Pre-cast panel form insert
The present invention is directed to a pre-cast panel form insert used in precast construction. The insert comprises a substantially planar portion defining dimensions suitable to complement dimensions of a pre-cast panel form and a fluid diverting portion. The fluid diverting portion is configured to define a fluid-diverting recess in an edge face of a pre-cast panel bounded by a form including the form insert. The fluid diverting portion is configured such that said fluid diverting recess defines, a circular cross-sectional profile, or a multi-angular cross-sectional profile, that impedes the flow of water along said pre-cast panel edge face when said edge face assumes a substantially horizontal orientation.
1. A panel form comprising a panel frame, an opening frame, and a panel form insert, wherein:
said panel frame is configured to contain casting material within said panel frame;
said opening frame is configured to define an area within said panel frame that is free of casting material;
said panel form insert abuts a portion of said opening frame so as to permit casting material within said panel frame to cure with a profile defined by said panel form insert;
said panel form insert comprises a substantially planar portion and a fluid diverting portion;
said fluid diverting portion is configured to protrude from said substantially planar portion;
said fluid diverting portion is characterized by a curved cross sectional profile; and
said substantially planar portion is characterized by a first peripheral edge and a second peripheral edge extending longitudinally along said substantially planar portion.
2. A panel form as claimed in claim 1 , wherein said fluid diverting portion is characterized by a semi-circular cross-section.
3. A panel form as claimed in claim 1 , wherein said fluid diverting portion is characterized by an elliptical cross-section.
4. A panel form as claimed in claim 1 , wherein said fluid diverting portion creates a recessed area in said substantial planar portion.
5. A panel form as claimed in claim 1 , wherein said fluid diverting portion is configured to define a fluid diverting recess in an edge face of a pre-cast panel bounded by a form including said form insert.
6. A panel form as claimed in claim 1 , wherein said fluid diverting portion decreases in cross sectional size from a maximum cross sectional dimension.
7. A panel form insert as claimed in claim 1 wherein said fluid diverting portion comprises a cross sectional dimension sufficient to substantially impede the flow of fluid across said fluid diverting portion.
8. A panel form as claimed in claim 1 , wherein said fluid diverting portion is displaced a substantial distance from said first peripheral edge of said substantially planar portion.
9. A panel form as claimed in claim 1 , wherein said fluid diverting portion is displaced a substantial distance from said second peripheral edge of said substantially planar portion.
10. A panel form as claimed in claim 1 , wherein said fluid diverting portion is disposed between said first peripheral edge and said second peripheral edge of said substantially planar portion.
11. A panel form as claimed in claim 1 , wherein said fluid diverting portion is oriented generally parallel to said first and second peripheral edges.
12. A panel form as claimed in claim 1 , wherein said fluid diverting portion protrudes from said substantially planar portion along said second peripheral edge.
13. A panel form as claimed in claim 12 , wherein said fluid diverting portion protrudes from said substantially planar portion along said second peripheral edge at a beginning point of said fluid diverting portion.
14. A panel form as claimed in claim 13 , wherein said fluid diverting portion extends from said beginning point to a terminating point.
15. A panel form as claimed in claim 12 , wherein said fluid diverting portion further comprises a sealing edge extending along said second peripheral edge.
16. A panel form as claimed in claim 15 , wherein said sealing edge is defined at a terminating end of said fluid diverting portion.
17. A panel form as claimed in claim 15 , wherein said sealing edge extends across a plane defined by substantially planar portion.
18. A panel form as claimed in claim 1 , wherein said substantially planar portion further comprises a longitudinal area of weakness.
19. A panel form as claimed in claim 18 , wherein said longitudinal area of weakness is disposed between said second peripheral edge and said fluid diverting portion.
20. A panel form as claimed in claim 18 , wherein said longitudinal area of weakness comprises a reduced thickness portion of said substantially planar portion.
21. A panel form as claimed in claim 18 , wherein said longitudinal area of weakness comprises a score line.
22. A panel form as claimed in claim 18 , wherein said longitudinal area of weakness comprises a brittle material.
23. A panel form as claimed in claim 1 , wherein said substantially planar portion and said fluid diverting portion define at least a portion of a monolithic structure of said insert.
