Abstract:
The present invention relates to configurations of pre-cast panel forming systems and various components of the panel forming systems. In one embodiment, a bulkhead is provided wherein a cross-sectional support member is located at a point along the height dimension of the upstanding portion of the bulkhead so as to provide substantial resistance to reduction of the width dimension under significant panel forming pressure applied to one of the exterior faces of the upstanding walls. In accordance with 37 CFR 1.72(b), the purpose of this abstract is to enable the United States Patent and Trademark Office and the public generally to determine quickly from a cursory inspection the nature and gist of the technical disclosure. The abstract will not be used for interpreting the scope of the claims.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
   This application claims the benefit of two U.S. Provisional Applications—Ser. Nos. 60/348,207, filed Nov. 7, 2001, and 60/344,835, filed Dec. 21, 2001. 

   BACKGROUND OF THE INVENTION 
   The present invention relates forms and form supports used for creating cured pre-cast structures. More specifically, the present invention relates to configurations of pre-cast panel forming systems and various components of the panel forming systems. 
   Many residential and commercial construction methods involve the use pre-cast structures. Pre-cast panels, for example, are integral to the tilt-up construction process. In the tilt-up approach, concrete forms are arranged on a flat casting surface in the shape and dimension of the desired tilt-up panel and filled with concrete. When the concrete cures, the panel and the form are separated and the panel is tilted up into a preferred, typically vertical, orientation, where it can be joined to structural frames or other panels. The present inventors have recognized a need for improvements in pre-cast panel forming systems and in various components of the panel forming systems. The improvements introduced by the present invention have applicability in the tilt-up construction process and in other pre-cast construction processes. 
   BRIEF SUMMARY OF THE INVENTION 
   This need is met by the present invention wherein improvements in pre-cast panel forming systems and in various components of the panel forming systems are introduced. In accordance with one embodiment of the present invention, a bulkhead is provided comprising a base portion and an upstanding portion. The base portion and the upstanding portion define at least a portion of a monolithic structure of the bulkhead. The base portion is configured for securement to a panel forming slab. The upstanding portion comprises a pair of upstanding walls defining a height dimension of the upstanding portion. The upstanding walls comprise respective exterior and interior faces and are spaced from each other to define a width dimension of the upstanding portion. The bulkhead comprises at least one cross-sectional support member extending from an interior face of one of the pair of upstanding walls to an interior face of the other of the pair of upstanding walls. The cross-sectional support member is located at a point along the height dimension of the upstanding portion so as to provide substantial resistance to reduction of the width dimension under pressure applied to one of the exterior faces of the upstanding walls. 
   In accordance with another embodiment of the present invention, a bulkhead connector is provided comprising a base portion and an upstanding portion. The base portion and the upstanding portion define at least part of a monolithic structure. The upstanding portion comprises a pair of upstanding walls. The monolithic structure defines at least one bulkhead receiving area bounded in part by the pair of upstanding walls and the base portion. The bulkhead receiving area defines dimensions sufficient to accommodate an end portion of a bulkhead securely therein. The monolithic structure is characterized by a rigidity sufficient to resist significant deformation and breakage under a cross-longitudinal panel-forming pressure exerted upon a bulkhead having an end portion secured within the bulkhead receiving area. 
   In accordance with yet another embodiment of the present invention, a panel forming system is provided comprising a plurality of bulkheads and a plurality of bulkhead connectors interconnecting corresponding end portions of respective bulkhead members. Each of the bulkheads comprises a base portion and an upstanding portion. The base portion and the upstanding portion define a monolithic structure. The base portion is configured for securement to a panel-forming slab. The upstanding portion comprises a pair of upstanding walls defining a height dimension of the upstanding portion. The pair of upstanding walls comprise respective exterior and interior faces. Each of the bulkhead connectors comprises a base portion and an upstanding portion. The base portion and the upstanding portion define at least part of a monolithic structure. The upstanding portion comprises a pair of upstanding walls. The monolithic structure defines at least one bulkhead receiving area bounded in part by the pair of upstanding walls and the base portion. The bulkhead receiving area define dimensions sufficient to accommodate an end portion of one of the bulkheads securely therein. The monolithic structure is characterized by a rigidity sufficient to resist significant deformation and breakage under the cross-longitudinal panel-forming pressure exerted upon a bulkhead having an end portion secured within the bulkhead receiving area. 
