Patent Publication Number: US-2022220738-A1

Title: Method of Forming a Concrete Panel

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a Continuation-In-Part of U.S. patent application Ser. No. 16,728,620, filed on Dec. 27, 2019, which is a continuation of PCT/US2018/040014, filed on Jun. 28, 2018, which claims the benefit of Unites States Provisional Patent Application No. 62/526,101, filed on Jun. 28, 2017, and is a Continuation-In-Part of U.S. patent application Ser. No. 14/610,475, filed on Jan. 30, 2015 (now U.S. Pat. No. 11,077,583, issued on Aug. 3, 2021), which claims the benefit of U.S. Provisional Patent Application No. 61/934,405, filed on Jan. 31, 2014, the contents of which are incorporated herein in their entirety by reference. 
    
    
     STATEMENT REGARDING FEDERALLY-SPONSORED RESEARCH OR DEVELOPMENT 
     Not Applicable 
     BACKGROUND OF THE INVENTION 
     1. Field of Invention 
     The present general inventive concept relates to prefabricated wall structures, and more particularly, to a precast concrete composite wall structure and method for manufacturing a precast concrete composite wall structure. 
     2. Description of the Related Art 
     Precast concrete wall structures are often used as a way of avoiding more costly, time consuming, and/or labor intensive processes of fabricating walls from brick or block materials, wood, metal studs, or the like, or fabricating walls by pouring and curing concrete in situ. Generally, the manufacture of a precast concrete wall structure involves the use of a casting bed fabricated to form a mold for pouring and curing concrete in the shape of a desired wall structure. The casting bed is typically oriented with the desired wall structure shape extending in a horizontal plane. Desired non-concrete structural fixtures may be added to the casting bed, and concrete may then be poured into the casting bed, thereby filling the mold shape and at least partially surrounding the fixtures. The concrete may then be allowed to cure, thereby forming a concrete wall structure in the desired shape. Once cured, the wall structure may be removed from the casting bed, such as for example by disassembling the casting bed from around the wall structure. The wall structure may then be transported to a desired location, where it can be stood upright along a substantially vertical plane (or other desired orientation) for use as a structural member in a building construction. 
     One prior art method for manufacturing a precast concrete wall structure is described in U.S. Pat. No. 8,491,831, issued to Buedel et al. (hereinafter “the &#39;831 patent”). In the method of the &#39;831 patent, a frame is provided having a plurality of spaced-apart wall studs interconnecting opposing first and second wall plate members. The frame is placed within a casting bed extending along a horizontal plane, and a layer of insulating material is positioned overlaying the frame. A plurality of insulating foam blocks are then placed above the insulating layer at spaced apart intervals to define void channels extending therebetween along the length of the casting bed. Lengths of rebar are positioned within the channels, and concrete is poured into the casting bed, thereby filling the channels and surrounding the rebar, covering the insulating foam blocks, and filling the spaces between the first and second wall plate members and the adjacent sides of the casting bed. The concrete is allowed to cure, thereby forming a concrete wall structure having a substantially planar concrete first outer surface, a plurality of steel-reinforced concrete “ribs” extending internally of the structure, and a second outer surface defined by the frame structure and adjacent surface of the insulating layer. Concrete top beam and toe sections are provided extending above and below the frame structure at locations corresponding to the spaces between the first and second wall plate members and the adjacent sides of the casting bed. Thereafter, the concrete wall structure may be removed from the casting bed, such as by removing one or more sides of the casting bed and/or lifting the wall structure therefrom. 
     In methods and apparatus for forming precast wall structures of the type described above, significant problems may be encountered with regard to quality control of the finished precast wall structure. Specifically, while pouring the unfinished concrete into the casting bed described above, difficulty may be encountered in maintaining the desired spaced-apart configuration of the insulating foam blocks. As the unfinished concrete flows over and around the insulating foam blocks, such blocks may be prone to flex and/or shift laterally along the layer of insulating material, and may further be prone to shift vertically due to buoyancy of the blocks in the more dense unfinished concrete. Furthermore, depending upon the flexural strength and stiffness of the layer of insulating material, the layer of insulating material may be subject to flexural deformation and/or failure under the weight of the unfinished concrete. The end result may be a finished wall structure which does not strictly conform to desired specifications. 
     In light of the above, an improved method for manufacturing a precast concrete wall structure, and a precast concrete wall structure manufactured to conform to more strict tolerances, is desired. 
     BRIEF SUMMARY OF THE INVENTIVE CONCEPT 
     The present general inventive concept, in various example embodiments, provides a precast concrete wall and a method for forming a wall structure. In one embodiment a frame is positioned within a casting bed having a plurality of upright surfaces defining a generally rectangular interior area. The frame comprises first and second spaced apart members extending along a width dimension of the frame and a plurality of studs interconnecting the first and second spaced apart members, the studs extending along a length dimension of the frame. A forming member is positioned in overlying relation above the frame. The forming member comprises a layer of insulating material defining a plurality of integrally-formed rectangular protrusions extending along a length dimension of the forming member in a parallel and spaced-apart relationship to one another to define a plurality of rectangular-shaped channels therebetween. Uncured concrete is placed within the casting bed and allowed to cover the forming member and substantially fill the channels. The concrete is then allowed to cure. 
     In various example embodiments according to several features of the present general inventive concept, the frame may comprise a plurality of metal studs. The forming member may be oriented in relation to the frame such that the length dimension of the forming member extends along the length dimension of the frame. The forming member may be sized to extend fully along length and width dimensions of the frame to limit the uncured concrete from flowing between the studs of the frame. The frame and forming member may be of a sufficient width to extend adjacent opposite first and second upright surfaces of the casting bed. The frame and forming member may be positioned within the casting bed to provide a first space between the frame first member and an associated third upright surface of the casting bed, wherein the uncured concrete is allowed to fill the first space to form a top beam portion of the wall structure. The frame and forming member may further be positioned within the casting bed to provide a second space between the frame second member and an associated fourth upright surfaces of the casting bed, wherein the uncured concrete is allowed to fill the second space to form a toe portion of the wall structure. 
     In various example embodiments, a spacer may be positioned between the frame first member and the third upright surface of the casting bed to form the first space. The spacer may be a strip of insulating material. The spacer and the forming member may each be fabricated from a material selected from the group consisting of expanded polystyrene, extruded polystyrene, and rock wool. The first and second upright surfaces of the casting bed may define structures shaped to allow the concrete to form matingly-shaped portions of a joint along opposite sides of the wall structure. For example, the first upright surface may define a ridge extending along a length thereof and the second upright surface may define a matingly-shaped groove extending along a length thereof. 
     In various example embodiments according to several features of the present general inventive concept, the forming member may be defined by a plurality of members arranged in side-by-side relationship. The plurality of forming member segments may be positioned in side-by-side relationship within the casting bed, each segment defining a portion of the total width of the forming member, including at least one rectangular protrusion and at least a portion of one channel. In certain embodiments, a plurality of reinforcing members may be positioned within the casting bed prior to placing the uncured concrete within the casting bed. For example, in certain embodiments, at least one reinforcing member may be placed along each channel. In certain embodiments, an upper surface of the concrete may be finished. For example, a desired texture may be stamped or otherwise formed into the upper surface of the concrete. 
