed perpendicularly to the connecting flange in a series along the longitudinal axis of the connecting flange with the embed tab being disposed between the two flat panels.

8 . The insulated wall system of claim 7 wherein the embed tab has one or more attachments holes and a hook is attached to embed tab with the attachment hole.

9 . The insulated wall system of claim 8 wherein the hook is configured to hold rebar.

10 . The insulated wall system of claim 1 wherein the external flange of the fastening strip is generally flush with the external surface of the foam materials.

11 . The insulated wall system of claim 6 wherein a complete wall is constructed using a plurality of the prefabricated panels secured within the retaining track and includes the upper concrete beam, the lower concrete beam and at least two concrete columns each located adjacent a longitudinal side end of the wall.

12 . The insulated wall system of claim 11 wherein the concrete columns located at the side ends of the wall are double concrete columns formed using two adjacent fastening strips with the embed tab from each fastening strip being embedded within the double concrete column.

13 . The insulated wall system of claim 11 wherein a window is installed within the wall using a double concrete column located adjacent a longitudinal side of the window and two fastening strips disposed horizontally and located adjacent a bottom end of the window, the two horizontal fastening strips being adjacent to each other with embed tabs extending into the space created by the adjacent fastening strips, the two horizontal fastening strips being connected by a spanner, each of the two fastening strips having foam material disposed between the external flange and internal flange, and a horizontal concrete sill is disposed between the internal surfaces of the foam material.

14 . An insulated concrete composite wall system that comprises

concrete;

foam panels; and

external metal reinforcing strips that are partially embedded within the concrete,

the metal strips acting as tensioning reinforcement for the concrete in lieu of utilizing conventional metal reinforcing bar thereby providing a concrete and metal composite that has greater strength than conventional concrete construction of similar scale utilizing internal steel reinforcing bar making possible lighter and stronger reinforced concrete wall structures.