   In accordance with yet another embodiment of the present invention, a longitudinal releasable panel insert is provided. The insert defines a cross section comprising first and second support portions oriented in substantially perpendicular relation to each other. A chamfered portion extends from the first support portion to the second support portion, wherein the chamfered portion and each of the first and second support portions define respective interior angles of the panel insert and a panel insert interior. At least one panel insert anchor extends from one or more of the chamfered portion and the first and second support portions in the general direction of the panel insert interior. A releasable extension is substantially co-planar with one of the first and second support portions. The releasable extension comprises a locking projection configured for engagement with a portion of a bulkhead for a panel forming system. A releasable coupling is configured to couple the releasable extension to a remainder of the panel insert and to enable non-destructive release of the releasable extension from the remainder of the panel insert. 
   In accordance with yet another embodiment of the present invention, a brace is provided. The brace is configured to oppose a cross-longitudinal panel-forming pressure applied to an upstanding portion of a panel-forming bulkhead. The brace portion comprises a multi-piece brace assembly. The multi-piece brace assembly comprises a bulkhead engaging extension and a bracket. The bracket includes a longitudinal securement slot configured to enable fixation of the bulkhead engaging extension in a plurality of different vertical positions relative to the bracket. The bulkhead engaging extension is configured to interlock with a locking channel disposed along an upper portion of the upstanding portion of the bulkhead. 
   In accordance with yet another embodiment of the present invention, a rustication coupling for a panel forming system is provided. The rustication coupling comprises a shell, an open end, and a bulkhead engaging end. The shell comprises outer dimensions configured to substantially mimic outer dimensions of a panel-forming rustication and inner dimensions configured to accommodate an end portion of a rustication within the shell. The open end is configured to accommodate the end portion of the rustication. The bulkhead engaging end is configured for engagement with a base portion of a bulkhead, wherein the bulkhead engaging end is configured to form barrier to the flow of uncured cementitious material along a contact profile defined by the base portion of the bulkhead and the bulkhead engaging end of the rustication coupling. 
   In accordance with yet another embodiment of the present invention, a panel forming system comprising a plurality of bulkheads, at least one rustication, and at least one rustication coupling is provided. Each of the bulkheads comprises a base portion and an upstanding portion. The rustication is configured for placement upon a panel-forming slab within a panel forming mold defined by the plurality of bulkheads. The rustication coupling comprises a shell an open end, and a bulkhead engaging end. 
   In accordance with yet another embodiment of the present invention, a stackable bulkhead is provided comprising a base portion, an upstanding portion, and a pair of complementary mating portions. One of the mating portions is defined in the base portion while the other mating portion is defined in the upstanding portion. The base portion and the upstanding portion are configured such that a pair of the bulkheads may be stacked upon each other with the base portion of one of the bulkheads engaged with the upstanding portion of another of the bulkheads. 
   Accordingly, it is an object of the present invention to provide improvements to pre-cast panel forming systems and the various components of the panel forming systems. Other objects of the present invention will be apparent in light of the description of the invention embodied herein. 