     Various example embodiments of the present general inventive concept may provide a method of forming the panel to be used as a floor, wall, or roof structure including positioning one or more forming members within a casting bed having a plurality of upright surfaces defining a generally rectangular interior area, the one or more forming members comprising an insulating material extending along a length dimension of the one or more forming members to define a plurality of rectangular-shaped channels in a parallel and spaced-apart relationship, placing uncured concrete within the casting bed and allowing the concrete to cover the one or more forming members and substantially fill the channels, and allowing the concrete to cure. 
     Various example embodiments of the present general inventive concept may provide a panel to be used as a floor, wall, or roof structure, the panel including a concrete portion including a face portion and a plurality of joists extending inwardly from the face portion, and a plurality of insulating portions configured between each adjacent pair of the joists. 
     Additional aspects and advantages of the present general inventive concept will be set forth in part in the description which follows, and, in part, will be obvious from the description, or may be learned by practice of the present general inventive concept. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
       The following example embodiments are representative of example techniques and structures designed to carry out the objects of the present general inventive concept, but the present general inventive concept is not limited to these example embodiments. In the accompanying drawings and illustrations, the sizes and relative sizes, shapes, and qualities of lines, entities, and regions may be exaggerated for clarity. A wide variety of additional embodiments will be more readily understood and appreciated through the following detailed description of the example embodiments, with reference to the accompanying drawings in which: 
         FIG. 1  is a perspective view showing one embodiment of a precast concrete wall constructed in accordance with several features of the present general inventive concept; 
         FIG. 2  is an exploded view of the precast concrete wall of  FIG. 1 ; 
         FIG. 3  is another exploded view of the precast concrete wall of  FIG. 1 ; 
         FIG. 4  is a partially exploded perspective view showing various operations of one embodiment of a method according to several features of the present general inventive concept; 
         FIG. 5  is a partially exploded perspective view showing other operations of the method of  FIG. 4 ; 
         FIG. 6  is a top view showing other operations of the method of  FIG. 4 ; 
         FIG. 7  is a perspective view of another embodiment of a precast concrete wall constructed in accordance with several features of the present general inventive concept; 
         FIG. 8  is a partially exploded perspective view showing various operations of another embodiment of a method according to several features of the present general inventive concept; 
         FIG. 9  is a partially exploded perspective view showing other operations of the method of  FIG. 8 ; 
         FIG. 10  is a top view showing other operations of the method of  FIG. 8 ; 
         FIG. 11  illustrates a plan view of a panel according to an example embodiment of the present general inventive concept; 
         FIG. 12  illustrates a lengthwise section of the panel of  FIG. 11 ; 
         FIG. 13  illustrates a crosswise section of the panel of  FIG. 11 ; 
         FIG. 14  illustrates a perspective view of the panel of  FIG. 11  with a partial breakout to show some of the inner components of the panel; 
         FIG. 15  illustrates a plan view of a panel according to another example embodiment of the present general inventive concept; 
         FIG. 16  illustrates a lengthwise section of the panel of  FIG. 15 ; 
         FIG. 17  illustrates a crosswise section of the panel of  FIG. 15 ; 
         FIG. 18  illustrates a perspective view of the panel of  FIG. 15  with a partial breakout to show some of the inner components of the panel; 
         FIG. 19  illustrates a perspective view of a prefabricated wall with a veneer according to an example embodiment of the present general inventive concept; 
         FIGS. 20A-D  illustrate the preparation of the horizontal trim member of  FIG. 19  according to an example embodiment of the present general inventive concept; 
         FIGS. 21A-B  illustrate the preparation of the vertical trim members of  FIG. 19  according to an example embodiment of the present general inventive concept; 
         FIGS. 22A-B  illustrate the preparation of a brick stamp used to form the brick pattern of  FIG. 19  according to an example embodiment of the present general inventive concept; and 
         FIGS. 23A-D  illustrate the forming of the prefabricated wall with the veneer of  FIG. 19  according to an example embodiment of the present general inventive concept. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Reference will now be made to certain example embodiments of the present general inventive concept which are illustrated in the accompanying drawings and illustrations. The example embodiments are described herein in order to explain the present general inventive concept by referring to the figures. The following detailed description is provided to assist the reader in gaining a comprehensive understanding of the structures and fabrication techniques described herein. Accordingly, various changes, modification, and equivalents of the structures and fabrication techniques described herein will be suggested to those of ordinary skill in the art. The progression of fabrication operations described are merely examples, however, and the sequence type of operations is not limited to that set forth herein and may be changed as is known in the art, with the exception of operations necessarily occurring in a certain order. Also, description of well-known functions and constructions may be omitted for increased clarity and conciseness. 
     Note that spatially relative terms, such as “up,” “down,” “right,” “left,” “beneath,” “below,” “lower,” “above,” “upper” and the like, may be used herein for ease of description to describe one element or feature&#39;s relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over or rotated, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the exemplary term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly. 
     In accordance with several features of the present general inventive concept, a precast concrete wall structure and method for manufacturing a precast concrete wall structure are disclosed herein and in the accompanying figures. With reference to the accompanying figures, and with particular reference to  FIGS. 1-3 , in one embodiment, a wall structure  10  is provided which includes an outer concrete face  12  defining an outer surface  36  forming an exterior surface of the wall structure  10 , and an inner surface  18  defining a plurality of inwardly-facing ribs  14 . In the illustrated embodiment, each of the ribs  14  is of a substantially rectangular cross-section and extends substantially vertically along the inner surface  18  of the concrete face  12  in substantially parallel-planar, spaced apart relation to the other ribs. In the illustrated embodiment, the concrete face  12  defines elongated top beam  38  and toe  40  portions extending inwardly from the inner surface  18  along respective upper  42  and lower  44  ends of the concrete face  12 , in an orientation substantially perpendicular to the ribs  14 . 
     In several embodiments, the concrete face  12  is fabricated from a reinforced concrete material, of the type having a plurality of reinforcing members embedded in a cement-based concrete material. For example, in the present embodiment, a plurality of elongated steel reinforcing members are provided within the concrete face  12 , extending substantially parallel to the inner and outer surfaces  18 ,  36  thereof. More specifically, in the present embodiment, a plurality of elongated steel members are provided, each member extending within and along a respective rib  14  of the concrete face  12 , thereby strengthening the concrete face  12  and resisting flexure of the concrete face  12 . In certain embodiments, additional reinforcement in the form of wire mesh or fiber materials may be provided within and along the concrete face  12 . 
     It will be recognized that the above-discussed reinforcement against flexure of the concrete face  12  may be useful in various applications of the wall structure  10 , such as for example use of the wall structure  10  in forming a basement or other below-ground or partially below-ground structure, or in forming a retaining wall structure. However, it will further be understood that the reinforcing members may be provided at other locations within the concrete face  12  without departing from the spirit and scope of the present general inventive concept. For example, in other embodiments, one or more reinforcing members may be provided slightly interior to the outer surface  36  of the concrete face  12  to reinforce the concrete face against flexure. Such reinforcement may be useful in other applications of the wall structure  10 , such as for example use of the wall structure  10  in forming portion of an above-ground or partially above-ground structure, such as an above-ground or partially above-ground residential, commercial, or industrial building. Additional reinforcement may also be provided extending within the top beam  38  or toe  40  to provide strength and reinforcement to those portions of the wall structure  10 . 