24. A panel form as claimed in claim 1 , wherein said fluid diverting portion is characterized by a rigidity sufficient to resist significant deformation and breakage under a panel forming pressure.
25. A panel form as claimed in claim 1 , wherein said substantially planar portion is elongated along a lengthwise dimension.
26. A panel form as claimed in claim 25 , wherein said fluid diverting portion extends along said lengthwise dimension of said substantially planar portion.
27. A panel form as claimed in claim 25 , wherein said fluid diverting portion extends along said lengthwise direction of said substantially planar portion parallel to a longitudinal peripheral edge of said substantially planar portion.
28. A panel form as claimed in claim 1 , wherein said insert further comprises a chamfer portion.
29. A panel form as claimed in claim 28 , wherein said chamfer portion is integral with said substantially planar portion.
30. A panel form as claimed in claim 28 , wherein said chamfer portion is separate from said substantially planar portion.
31. A panel form as claimed in claim 1 , wherein said substantially planar portion further comprises an extension leg extending from an end portion of said substantially planar portion.
32. A panel form as claimed in claim 1 , wherein said extension leg extends from said substantially planar portion at an angle of about 90°.
33. A panel form as claimed in claim 1 , wherein said extension leg extends a sufficient distance to provide an insert mounting surface.
34. A panel form as claimed in claim 1 , wherein said insert further comprises a first chamfer at said first peripheral edge of said substantially planar portion and a second chamfer at said second peripheral edge of said substantially planar portion.
35. A panel form as claimed in claim 34 , wherein said first and said second chamfers are integral to said substantially planar portion.
36. A panel form as claimed in claim 34 , wherein said first and said second chamfers are separate from said substantially planar portion.
37. A panel form as claimed in claim 34 , wherein said second chamfer is integral to said substantially planar portion.
38. A panel form as claimed in claim 34 , wherein said second chamfer is separate from said substantially planar portion.
39. A panel form comprising a panel frame, an opening frame, and a panel form insert, wherein:
said panel frame is configured to contain casting material within said panel frame;
said opening frame is configured to define an area within said panel frame that is free of casting material;
said panel form insert abuts a portion of said opening frame so as to permit casting material within said panel frame to cure with a profile defined by said panel form insert;
said panel form insert comprises a substantially planar portion and a fluid diverting portion;
said substantially planar portion is characterized by a first peripheral edge and a second peripheral edge extending longitudinally along said substantially planar portion;
said fluid diverting portion is configured to protrude from said substantially planar portion;
said fluid diverting portion is configured to define a fluid diverting recess in an edge face of a pre-cast panel bounded by said panel frame including said panel form insert;
said fluid diverting portion is configured such that said fluid diverting recess defines a curved cross-sectional profile; and
said fluid diverting portion is configured such that said curved cross-sectional profile is configured to substantially impede the flow of water along said pre-cast panel edge face when said edge face assumes a substantially horizontal orientation.
40. A panel form as claimed in claim 39 , wherein said panel form defines a height dimension of at least about 4 inches (10 cm).
41. A panel form as claimed in claim 39 , wherein said panel form defines a length dimension of at least about 24 inches (60 cm).
42. A panel form as claimed in claim 39 , wherein said fluid diverting portion decreases in cross sectional size from a maximum cross sectional dimension along said edge face to a minimum cross sectional dimension at a terminal portion of said fluid diverting recess.
43. A panel form as claimed in claim 39 , wherein said fluid diverting portion comprises a cross sectional dimension sufficient to substantially impede the flow of fluid.
44. A method of forming a pre-cast wall panel for tilt-up construction, said method comprising:
affixing a form to a casting surface;
configuring said form to define a panel with an opening;
coupling an insert to said form at a position corresponding to a header portion of said opening, said insert comprising a substantially planar portion and a fluid diverting portion, wherein:
said fluid diverting portion is configured to protrude from said substantially planar portion, and
said fluid diverting portion is characterized by a curved or multi-angular cross-sectional profile;
pouring casting material into said form including said insert;
curing said casting material to form a cured panel; and
removing said panel from said form.