   
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
     The following detailed description of specific embodiments of the present invention can be best understood when read in conjunction with the following drawings, where like structure is indicated with like reference numerals and in which: 
       FIGS. 1–3  are illustrations of alternative bulkhead configurations according to the present invention; 
       FIG. 4  is a three-dimensional illustration of a bulkhead configuration according to the present invention; 
       FIG. 5  is a three-dimensional illustration of a comer bulkhead connector according to the present invention; 
       FIG. 6  is a three-dimensional illustration of a T joint bulkhead connector according to the present invention; 
       FIG. 7  is a three-dimensional illustration of an in-line bulkhead connector according to the present invention; 
       FIG. 8  is a schematic illustration of a panel forming system according to the present invention; 
       FIGS. 9–11  are illustrations of bulkhead configurations including bulkhead intermediates according to the present invention; 
       FIGS. 12–15  are illustrations of alternative bulkhead intermediates according to the present invention; 
       FIGS. 16–19  illustrate a variety of base clip configurations according to the present invention; 
       FIG. 20  illustrates a bulkhead including bulkhead cap variations according to the present invention; 
       FIGS. 21–23  illustrate bulkhead and panel insert configurations according to the present invention; 
       FIGS. 24A and 24B  illustrate a bulkhead brace according to the present invention; 
       FIG. 25  illustrates a bulkhead brace according to another embodiment of the present invention; 
       FIGS. 26–28  illustrate a bulkhead and rustication coupling according to the present invention; 
       FIGS. 29–30  illustrate a stackable bulkhead assembly according to the present invention; and 
       FIGS. 31–40  illustrate bulkhead stacking intermediates and bulkhead caps according to the present invention. 
   

   DETAILED DESCRIPTION 
     FIGS. 1–4  illustrate a variety of bulkheads  10  according to the present invention.  FIGS. 5–7  illustrate a variety of bulkhead connectors  20 ,  30 ,  40  according to the present invention. Generally, referring to the schematic illustration of  FIG. 8 , a plurality of bulkheads  10  and a plurality of bulkhead connectors  30 ,  40 ,  50  may be configured as a panel forming system  60 . A panel forming material may be poured or otherwise presented in respective panel sections  62 ,  64  of the panel forming system  60  and subsequently cured to form respective monolithic panels. The cured panels may be removed from the respective cavities  62 ,  64  and used in a variety of applications including, but not limited to, tilt-up and other pre-cast construction applications. 
   The panel forming system  60  and its various components may be formed from any of variety of suitable materials including, but not limited to, plastics, metals, resins, fibrous composites, and combinations thereof. One or more of the components of the panel forming system  60 , which may include components in addition to the bulkheads  10  and connectors  30 ,  40 ,  50 , may comprise partially or fully synthetic materials. For example, the synthetic or partially synthetic materials may comprise an extrudable material such as an extrudable plastic. Indeed, certain embodiments of the present invention relate directly to the bulkhead as an extruded member. 
   Referring initially to  FIGS. 1–4 , some bulkhead designs according to the present invention are illustrated. Each bulkhead  10  illustrated in  FIGS. 1–4  comprises a base portion  12  and an upstanding portion  14 . The base portion  12  and the upstanding portion define at least a portion of a monolithic structure of the bulkhead  10 . For the purposes of defining and describing the present invention, it is noted that a monolithic structure constitutes a single unit devoid of any disconnecting joints or seams. 
   The base portion  12  is configured for securement to a panel forming slab  15  (see  FIG. 8 ), as will be described in greater detail below. Although not illustrated as such in  FIG. 8 , the panel forming slab  16  typically extends beyond the boundaries of the panel forming system  60 . The upstanding portion  14  comprises a pair of upstanding walls  16  defining a height dimension of the upstanding portion  14 . Each of the upstanding walls  16  comprises an exterior face  17  and an interior face  18 . The pair of upstanding walls  16  are spaced from each other to define a width dimension of the upstanding portion  14 . 
   The bulkhead  10  comprises at least one cross-sectional support member  20  extending from an interior face  18  of one of the pair of upstanding walls  16  to an interior face  18  of the other of the pair of upstanding walls  16 . At least one of the cross-sectional support members  20  is located at a point along the height dimension of the upstanding portion  14  so as to provide substantial resistance to reduction of the width dimension under pressure applied to one of the exterior faces  17  of the upstanding walls  14 . In this manner, the integrity of the panel shape defined by each panel section  62 ,  64  of the panel forming system  60  may be maintained under the significant pressure created by uncured panel forming material present in each panel section  62 ,  64 . 