     A substantially planar forming member  16  is provided extending along the inner surface  18  of the concrete face  12 . The forming member  16  defines a plurality of outwardly-extending rectangular protrusions  20  sized and shaped to be received in mating engagement between each of the ribs  14 . In several embodiments, the forming member  16  is constructed from a material that allows the forming member  16  to provide moisture resistance and vapor permeability to the wall structure  10  and/or to decrease the overall thermal conductivity of the wall structure  10 . For example, in several embodiments, the forming member  16  is fabricated from an insulating material, such as for example expanded polystyrene (EPS), extruded polystyrene (XPS), rockwool, or other such material. In a preferred embodiment, the forming member  16  is both resistant to moisture and thermally insulating. 
     Referring to  FIGS. 2 and 3 , in one embodiment, the forming member  16  comprises a layer of EPS material having a plurality of integrally-formed protrusions  20  extending along an outer surface  32  thereof. The protrusions  20  are generally rectangular in shape and extend in a parallel and spaced-apart relationship to one another to define a plurality of rectangular-shaped channels  30  therebetween. As will be discussed in greater detail below, the channels  30  provide mold forms for forming the ribs  14  of the concrete face  12  during manufacture of the wall structure  10 . Hence, each rib  14  of the concrete face  12  is mated to, and is received within, a respective channel  30  of the forming member  16 , and each protrusion  20  is received between and adjacent corresponding ribs  14  of the concrete face  12 . It will be understood that the specific dimensions of the various elements of the forming member  16  may vary depending upon the desired characteristics of the finished wall structure  10 . For example, in one embodiment, the rectangular protrusions  20  may be approximately sixteen inches wide, while the channels  30  may be approximately 3.5 inches wide and approximately 5.5 inches deep. Accordingly, each mating rib  14  may be approximately 3.5 inches wide and approximately 5.5 inches deep, and each rib  14  may be spaced approximately 19.5 inches apart, centerline-to-centerline. In this embodiment, the portions of the forming member  16  extending between the rectangular protrusions  20  may be approximately 1.5 inches thick. However, it will be understood that the present general inventive concept is not limited to such dimensional restrictions. 
     In several embodiments, the forming member  16  terminates at a lower edge of the top beam  38  and at an upper edge of the toe  40 . In certain of these embodiments, the top beam  38  and toe  40  each extend inwardly to at least partially surround upper and lower ends, respectively, of the forming member  16 . In some embodiments, the top beam  38  and toe  40  portions of the concrete face  12  may each extend inwardly to completely surround the upper and lower ends, respectively, of the forming member  16 . In other words, the top beam  38  and toe  40  portions of the concrete face  12  may each extend inwardly to terminate substantially flush with an inner surface  24  of the forming member  16 . In other embodiments, the top beam  38  and toe  40  portions of the concrete face  12  may terminate outwardly of the forming member inner surface  24 , or in other words, may terminate short of the inner surface  24  of the forming member  16 . In certain of these embodiments, at least one insulating member  46  may be provided along an inner surface of the top beam  38  and/or the toe  40 . 
     In several embodiments, the forming member  16  defines a relatively smooth inner surface  24  opposite the outwardly-extending protrusions  20 . The inner surface  24  of the forming member  16  defines an interior surface of the wall structure  10 . In several embodiments, a stud frame  22  is secured along the inner surface  24  of the forming member  16  to provide an attachment means for additional structures which may be useful in conjunction with the wall structure  10 , i.e., drywall or other interior wall sheathing, additional insulation, plumbing or electrical fixtures, or the like. In the illustrated embodiment, the stud frame  22  comprises generally first and second spaced apart members  26  extending along opposite upper and lower edges  48 ,  50  of the forming member  16 . The upper and lower members  26  are interconnected by a plurality of studs  28  extending perpendicular to the members  26  in parallel, spaced apart relation to one another. The stud frame  22  may be fabricated from any of a variety of conventional materials commonly used in the construction of building framing without departing from the spirit and scope of the present general inventive concept. However, in a preferred embodiment, the stud frame  22  is of a metal construction and comprises generally first and second spaced apart metal tracks  26  having metal studs  28  extending therebetween. 
     In the illustrated embodiment, the various studs  28  of the stud frame  22  extend uniformly between the upper and lower members  26  at evenly-spaced locations along the width of the stud frame  22 . However, it will be recognized that the configuration of the stud frame  22  may vary in order to allow the stud frame  22  to provide any of numerous desirable features commonly associated with framed building construction. For example, in several embodiments, the upper and lower members  26  of the stud frame  22  may comprise double cap or sole members of the type commonly found in traditional building framing. The stud frame  22  may further define door or window frames, with associated cripple studs, top beam members, etc., of the type commonly found in building framing. It will be recognized that, in such embodiments, corresponding through openings may be defined in the concrete face  12  and forming member  16  to accommodate such door and window frames. Numerous such configurations will be recognized by one of skill in the art and may be used without departing from the spirit and scope of the present general inventive concept. 
     In several embodiments, opposite first and second sides  52 ,  54  of the wall structure  10  define suitable structures or mating surfaces to allow the wall structure  10  to be joined along its first or second side  52 ,  54  with an adjacent wall structure  10  to form a continuous wall. For example, in several embodiments, suitable fasteners are embedded along the first or second sides  52 ,  54  of the wall. In other embodiments, the first and second sides  52 ,  54  of the wall structure  10  define mating joint surfaces adapted to form a joint with an adjacent wall structure  10 . With reference to  FIGS. 1-3 , in the illustrated embodiment, the first and second sides  52 ,  54  of the wall structure define matingly-shaped female and male lap joints, respectively, extending along respective lengths of the first and second sides  52 ,  54 . More specifically, in the illustrated embodiment, the portion of the concrete face  12  along the first side  52  defines a female portion of a lap joint  56 , while the portion of the concrete face  12  along the second side  54  defines a male portion of a lap joint  58 . The female and male lap joint portions  56 ,  58  are matingly-shaped, such that each male portion  56  may mate with a corresponding female portion  58  of an adjacent wall structure  10 , thereby joining adjacent wall structures in side-by-side relationship with one another. Those of skill in the art will recognize other suitable shapes which may be used in forming the mating surfaces of the first and second sides  52 ,  54  of the wall structure without departing from the spirit and scope of the present general inventive concept. 
     In accordance with several additional features of the present general inventive concept, a method of manufacturing a precast concrete wall structure is also disclosed herein and in the accompanying figures. Various operations according to one embodiment of a method of manufacturing a precast concrete wall structure, or “method,” may be understood by reference to the illustrations depicted in  FIGS. 4-6  and the description herein. With reference to  FIGS. 4-6 , in one embodiment, a casting bed  60  is provided having a plurality of surfaces  62 ,  64  for defining a generally rectangular interior area  66  corresponding generally to a desired overall shape of the finished wall structure  10 . In the embodiment of  FIG. 4 , the casting bed  60  includes generally first and second elongated side rails  67 ,  68  arranged in a parallel, spaced-apart relationship, with first and second elongated gate members  70 ,  72  extending therebetween in parallel, spaced-apart relationship with one another, and in perpendicular relationship with the first and second side rails  67 ,  68 . Each side rail  67 ,  68  defines an interior planar surface  62  facing an interior planar surface  62  of the opposite side rail  67 ,  68 , and likewise, each gate member  70 ,  72  defines an interior planar surface  64  facing an interior planar surface  64  of the opposite gate member. Thus, the planar surfaces  62 ,  64  cooperate to define a substantially rectangular interior area  66  therebetween. The various side rails  67 ,  68  and gate members  70 ,  72  may be assembled and placed along a substantially flat, level support surface, such as a table or the floor, with respective lower edges of the interior planar surfaces  62 ,  64  substantially flush with the support surface, thereby substantially closing the lower end of the rectangular interior area  66 . Thus, the interior area  66  forms a substantially planar, rectangular mold having an interior shape substantially corresponding to a desired overall shape of the finished wall structure  10 . 
