CROSS-REFERENCE TO RELATED APPLICATION

N/A

FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

N/A

BACKGROUND OF THE INVENTION

Technical Field

The present invention pertains to autoclave aerated concrete (AAC) elements with embedded hardware for connecting, suspending and use in construction; and more particularly to AAC panels with embedded hangers and connectors.

Background

AAC is typically formed as a blend of sand or fly ash, lime, Portland cement, water, and an expansion agent of aluminum powder or paste. The mixture is usually cast into large molds and allowed to expand to a volume greater than the original semi-fluid mass. The processed elements are then placed into large pressurized chambers called autoclaves to complete the curing or hardening of the finished product. The structural elements are typically cured for 8-12 hours at 12-13 atmospheric pressures at 360-385 degrees Fahrenheit. The elements are cut to size either prior to or after autoclaving.

AAC is lightweight compared to normal concrete. For example, typical AAC weighs one-fourth to one-fifth the weight of normal concrete, which weighs in the range 130 to 145 lbs/ft. AAC has extreme thermal properties. It displays no spalling of material when exposed to temperatures at or approaching 2000 degrees Fahrenheit. AAC is an inorganic material resistant to weather decay and pest attack. AAC also provides significant acoustical barrier properties. Suitable AAC materials are sold by THERMACRETE the assignee of the present invention. Another material aerated concrete (AC) is also available for purchase in the form of panels, for example. Unlike AAC, AC is allowed to air cure in normal single atmospheric pressures and ambient temperatures. The process for achieving maximum strength takes longer than AAC. Typical curing time for AC is 7-28 days versus 20-24 hours for AAC. Aerated concrete is sold under the trade names FLEXCRETE, PEARLITE, DURROCK and HARDIE BOARD.

SUMMARY OF THE INVENTION

The present invention provides an autoclave aerated concrete (AAC) element having a web of material of a second material, different from AAC, embedded therein and supporting hardware for connecting the AAC element to other structures.

The present invention also provides a method for forming a plurality of autoclave aerated concrete panels using the steps of: (1) providing a mold for forming the plurality of the aerated concrete panels; (2) inserting into the mold a plurality of webs of material supporting a member for connecting to another structure, one web of material for each of the plurality of aerated concrete panels and positioned in parallel spaced relationship and spaced from one another; (3) adding into the mold a first set of ingredients; (4) adding into the mold an expansion agent for reacting with one or more of the first set of ingredients to generate a gas to expand the volume of first set of ingredients to form the concrete into a solid block; (5) removing the solid block from the mold; (6) cutting the block between each pair of adjacent panels to form a plurality of uncured, green panels; and (7) placing the green panels in an autoclave and heating at an elevated temperature and an elevated pressure for an effective period of time to form the plurality of AAC panels. Step6of cutting the block can also occur after step7of autoclaving.

A method for installing an autoclave aerated concrete (AAC) panel on to a structure including the steps of: (1) providing an autoclave aerated concrete panel having a web of material of a second material different from AAC embedded therein and supporting hardware for connecting the AAC panel to other structures; (2) positioning the AAC panel into engagement with the structure; and (3) connecting a portion of the structure to the hardware with a fastener to secure the AAC panel to the structure.