   The bulkhead designs illustrated in the present application employ a plurality of these types of cross sectional support members  20  spaced along the interior faces of the pair of upstanding walls  16 , including a support member at the terminal ends  19  of the pair of upstanding walls  16 . An additional cross-sectional support member  20  may be positioned near the base portion  12 . The cross sectional support members  20  may simply comprise a single linear extension that is substantially perpendicular to the pair of upstanding walls  16 . Alternatively, the cross sectional support members  20  may be configured as more complex structures arranged in perpendicular or non-perpendicular configurations. 
   Referring specifically to  FIG. 1 , the cross-sectional support member  20  furthest displaced from the base portion  12  along an upper portion of the upstanding portion  14  may comprise a locking channel  22  defining a restricted locking channel opening  24 . As is illustrated in  FIG. 4 , the locking channel  22  is defined along a longitudinal dimension of the bulkhead  10 . The locking channel  22  illustrated in  FIG. 1  is configured to permit forcible, repeatable engagement and disengagement of a locking projection with the locking channel  22 . As will be described in further detail with reference to  FIGS. 5–7 ,  24 A and  24 B, the presence of the locking channel  22  in the bulkhead  10  provides a means by which additional components including locking projections, such as connectors and braces, may be engaged with the upstanding portion  14  of the bulkhead  10 . 
   Turning now to examples of how the base portion  12  of the bulkhead  10  may be configured for securement to a panel forming slab  15 , the bulkhead  10  may further comprise a base clip  24 . The base portion  12  is configured for securement to the panel forming slab  15  via the base clip  24 . The base clip  24  may be secured to the panel forming slab  15  by any number of suitable means including adhesives, adhesive tapes, and mechanical fasteners such as nails or screws. In the illustrated embodiments, the base clip  24  is not part of the monolithic structure defined by the base portion  12  and the upstanding portion  14 , although a monolithic structure incorporating the base clip  24  is not outside the scope of the present invention. 
   In the illustrated embodiments, providing the base portion  12  with at least one locking projection  13  configured for engagement with the base clip  24  enables securement to the slab  15 . In the embodiments of  FIGS. 1–3 , the base portion  12  includes a plurality of relatively small locking projections  13 . In the embodiments of  FIGS. 16–19 , where a variety of base clip  24  and base portion  12  configurations are illustrated, the base portion comprises a pair of relatively large locking projections  13 . The locking projections  13  may extend from an interior face  18  of the upstanding walls  16  (see  FIG. 17 ) or from a cross-sectional support member  20  extending between interior faces  17  of the upstanding walls  16  (see  FIGS. 1–3 ,  16 ,  18 , and  19 ). The pair of locking projections  13  may be configured to enclose at least a portion of the base clip  24  (see  FIG. 17 ) or to be at least partially enclosed by the base clip  24  (see  FIGS. 1–3 ,  16 ,  18 , and  19 ). 
   The base clip  24  comprises a pair of base clip walls  26  and is configured to connect to the bulkhead  10  such that the pair of base clip walls  26  and the pair of upstanding walls  14  lie along respective substantially common planes. In this manner, a panel with substantially uniform edge faces may be cured within the panel sections  62 ,  64 . 
   Referring to  FIGS. 3 ,  23 , and  38 , the base clip  24  may comprise an integral brace portion  25  formed such that it is positioned on one side of the upstanding portion  14  when the base portion  12  is engaged with the base clip  24 . The integral brace portion  25  is configured to oppose a cross-longitudinal panel forming pressure applied to a side of the upstanding portion  14  opposite the side at which the brace portion  25  is formed. In this manner the integral brace portion  25  provides stability to the bulkhead under the pressure of uncured panel forming material within one of the panel sections  62 ,  64 . As will be described in further detail below, the integral brace portions  25  illustrated in  FIGS. 3 and 38  may also be utilized to function as a panel forming chamfer in the panel forming process. 