     In several embodiments, one or more of the interior planar surfaces  62 ,  64  of the casting bed may optionally define shapes suitable for forming the above-discussed fasteners and/or joint portions of the wall structure  10 . For example, in one embodiment, the interior surface  64  of the second gate member  72  defines a lip  80  extending outwardly therefrom along a length thereof, while the interior surface  64  of the opposite first gate member  70  defines a groove  82  extending along a length thereof. The lip and groove  80 ,  82  provide mold surfaces of the casting bed  60  suitable to form the above-discussed matingly-shaped joint portions  56 ,  58  along opposite side surfaces of the finished wall structure  10 . In other embodiments, suitable cutouts are provided along interior surfaces  62 ,  64  to allow the placement of fasteners along the interior surfaces, protruding into the interior area  66  of the casting bed  60 . 
     With reference to  FIG. 4 , a stud frame  22  may be provided and positioned within the casting bed  60  to extend along the support surface. In several embodiments, the casting bed  60  is sized such that the frame  22  extends substantially fully between opposite interior surfaces  64  of the of the gate members  70 ,  72  and/or between opposite interior surfaces  62  of the side rails  67 ,  68 . In other embodiments, the frame  22  may be sized to extend only partially between opposite interior surfaces  62  of the of the side rails  67 ,  68  and/or between opposite interior surfaces  64  of the gate members  70 ,  72 . In such embodiments, the frame  22  may be positioned between the opposite interior surfaces  62 ,  64  of the side rails  67 ,  68  and gate members  70 ,  72  so as to provide space between the frame  22  and the interior surfaces  62 ,  64  for formation of the top beam  38  and toe  40  portions of the wall structure  10  discussed above. In some embodiments, a suitable spacer may optionally be positioned between the frame  22  and at least one interior surface  62 ,  64  of the casting bed  60  to assist in positioning the frame  22  at a desired location along the support surface of the casting bed  60 . In some embodiments, the spacer may be designed to form a portion of the top beam  38  or toe  40  of the wall structure  10  upon completion of the wall structure  10  as described hereinbelow. For example, in the illustrated embodiment, the above-discussed insulating member  46  serves as an elongated spacer during manufacture of the wall structure  10 . The insulating member (hereinafter, “spacer”)  46  comprises a strip of insulating extruded polystyrene (XPS) approximately one inch in thickness. The spacer  46  is positioned between the upper member  74  of the stud frame  22  and an adjacent interior surface  62  of the casting bed  60 . Upon completion of the present embodiment of the method as further described hereinbelow, the spacer  46  forms an interior portion of the top beam  38  of the wall structure  10  and provides a layer of insulation and moisture resistance to the top beam portion  38  of the wall structure  10 . 
     With reference to  FIG. 5 , upon positioning the frame  22  within the casting bed  60 , a forming member  16  may then be positioned in overlying relationship above the stud frame  22 , with the rectangular protrusions  20  of the forming member  16  protruding generally upwardly away from the frame  22 . In several embodiments, the forming member  16  may be sized to extend along the frame  22  to span the length and width of the frame  22 , thereby cooperating with the support surface of the casting bed to encapsulate the spaces between each of the studs  28  of the frame  22  and to limit fluid communication between the spaces between the studs  28  and the remainder of the interior area  66  of the casting bed  60 . In a preferred embodiment, the forming member  16  is positioned such that the protrusions  20  extend generally parallel to the studs  28  of the frame  22 . However, it will be recognized that the protrusions  20  may be positioned non-parallel to the studs  28  without departing from the spirit and scope of the present general inventive concept. 
     As discussed above, the forming member  16  includes a plurality of rectangular protrusions  20  extending in parallel and spaced-apart relationship to define a plurality of parallel channels  30  extending along a width dimension of the forming member  16 . In one embodiment, the forming member  16  is defined by a single, unitary member. In other embodiments, the forming member  16  is defined by a plurality of members arranged in side-by-side relationship to form the forming member  16 . For example, in one embodiment, a plurality of forming member segments are provided, with each segment defining a portion of the total length of the forming member  16 , including one or more of the rectangular protrusions  20  and one or more channels  30 . In this embodiment, a plurality of forming member segments are provided and arranged in side-by-side relationship to form the complete forming member  16 , including the desired number of rectangular protrusions  20  and channels  30  interposed therebetween. The forming member segments may be secured to one another via suitable fasteners of the type known to one of skill in the art. 
     With further reference to  FIG. 5 , following placement of the forming member  16  in the casting bed  60 , a plurality of reinforcing members  76  are optionally positioned within the casting bed  60  at locations either above the forming member  16  or between the protrusions  20 , within the channels  30 . As discussed above, the reinforcing members  76  may be of the type commonly used to reinforce concrete, such as for example rebar segments, wire mesh, or the like. The reinforcing members  76  may be supported centrally along each of the channels  30  or may be supported from contact with the surfaces of the forming member  16  using suitable spacers of the type known to one of skill in the art. 
     As shown in  FIG. 6 , following placement of the forming member  16  and optional placement of the reinforcing members  76 , uncured, flowable concrete  78  is placed within the casting bed  60 . The concrete  78  is allowed to fill each of the channels  30  and any voids between the side walls  62 ,  64  of the casting bed  60  and the frame  22  and forming member  16 . For example, as discussed above, in one embodiment, suitable spaces are left between each of the upper and lower members  26  of the frame  22  and the adjacent walls  62 ,  64  of the casting bed  60  for formation of the top beam  38  and toe  40  portions of the wall structure  10  along outer edges of the wall structure adjacent the upper and lower members  26  of the frame  22 . In such embodiments, the flowable concrete  78  is allowed to fill such spaces, thereby forming the top beam  38  and toe  40  portions of the wall structure  10 . However, it will be recognized that, because the forming member  16  serves to encapsulate the spaces between each of the studs  28  of the frame  22 , the forming member  16  limits the concrete from flowing into the spaces between each of the studs  28 . 
     In certain embodiments, an upper surface of the uncured concrete  78  is finished to a substantially level surface. In other embodiments, self-leveling concrete is employed, such that finishing the upper surface subsequent to pouring the concrete  78  into the casting bed  60  is not necessary. In still other embodiments, and in particular in certain embodiments in which the outer surface of the concrete face  12  is to be exposed, such as for example when the wall structure  10  is to be used in an above-ground or partially above-ground setting, the uncured concrete  78  may be finished to a desired texture via tamping, troweling, brushing, stamping, or other techniques known in the art. Thereafter, the concrete is allowed to at least partially cure to form a rigid concrete face  12 , thereby forming the finished wall structure  10 . The wall structure  10  may then be removed from the casting bed  60  by means known in the art, such as for example by lifting the wall structure  10  and/or by disassembling, or partially disassembling, the casting bed  60 . In still other embodiments, following curing of the concrete to form the rigid concrete face  12 , the exterior surface of the concrete face  12  is further finished to a desired surface or texture. For example, in one embodiment, following curing of the concrete, an additional application of material, such as for example paint, stain, wood or brick veneer, plaster, or the like, is applied to the outer surface of the concrete face  12 . In another embodiment, following curing of the concrete, the outer surface of the concrete face  12  is abraded, such as for example by sanding, sandblasting, or the like, to a desired finish. 
       FIGS. 7-10  illustrate another embodiment of a wall structure  10   a , as well as various operations of another embodiment of a method according to several features of the present general inventive concept. In the embodiment of  FIGS. 7-10 , a wall structure  10   a  is formed which may be used in the construction of a wall which extends upwards to provide multiple floors in height. With reference to  FIG. 7 , in one embodiment, the wall structure  10   a  includes generally a first stud frame  22   a  and corresponding forming member  16   a  arranged in parallel-planar, overlying relationship with one another, and a second stud frame  22   b  and corresponding forming member  16   b  arranged in parallel-planar, overlying relationship with one another. The first stud frame  22   a  and corresponding forming member  16   a  are arranged in a spaced-apart, end-to-end configuration in relation to the second stud frame  22   b  and corresponding forming member  16   b . Thus, the outer concrete face  12   a  extends around an upper end  84  of the first stud frame  22   a  and corresponding forming member  16   a  to form a top beam  38   a , around a lower end  86  of the second stud frame  22   b  and corresponding forming member  16   b  to form a toe  40   a , and between the two sets of stud frames and forming members to form an intermediary beam  88 . 
     In the illustrated embodiment, the first and second sets of stud frames and forming members  16   a ,  22   a  and  16   b ,  22   b  are arranged in an end-to-end vertical configuration, such that the wall structure  10   a  may provide multiple floors in height. In such an embodiment, it will be recognized that the intermediary beam  88  may serve to provide a location for anchoring additional structures suitable to form an elevated ceiling, floor structure, or the like. However, it will further be understood that other configurations for the first and second sets of stud frames and forming members  16   a ,  22   a  and  16   b ,  22   b  may be utilized without departing from the spirit and scope of the present general inventive concept. For example, in another embodiment (not shown), the first and second sets of stud frames and forming members are arranged in a horizontal, side-by-side configuration, such that the concrete face forms a top beam along upper ends of both sets of stud frames and forming members, a toe along lower ends of both sets of stud frames and forming members, and a vertical stud extending between the two sets of stud frames and forming members. It will further be recognized that multiple sets of stud frames and forming members may be provided in side-by-side arrangement, end-to-end arrangement, or a combination thereof, without departing from the spirit and scope of the present general inventive concept. 
     With reference to  FIGS. 8-10 , in one embodiment of the method, a casting bed  60   a  is provided having a plurality of surfaces  62   a ,  64   a  for defining a generally rectangular interior area  66   a  corresponding generally to a desired overall shape of the finished wall structure  10   a . Of note in the present illustrated embodiment, the depicted casting bed  60   a  does not include the above-discussed structures suitable for formation of the joint. Thus, each of the interior surfaces  62   a ,  64   a  of the casting bed  60   a  is relatively smooth and upright. 
     As shown in  FIG. 8 , in one embodiment of the method, the above-discussed first and second stud frames  22   a ,  22   b  may be provided and positioned within the casting bed  60   a  in a parallel-planar relationship along the support surface, and in an end-to-end, or side-by-side, and spaced-apart relationship with one another. In the illustrated embodiment, the casting bed  60   a  is sized such that the first and second frames  22   a ,  22   b  each extend substantially fully between opposite interior side surfaces  64   a  of the of casting bed  60   a . However, the distance between opposite interior end surfaces  62   a  of the casting bed  60   a  is such that the frames  22   a ,  22   b  extend between the end surfaces  62   a  in their end-to-end and spaced-apart configuration and allow sufficient space from the end surfaces  62   a  to form the above-discussed top beam  38   a  and toe  40   a . It will be noted that, in the illustrated embodiment, the above-discussed spacer between the frames and the interior surfaces of the casting bed is not provided. However, one or more such spacers similar to the one described above may be provided without departing from the spirit and scope of the present general inventive concept. 
     With reference to  FIG. 9 , upon positioning the first frame  22   a  within the casting bed  60   a , the first forming member  16   a  may then be positioned in overlying relationship above the first frame  22   a , with the rectangular protrusions  20  of the first forming member  16   a  protruding generally upwardly away from the first frame  22   a . Likewise, upon positioning the second frame  22   b  within the casting bed  60   a , the second forming member  16   b  may then be positioned in overlying relationship above the second frame  22   b , with the rectangular protrusions  20  of the second forming member  16   b  protruding generally upwardly away from the second frame  22   b . Similar to the above-discussed embodiment, the forming members  16   a ,  16   b  may be sized to extend along their respective frames  22   a ,  22   b  to span the length and width of the frame, thereby cooperating with the support surface of the casting bed  60   a  to encapsulate the spaces between each of the studs  28  of the respective frame  22   a ,  22   b  and to limit fluid communication between the spaces between the studs  28  and the remainder of the interior area  66   a  of the casting bed  60   a . Furthermore, as discussed above, each of the forming members  16   a ,  16   b  may be defined by a single, unitary member, or may be defined by a plurality of members arranged in side-by-side relationship to form the forming member. 
     With further reference to  FIG. 9 , following placement of the forming members  16   a ,  16   b  in the casting bed  60   a , a plurality of reinforcing members  76   a  are optionally positioned within the casting bed  60   a  at locations either along or between the forming members  16   a ,  16   b . In the illustrated embodiment, the reinforcing members  76   a  are distributed generally along the various channels  30  of the forming members  16   a ,  16   b , along the space between the two forming members  16   a ,  16   b  and between the two frames  22   a ,  22   b , and along the spaces between each of the forming members  16   a ,  16   b  and their respective adjacent interior end surfaces  62   a  of the casting bed  60   a . As shown in  FIG. 10 , following placement of the reinforcing members  76   a , uncured, flowable concrete  78   a  is placed within the casting bed  60   a . The concrete  78   a  is allowed to fill each of the channels  30  of the forming members  16   a ,  16   b , the space between the two forming members  16   a ,  16   b  and between the two frames  22   a ,  22   b , and any voids between the side walls  62   a ,  64   a  of the casting bed  60   a  and the frames  22   a ,  22   b  and forming members  16   a ,  16   b . Thus, the flowable concrete  78  is allowed to form the top beam  38   a , toe  40   a , and intermediate beam  88  portions of the wall structure  10 . 
     Similar to the above-discussed method, in certain embodiments, an upper surface of the uncured concrete  78   a  is finished to a desired surface. For example, in certain embodiments, the upper surface of the uncured concrete  78   a  is finished to a substantially level surface. In still other embodiments, the uncured concrete  78   a  is finished to a desired texture via techniques known in the art, such as for example painting, staining, tamping, troweling, brushing, stamping, or the application of veneers or other such surface coverings. The concrete is allowed to at least partially cure to form the rigid concrete face  12   a , thereby forming the finished wall structure  10   a . The wall structure  10   a  may then be removed from the casting bed  60   a  by means known in the art, such as for example by lifting the wall structure  10   a  and/or by disassembling, or partially disassembling, the casting bed  60   a.    