   Referring now to an explanation of the manner in which chamfers may be provided in the bulkhead  10  of the present invention, it is initially noted that  FIGS. 1–4  each illustrate a pair of chamfers  21 . Presented in one of the panel sections  62 ,  64 , a chamfered portion of the bulkhead  10  will form a chamfered surface in the cured panel. A chamfer  21  may be formed integral with the base portion  12 , the base clip  24 , or both. For example, in  FIG. 1 , the base portion  12  comprises a pair of integrally formed  21  extending outwardly from different ones of the pair of upstanding walls. In  FIG. 2 , the base portion  12  comprises a single integrally formed chamfer  21 . In  FIG. 3 , the base portion  12  comprises a single integrally formed chamfer  21  and the base clip  24  comprises a single integrally formed chamfer  21 . The chamfered portions  21  according to the present invention may comprise a sealing projection  23  configured for substantially isolated engagement with the slab  15  or any other planar surface oriented substantially perpendicular to the bulkhead  10 . As is collectively illustrated in  FIGS. 1–3 ,  8  and  9 , the chamfered portions of the bulkhead  10  extend outwardly from a position substantially co-planar with an upstanding wall  16  to a position extending as far as, or beyond, the slab engaging face of the base clip  24 . 
   Referring now to  FIGS. 5–8 , the structure and role of the bulkhead connectors  30 ,  40 ,  50  will be described in detail. Each bulkhead connector  30 ,  40 ,  50  comprises a base portion  32 ,  42 ,  52  and an upstanding portion  34 ,  44 ,  54  defining at least part of a monolithic structure. The upstanding portions  34 ,  44 ,  54  comprise at least one pair of upstanding walls  36 ,  46 ,  56 . The monolithic structure of each connector defines at least one bulkhead receiving area  38 ,  48 ,  58  bounded in part by the pair of upstanding walls  36 ,  46 ,  56  and the base portion  32 ,  42 ,  52 . Each of the bulkhead receiving areas  38 ,  48 ,  58  defines dimensions sufficient to accommodate an end portion of a bulkhead  10  securely therein. The degree of securement is preferably sufficient to serve as a barrier to the flow of uncured cementitious material between the connector  30 ,  40 ,  50  and the end portion of the bulkhead  10 . The monolithic structure of the connectors  30 ,  40 ,  50  is characterized by a rigidity sufficient to resist significant deformation and breakage under cross-longitudinal panel forming pressure exerted upon a bulkhead having an end portion secured within the bulkhead receiving area. 
   The bulkhead connectors  30 ,  40 ,  50  may further comprise at least one cross-sectional support member  39 ,  49 ,  59  extending from an interior face of one of the pair of upstanding walls  16  to an interior face of the other of the pair of upstanding walls  16 . In addition, the base portion  32 ,  42 ,  52  may comprise chamfered portions  21 . An integral or separate brace portion  25  may also be provided and configured to oppose the cross-longitudinal panel forming pressure exerted by uncured panel forming material. Cross-longitudinal panel forming pressures are typically at least as large as that produced by an uncured cementitious mixture having length and width dimensions of at least six feet (about 2 meters) and a thickness dimension of at least four inches (about 10 cm). 
   The bulkhead connectors  30 ,  40 ,  50  may further comprise connector caps  35 ,  45 ,  55  sized and configured to complement the size and configuration of the upstanding portions  34 ,  44 ,  54  of the bulkhead connectors  30 ,  40 ,  50 . The connector caps  35 ,  45 ,  55  may be configured to form a sealed interface with the upstanding portions  34 ,  44 ,  54  and may comprise locking projections  33 ,  43 ,  53  configured to engage an end portion of a bulkhead secured within the bulkhead receiving areas  38 ,  48 ,  58 . 
   Referring specifically to the corner bulkhead connector  30  of  FIG. 5 , it is noted that the monolithic structure comprises two pairs of upstanding walls  36 , each defining a separate bulkhead receiving area  38  oriented in a substantially orthogonal manner. The T joint bulkhead connector  40  of  FIG. 6 , also comprises first and second pairs of upstanding walls  46 . One of the pairs of upstanding walls  46  defines first and second bulkhead receiving areas  48 . The remaining pair of upstanding walls  46  defines a third bulkhead receiving area  48 . The first and second bulkhead receiving areas  48  are oriented substantially along a common axis while the third bulkhead receiving area  48  is oriented in a substantially orthogonal manner, relative to the first and second bulkhead receiving areas  48 . The in-line joint connector  50  of  FIG. 7  comprises one pair of upstanding walls  56 , which defines first and second bulkhead receiving areas  58  oriented substantially along a common axis.  FIG. 8 , illustrates schematically the manner in which each of the connectors  30 ,  40 ,  50  may be employed in a panel forming system  60  according to the present invention. 
   Referring to  FIGS. 9–15 , the bulkhead  10  of the present invention may also incorporate one or more bulkhead intermediates  70  comprising a pair of intermediate upstanding walls  76  that complement and serve to extend the upstanding walls  16  of the bulkhead  10 . As is the case with the base clip  24  described herein, the bulkhead intermediate  70  and the bulkhead  10  are configured to define a releasable connection there between. In addition, the bulkhead intermediate  70  is configured to connect to the bulkhead  10  such that the pair of intermediate upstanding walls  76  and the pair of upstanding walls  16  lie along respective substantially common planes. 
   Each of the bulkhead intermediates  70  may comprise a pair of complementary mating portions  75 , one of the pair of mating portions  75  being defined in a base portion  72  of the intermediate  70 , another of the pair of mating portions  75  being defined in an upstanding portion  74  of the intermediate  70 . The base portion  72  and the upstanding portion  74  are configured such that a pair of the intermediates  70  may be stacked upon each other with the base portion  72  of one of the intermediates  70  engaged with the upstanding portion  74  of another of the intermediates  70 . 
   A bulkhead intermediate  70  and base clip  24  may also be configured to define a releasable connection there between. In addition, the bulkhead intermediate  70  may be configured to interconnect the base clip  24  and the monolithic structure defined by the base portion  12  and the upstanding portion  14  of the bulkhead  10  in a releasable manner. The number of bulkhead intermediates  70  incorporated in the bulkhead  10  of the present invention is merely a function of the available heights of the upstanding walls  16  and the intermediate upstanding walls  76  and desired height of the bulkhead  10 . 
   Turning now to  FIG. 20 , the bulkhead  10  may further comprise a bulkhead cap  11  and an upper portion of the upstanding portion  14  of the bulkhead  10  may be configured to receive the bulkhead cap  11 . As is illustrated in phantom in  FIG. 20 , the bulkhead cap may comprise one or more chamfers  21  in addition to chamfers  21  defined proximate the base portion  12  of the bulkhead  10 . In this manner, chamfer portions may be formed on opposing major faces of a cured panel. 
     FIGS. 21–23  illustrate bulkhead configurations where the bulkhead  10  further comprises a longitudinal releasable panel insert  80  configured for engagement with the base portion  12  of the bulkhead  10 . The cross section of the panel insert  80  comprises first and second support portions  81 ,  82  oriented in substantially perpendicular relation to each other and a chamfered portion  84  extending from the first support portion  81  to the second support portion  82 . The chamfered portion  84  and each of the first and second support portions  81 ,  82  define respective interior angles θ of the panel insert and a panel insert interior  85 . In the illustrated embodiment the interior angles θ are about 135°. 