     From the foregoing description, it will be recognized by one skilled in the art that a precast concrete wall structure and method for manufacturing a precast concrete wall structure are provided herein which allow significant improvement over prior art methods and apparatus. For example, it will be recognized that, by forming the forming layer  16  from an insulating material, such as for example expanded polystyrene (EPS), extruded polystyrene (XPS), rockwool, or other such material, the forming layer  16  serves to increase the insulating properties of the wall structure  10 , thereby allowing the wall structure  10  to be used in applications in which an insulating wall is desired absent the need to add further insulating material to the wall structure  10 . It will further be recognized that the amount of thermal resistance provided by the materials of the forming layer  16  are, at least in part, a function of the average thickness per unit area of forming layer material along the surface of the wall structure  10 . Accordingly, it will be recognized that the specific dimensions of the forming layer  16 , i.e., the thickness, width, and spacing of the protrusions  20  and of the portions of the forming layer  16  between the protrusions  20 , may vary in order to achieve a desired thermal resistance of the wall structure  10 , while also maintaining structural integrity of the wall structure  10  and suitability of the wall structure  10  for use in a specific application. 
     It will be recognized that, through application of the method disclosed herein, a precast concrete wall structure may be made having significant advantages over conventional poured-in-place concrete wall structures. Through application of the method disclosed herein, a precast concrete wall structure weighing approximately 50 lbs. per square foot may be produced, wherein a poured-in-place concrete structure of the same thickness would weigh approximately 126 lbs. per square foot. Thus, significant reductions in material cost and associated transportation expense may be achieved. Furthermore, it will be recognized that the precast concrete wall structure provided herein includes a frame having studs pre-installed along one surface thereof, thereby saving the expense and labor associated with installing these fixtures at the desired finished location for the wall structure. In several embodiments, the EPS and XPS materials forming the wall structure may be recycled into other products following their use in the wall structure, and in certain embodiments, scrap EPS materials may be used to form the forming member. Furthermore, it will be understood that the reinforcing members may be formed from recycled materials, i.e., recycled rebar, without departing from the spirit and scope of the present general inventive concept. 
     Various example embodiments of the present general inventive concept may also be used to produce floor and/or roof structures such as floor panels, roof panels, deck panels, etc.  FIGS. 11-18  illustrate various features and configurations of two example embodiments of such panels. For the sake of simplicity in these descriptions, the structures may be referred to simply as panels, but it is understood that the structures can be utilized as floor panels, deck panels, roof panels, etc., or any other number of similar structures, including wall panels. 
       FIG. 11  illustrates a plan view of a panel according to an example embodiment of the present general inventive concept,  FIG. 12  illustrates a lengthwise section of the panel of  FIG. 11 ,  FIG. 13  illustrates a crosswise section of the panel of  FIG. 11 , and  FIG. 14  illustrates a perspective view of the panel of  FIG. 11  with a partial breakout to show some of the inner components of the panel. The example embodiment illustrated in  FIGS. 11-14  is a panel with no soffit. As can be seen from  FIGS. 11-14 , the panel  100  is similar to the example embodiments illustrated in  FIGS. 1-10 , but is formed without a stud frame. As illustrated in the plan view of  FIG. 11 , the panel  100  has bearing closures  104  provided across the entirety of both respective ends of the panel  100 . These bearing closures  104  are analogous to the top beam  38  and toe  40  illustrated in  FIGS. 1-3 . An intermediary beam  108 , which may be referred to herein as a web stiffener, is provided across the panel  100  at approximately the center point of the panel  100 . In various example embodiments of the present general inventive concept, the panel  100  may be formed with a length of 10 feet from an end of the panel  100  to a center of the intermediary beam  108 , but placement of such a beam in other example embodiments may vary. As a floor or roof panel is likely to encounter more forces acting in a direction perpendicular to a face of the panel  100 , such intermediary beams  108  may be more necessary than would be needed for a wall panel. The web stiffener or intermediary beam  108  may be provided with a reinforcement component such as rebar, prestressing strand, wire, etc., to produce increased structural support against flexing or other undesired forces. Although the example embodiment in  FIG. 11  illustrates one intermediary beam  108 , or web stiffener, proximate the center of the panel  100 , other example embodiments of the present general inventive concept may include no or more intermediary beams, and/or may vary in the placement of the beam(s). The longitudinal section of the panel  100  illustrated in  FIG. 12  shows the bearing closures  104 , as well as the web stiffener  108 , which in various example embodiments may each have a width of approximately 4 inches.  FIG. 12  also shows the upper surface of the panel having a face  112  which may have, for example, a thickness of approximately two inches. Similar to the previously described example embodiments, the face, bearing closures, and web stiffener are formed of concrete. However, it is understood that different example embodiments may include more or fewer components, and may have different dimensions, than those illustrated in  FIGS. 11-14  without departing from the scope of the present general inventive concept. 
     As illustrated in  FIG. 12 , the web stiffener  108  of this example embodiment does not extend as far from the face  112  of the panel  100  as do the bearing closures  104  formed at each end of the panel  104 . This configuration may be formed by the forming member  120  used in the construction of the panel  100 , in which the forming member defines a channel in which the web stiffener  108  is formed. As discussed herein, the forming member  120  may be of single piece construction, or may include several separately formed components depending upon the desired configuration and features.  FIG. 12  also illustrates lifting devices  116  such as lift hooks that may be formed to aid in the lifting and otherwise moving, installation, etc., of the panel  100 . The lifting devices may vary according to different example embodiments and/or desired usage, and may be simply omitted in various example embodiments of the present general inventive concept. 
     As illustrated in  FIG. 13 , the forming member  120  defines a plurality of parallel and evenly spaced channels in which concrete joists  124  are formed. In various example embodiments of the present general inventive concept, the forming member  120  may be constructed of any of a host of types of insulation, but are preferably structurally robust enough for concreted to be poured over without being deformed. As illustrated in  FIG. 13 , every other concrete joist  124  is provided with a nailer strip  128  on the face thereof, such as, for example, a P.T. 2×4 nailer strip, for attaching other surface fixtures/bodies/members to a bottom face of the panel. In various example embodiments of the present general inventive concept, wooden 2×4&#39;s may be employed as the nailer strips  128 . It is understood that “upper” and “bottom” surface terms are used relative to the orientation illustrated in  FIGS. 11-14 , and the panel  100  may be used in different orientations such as, for example, the discussed “upper” surface facing a bottom of an installation. To provide the nailer strips  128  to the panel, the insulation forming member  120  may actually include a number of separately formed components. For example, to produce the example embodiment illustrated in  FIG. 13 , four separate forming member  120  components may be employed. Each of the four separate forming members  120  may define a central longitudinal channel in which an entire concrete joist  124  may be formed, and a centrally defined cross channel in which the previously described web stiffener  108  may be formed. By alternating these forming member  120  components with nailer strips  128 , and arranging the components so that all are in flush contact with one another, the regularly spaced and formed concrete joists  124  may be formed in the channels defined therein. In various example embodiments, the nailer strips  128  may be formed integrally with the insulation components of the forming member  120  to provide a single piece construct. As indicated in  FIG. 14 , each of the concrete joists may have reinforcing members  76  such as, for example, rebar, prestressing strand, wire, etc., formed therein to provide enhanced structural support. Multiple strands of rebar or other structural components may be employed in each web location, and depth placement of the structural components may vary according to various example embodiments of the present general inventive concept. As illustrated in  FIG. 14 , rebar has been placed in each of the channels defined by the forming member(s), in which the concrete joists are formed, to act as the reinforcing members  76 . 
     As illustrated in  FIG. 13 , grout keyways  132  may be formed on the respective outer surfaces of the outermost concrete joists  124  to improve the connection of panels  100  to one another. The grout keyways  132  may be formed by protusions in the casting bed in which these panels  100  are formed. In the example embodiment illustrated in  FIG. 13 , the grout keyways  132  may be approximately 2 inches wide, and may start at a point approximately 3 inches from the upper surface of the panel. As also illustrated in  FIG. 13 , the width of the portion of the outermost concrete joists  124  between the grout keyway  132  and the upper surface may be approximately ½ inch smaller than width of the concrete joist  124  below the grout keyway  132 . Such an indention may also be formed in the casting bed, and may be formed by the same protrusions respectively forming the grout keyways  132 . 
     The forming of a panel such as that illustrated in  FIGS. 11-14  may in various example embodiments be very similar to the process previously described in relation to  FIGS. 4-6 , albeit without the inclusion of a stud frame. A casting bed defining the desired length, width, and thickness of the frame may be constructed and placed upon a flat forming surface. The inner surface of the lengthwise members of the casting bed may have formed thereon the protrusion(s) to form the grout keyways  132  of the panel, as well as the outer indentation of the upper part of the outermost concrete joists. In various example embodiments, a nailer strip  128  may be placed on the flat surface inside the casting bed and flush against one lengthwise member of the casting bed. Space may be left at either end of the nailer strip  128  to form the bearing closures  104 . Such spacing may be actuated by other methods rather than simply leaving an empty space, in order to prevent the forming members  120  from movement during fabrication of the panel  100 . Then a forming member  120  may be placed flush alongside the nailer strip  128 , and the process may be repeated until the casting bed is filled. After the forming members  120  are placed, rebar or other structural components may be placed in the respective grooves or channels to act as reinforcing members  76  in the spaces that will form the concrete joists  124 . The channels may be defined such that the concrete joists  124  will be parallel and evenly spaced across the width of the panel  100 , and running end to end to the bearing closures  104 . The insulation used in the forming members  120  may be one of the types mentioned in the previously described embodiments of the present general inventive concept. After placement of all the forming members  120  and structural reinforcements, uncured, flowable concrete is placed within the casting bed. The concrete is allowed to fill each of the channels of the forming members  120 , the space at the longitudinal ends of the forming members  120 , and to form the face  112  or upper surface over the forming members  120  to the desired thickness. The upper surface of the uncured concrete may be finished to a desired surface as described in the previous example embodiments of the present general inventive concept. Upon removal from the casting bed, or upon removal of the casting bed, the panel  100  will have the form illustrated in  FIGS. 11-14 . 
       FIG. 15  illustrates a plan view of a panel according to another example embodiment of the present general inventive concept,  FIG. 16  illustrates a lengthwise section of the panel of  FIG. 15 ,  FIG. 17  illustrates a crosswise section of the panel of  FIG. 15 , and  FIG. 18  illustrates a perspective view of the panel of  FIG. 15  with a partial breakout to show some of the inner components of the panel. The example embodiment panel  136  illustrated in  FIGS. 15-18  is similar to the example embodiment illustrated in  FIGS. 11-14 , except that a concrete soffit  140  is provided to the panel  136 . Thus, rather than having a lower surface formed of insulation and nailer strips, the lower surface will be formed uniformly with concrete that may be the same as the upper surface or face  112  of the panel  136 . To form such a panel  136 , in which insulation portions  144  acting as forming members are “floating” inside the concrete wall, in various example embodiments an approximately 2 inch layer of concrete is poured into the casting bed before the forming members or insulation portions  144  of the panel  136  are placed therein. This lower sheet of concrete will form the soffit  140  of the panel  136 . After the lower sheet of concrete has hardened to a desired state so as to support the weight of the forming members or insulation portions  144  and concrete poured thereon, the insulative forming members  144  are placed at regular intervals in the casting bed on top of the soffit  140  such that channels are defined therebetween in which concrete joists  124  will be formed. As in the example embodiment illustrated in  FIGS. 11-14 , space may be left at each end for the bearing closures  104 , and approximately 4 inch spaces may be left between each of the forming members  144 , and between the outermost forming members  144  and the casting bed, to define the channels in which the concrete joists  124  will be formed. In various example embodiments, methods of maintaining the spacing may be employed to keep the forming members  144  in place during the pouring of the uncured concrete. The structural reinforcement components  76  and lift hooks  116  may be placed as in  FIGS. 11-14 , and the uncured concrete is poured over the forming members  144 . In the example embodiment illustrated in  FIGS. 15-18 , no intermediate beam or web stiffener is included at a center of the panel  136 , as the soffit  140  will provide additional structural support for the panel  136 . However, in various example embodiments of the present general inventive concept, one or more such web stiffeners may be provided. Various example embodiments of the present general inventive concept may employ connection components to assist the soffit  140  and the later poured concrete to adhere to one another. In various example embodiments of the present general inventive concept, the soffit layer  140  may be added after the upper layer has been formed by simply inverting the partially poured panel and adding the soffit layer  140  atop the panel  136  in a casting bed. In the example embodiment illustrated in  FIGS. 15-18 , the soffit layer  140  is approximately 2 inches thick, but various example embodiments of the present general inventive concept may provide soffits of various thicknesses. The soffit  140  may be finished to a desired surface as described in the previous example embodiments of the present general inventive concept. 
     While various example embodiments of the present general inventive concept described thus far have included a precast wall structure typically having a concrete outer surface, which may be used, for example, in an underground or partially underground situation in which the outer surface of the wall structure is not seen or not aesthetically important, other various example embodiments of the present general inventive concept may include a prefabricated wall veneer that may be adhered to the outer concrete surface to provide a more aesthetically pleasing precast wall structure, and/or stylings formed in the outer concrete surface to provide various types of facades. Such prefabricated wall veneers may be formed to have a host of different looks, such as, for example, brick, stone, stucco, ribbed or other raised and/or unraised geometric patterns, etc. The different desired looks/textures of the veneers may be formed by stamping during production of the veneer panels. These prefabricated wall veneers may be fixed to a precast wall structure during the production of the precast wall structure to provide a desired look for an outside wall of a building employing the precast wall structure. The prefabricated wall veneers may be formed of wood composite and/or other composite materials which resist damage from moisture, rot, splitting, pests, and so on, while providing many years of maintenance free use. By forming the veneers to a desired look, painting and other types of general maintenance may be avoided. 