   At least one panel insert anchor  86  extends from one or more of the chamfered portion  84  and the first and second support portions  81 ,  82  in the general direction of the panel insert interior  85 . A releasable extension  87  substantially co-planar with the first support portion  81  comprises a locking projection  88  and may be configured for engagement with the base portion  12  or the base clip  24  of the bulkhead  10  (see  FIGS. 21 and 22 ). A releasable coupling  89  is configured to couple the releasable extension  87  to a remainder of the panel insert  80  and to enable non-destructive release of the releasable extension  87  from the remainder of the panel insert. More specifically, the nature of the releasable coupling  89  is such that the remainder of the panel insert  80 , when embedded in a cured panel, may be broken away cleanly from the releasable extension  87  by removing the cured panel from a panel forming system including the bulkhead  10  or otherwise separating the cured panel and the bulkhead  10 . As will be appreciated by those familiar with pre-cast construction techniques, the embedded panel insert helps reduce damage to panel forming slabs over which the cured panel is moved. 
   A plurality of panel insert anchors  86  may be provided in the panel insert  80 . For example, in  FIGS. 21 and 23 , a pair of panel insert anchors  86  are provided. The panel insert anchors  86  may be provided with one or more cross sectional vias  83  configured to permit passage of a cementitious material there through to improve adhesion of the insert  80  to the cured panel. Referring to  FIG. 22 , a plurality of suitably profiled panel insert anchors  86  may be provided extending from the chamfered portion  84 . 
   Referring to  FIGS. 24A and 24B , a brace portion in the form of a multi-piece brace assembly  90  is illustrated. The multi-piece brace assembly  90  comprises a bulkhead engaging extension  92  and a bracket  94 . The bracket  94  includes a longitudinal securement slot  96  configured to enable fixation of the bulkhead engaging extension  92  in any one of a plurality of different vertical positions relative to the bracket  94 . The bulkhead engaging extension  92  is configured to interlock with a locking channel  22  disposed along an upper portion of the upstanding portion  14  of the bulkhead  10 . The bracket  94  includes a generally planar base  95  and, as such, may be secured to the slab  15  or another panel forming surface by any suitable means including adhesives, adhesive tapes, and mechanical fasteners. In this manner, the bulkhead  10  may be securely braced against displacement during panel curing. 
   An alternative brace is illustrated in  FIG. 25 . The monolithic brace  100  illustrated in  FIG. 25  comprises a pair of solid end faces  102  and a brace body  104  extending between the end faces  102 . Each solid end face  102  defines a complementary major edge  106  of the brace  100  and at least two complementary minor edges  108  of the brace  100 . The brace body  104  merely extends between the two complementary minor edges  108  of the solid end faces  102  and is open along a plane extending between the complementary major edges  106  of the end faces  102  to conserve material without sacrificing brace strength. 
   Referring again to  FIG. 8 , a rustication  120  may be utilized in a panel forming system  60  according to the present invention to create a particular profile or pattern in the surface of a panel cured therein. FIGS.  8  and  26 – 28  illustrate the inclusion of a rustication coupling  110  in the bulkhead  10  and panel forming system  60  of the present invention. The rustication coupling  110  comprises an open end  112  and a bulkhead engaging end  114  and is configured for engagement with the base portion  12  of the bulkhead  10  and with an end portion  122  of a rustication  120  and is particularly advantageous because it provides for some degree of tolerance to variations in the length of the rustication  120  while forming a barrier to the flow of uncured cementitious material along a contact profile defined by the base portion  12  of the bulkhead  10  and the bulkhead engaging end  114  of the rustication coupling  110 . 
   Specifically, the rustication coupling  110  comprises a structure configured to define a shell, where the open end  112  of the shell is configured to accommodate the end portion  122  of the rustication  120  within the shell. The interior dimensions of the shell approximate the exterior dimensions of the end portion  122  of the rustication  120 . The bulkhead engaging end  114  may comprise a locking projection  116  configured for engagement with the base portion  12  of the bulkhead  10 . 
   Referring to  FIGS. 29 and 30 , the bulkhead  10  of the present invention may further comprise a pair of complementary mating portions  130 ,  132 . One of the pair of mating portions  130  being defined in the base portion  12 , another of the pair of mating portions  132  being defined in the upstanding portion  14 . The base portion  12  and the upstanding portion  14  are configured such that a pair of the bulkheads  10  may be stacked upon each other with the base portion  12  of one of the bulkheads  10  engaged with the upstanding portion  14  of another of the bulkheads  10 . A bulkhead cap  134  may also be provided and may be configured to be releasable from the upstanding portion  14  of the bulkhead  10 . In this manner, a first panel  136  may be formed and cured in the manner illustrated in  FIG. 29  with the bulkhead cap  134  in place. Subsequent to curing, the bulkhead cap  134  may be removed and replaced with an additional bulkhead  10  having its own bulkhead cap  134 , as is illustrated in  FIG. 30 . A second panel  138  may then be formed and cured directly over the first panel  136 . Further panels may be formed in a similar manner. 
     FIGS. 31–35  illustrate a further variation of a panel stacking scheme according to the present invention where the need for providing bulkheads with complementary mating portions is obviated. Specifically, a bulkhead stacking intermediate  140  interposed between the bulkheads  10  may complement engagement of the base portion  12  of one bulkhead  10  with an upstanding portion of another bulkhead  10 . To form the stacked cured panels, the bulkhead cap  134  is replaced with the bulkhead stacking intermediate  140  after the first panel  136  is cured. Next, a subsequent bulkhead (not shown) may be installed for formation and curing of a second panel (not shown) because the intermediate  140  is configured to mate with and support a base portion  12  of an additional bulkhead  10  and the upstanding portion  14  of the existing bulkhead  10 .  FIGS. 36 and 37  illustrate utilization of bulkhead caps  134  that are configured to define an increased-height dimension of the upper terminus of the upstanding portion  14  of the bulkhead  10 . 
     FIGS. 38–40  illustrate a further variation of a bulkhead stacking scheme employing a bulkhead  10  with a bulkhead cap  134  and complementary mating portions  130 ,  132  formed at the base portion  12  and upstanding portion  14  of the bulkhead  10 . Also represented in  FIG. 38  is the provision of relatively pliable widthwise projections  142  configured to enhance frictional engagement between a reduced-width upper terminus  144  of the upstanding portion  14  and a receptacle cavity  146  of the base portion  12 . Either, the reduced-width upper terminus  144  or the receptacle cavity  146  may be provided with the relatively pliable widthwise projections  142 .  FIG. 40  illustrates the use of a chamfered bulkhead intermediate  148  upon removal of the bulkhead cap  134 . In the embodiment of  FIG. 40 , the widthwise projections  142  would not yield the above-noted enhanced frictional engagement. However, absent the chamfered bulkhead intermediate  148 , the frictional engagement would be as described with reference to  FIGS. 38 and 39 . 
   As will be appreciated by those familiar with the art of extrusion, an extruded member defines a substantially uniform extruded cross section that extends along substantially the entire length of the member. Insignificant variations in the uniformity of the cross section due to fabrication process errors or post fabrication process steps are contemplated. For example, holes may be drilled in an extruded member in specific locations after the member is extruded. Similarly, cuts or cutouts may be formed in the extruded member after it is extruded. 
   It is noted that terms like “preferably,” “commonly,” and “typically” are not utilized herein to limit the scope of the claimed invention or to imply that certain features are critical, essential, or even important to the structure or function of the claimed invention. Rather, these terms are merely intended to highlight alternative or additional features that may or may not be utilized in a particular embodiment of the present invention. 
   For the purposes of describing and defining the present invention it is noted that the term “substantially” is utilized herein to represent the inherent degree of uncertainty that may be attributed to any quantitative comparison, value, measurement, or other representation. The term “substantially” is also utilized herein to represent the degree by which a quantitative representation may vary from a stated reference without resulting in a change in the basic function of the subject matter at issue. 
   Having described the invention in detail and by reference to specific embodiments thereof, it will be apparent that modifications and variations are possible without departing from the scope of the invention defined in the appended claims. More specifically, although some aspects of the present invention are identified herein as preferred or particularly advantageous, it is contemplated that the present invention is not necessarily limited to these preferred aspects of the invention.