       FIG. 19  illustrates a perspective view of a prefabricated panel with a veneer according to an example embodiment of the present general inventive concept. In this example embodiment the prefabricated wall and veneer  150  is configured to have an outer façade with two different decorative portions, including an upper portion having trim members such as a horizontal trim member  162  and a plurality of vertical trim members  166 , and a lower portion having a brick pattern  158 . Portions of concrete  154  of the panel  150  not adorned by the veneer are shown between the vertical members  166 . In this example embodiment the horizontal trim member  162  is configured as a frieze board, and the vertical trim members  166  are configured as batten strips, but various example embodiments may have a host of differently configured trim members, or no trim members at all. It is understood that the façade of the prefabricated wall and veneer  150  discussed herein may have any of a number of different surface looks, thicknesses, feel, etc., and may have fewer or more decorative areas than described herein. Various portions of the veneer may be configured to be fixed to the concrete  154  during the forming of precast concrete wall structure, and may have anchoring members that extend into the concrete  154  (as described further herein). In the example embodiment illustrated in  FIG. 19 , the brick pattern  158  is embedded into the concrete  154 , but in various example embodiments the brick pattern itself may be an external façade affixed to the concrete  154  of the panel  150 . 
       FIGS. 20A-D  illustrate the preparation of the horizontal trim member  162  of  FIG. 19  according to an example embodiment of the present general inventive concept. As previously described, the horizontal trim member  162  of this example panel  150  is configured as a frieze board, and serves as a border between the brick pattern  158  and the vertical trim members  166 . The horizontal trim member  162  of  FIG. 20A  has been cut to the desired size, e.g., having a length corresponding to the width of the prefabricated panel  150 , and coated with a sealant, as the trim member  162  may be exposed to outside weather elements. In this example embodiment the horizontal trim member  162  is coated with a bituminous coating as a sealant, but it is understood that different sealants may be used without departing from the scope of the present general inventive concept.  FIG. 20B  shows markings made on the horizontal trim member  162  to determine anchor points  170  for the anchor members  174  shown in  FIG. 20C . In this example embodiment, the anchor members  174 , an thus the anchor points  170  at which the anchor members  174  will be affixed, are to be attached to the horizontal trim member  162  at substantially nine-inch intervals along the length of the horizontal trim member  162 , and substantially one inch from the border of the horizontal trim member  162 . Thus, as shown, an assembler has measured the one-inch and nine-inch intervals along the length of the board, and the cross sections of the markings are the anchor points  170  at which the anchor members  174  are attached. In various example embodiments these described anchor point  170  intervals may be used with any trim member that is wider than four inches.  FIG. 20D  illustrates the anchor members  174  attached to the horizontal trim member  162  at those anchor points  170 . In this example embodiment the anchor members  174  are anchor screws that are screwed into the horizontal trim member  162 , and the heads of the anchor screws are wholly encased in the concrete  154  into which the anchor members  174  extend. Various example embodiments may provide a host of different anchor points and/or configurations of anchor members. In this example embodiment, the horizontal trim member  166  and vertical trim members  166  may be formed of a composite material such as MIRATEC®, and may simply be a non-structural decorative trim. After the anchor members  174  have been screwed into the horizontal trim member  162 , additional sealant may be provided about the insertion point of the anchor members  174  to seal the opening created by attaching the anchor members  174 . 
       FIGS. 21A-B  illustrate the preparation of the vertical trim members of  FIG. 19  according to an example embodiment of the present general inventive concept. Similarly to the preparation of the anchor points  170  in  FIG. 20B , in  FIG. 21A  anchor points  178  are provided at nine inch intervals along the length of the vertical trim members  166 , and one inch from the edge of the vertical trim members  166 . However, in this example embodiment, trim members having a width of less than 4″ may have anchor members  182  in the staggered pattern shown in  FIG. 21B , in which the anchor members  182  are provided in an alternating pattern as shown, with the anchor members  182  skipping every other anchor point such that no two anchor members  182  are side by side on the batten strips or vertical trim members  166 . After this preparation, the horizontal trim members  162  and vertical trim members  166  are ready to be placed in the curing concrete, so that they are anchored in place when the concrete  154  is dried. 
       FIGS. 22A-B  illustrate the preparation of a brick stamp used to form the brick pattern of  FIG. 19  according to an example embodiment of the present general inventive concept. As illustrated in  FIGS. 22A-B , a brick stamp  186  is cut to a desired size for the wall and veneer panel  150 . The brick stamp  186  is a model of a brick pattern that may be placed in the drying concrete to form the brick pattern  158  shown in  FIG. 19 . As illustrated, the brick stamp  186  is a skeletal structure in which the body of the brick stamp  186  corresponds to the mortar between the bricks, and the open spaces of the brick stamp  186  correspond to the bricks themselves. In various example embodiments the thickness of the brick stamp  158  corresponds to the desired depth of the mortar in the gaps between the bricks in the brick pattern  158 . In this example embodiment a plurality of the brick patterns  158  are cut to a desired size such that they all may be placed on the curing concrete to form the overall brick pattern  158  shown in  FIG. 19 . In various example embodiments a brick pattern may be cut that is large enough to only use that one brick pattern in the formation of the panel  150 , but using a plurality of smaller brick patterns  158  as described herein may be more convenient for the assembler/fabricator to place in, and remove from, the curing concrete. As illustrated in  FIGS. 22A-B  a plurality of grip members  190  are attached to the brick pattern  158  to provide the assembler a convenient point to hold in order to manipulate the brick patterns  158  into and out of the curing concrete. In this example embodiment, the grip members  190  are screws that are screwed in the brick pattern  158  close to each corner, with one in the middle, to provide a plurality of conveniently located grips for the assembler, but it is understood that a host of different grip members may be used, as well as in a host of different configurations, without departing from the scope of the present general inventive concept. In various example embodiments pattern stamps other than a brick pattern may be provided to form facades on the panel, and such stamps may be configured to be removed before the concrete is fully cured, or to remain in place after the concrete is fully cured. 
       FIGS. 23A-D  illustrate the forming of the prefabricated wall with the veneer of  FIG. 19  according to an example embodiment of the present general inventive concept. In  FIG. 23A , the concrete  154  has been freshly poured, and may have been poured over any of the various structures previously described herein to form various internal portions and/or the interior surface of the wall panel  150 , and thus has a substantially planar upper surface on which to form the veneer portion or portions. In  FIG. 23A  the brick stamps  186  are placed in the curing concrete  154 . An assembler may use the grip members  190  to easily place the brick stamps  186  in the concrete  154 , and as shown the brick stamps  186  may be cut so that they correspond to each adjacent brick stamp  186  to form a proper brick pattern  158 , including the edges between panels  150 . After placing the brick stamps  186  in the curing concrete, they may be tamped down until the upper surface of the brick stamps  186  is substantially flush with the upper surface of the curing concrete  154 , so as to provide desired and uniform depth of the “mortar” between the “bricks.” 
     In  FIG. 23B , after the brick stamps  186  have been placed in the concrete, the frieze board, or horizontal trim member  162 , is placed on the curing concrete  154  such that the bottom surface of the horizontal trim member  162  contacts the upper surface of the curing concrete  154 , and the anchor members  174  extend down into the curing concrete  154 . In this example embodiment the horizontal trim member  162  is placed immediately adjacent to the edge of the brick stamps  186  that will form the “top” of the brick pattern  158  relative to the finished panel  150  being stood upright. In  FIG. 23C , the batten strips, or vertical trim members  166  are placed such that the “lower” edges contact an “upper” edge of the horizontal trim member  162 , the bottom surface of the vertical trim members  166  contact the upper surface of the curing concrete  154 , and the anchor members  182  extend down into the curing concrete. The horizontal trim member  162  may be cut so that the ends of the horizontal trim member  162  meet corresponding ends of horizontal trim members of other panels, and the vertical trim members  166  may be arranged such that the gaps between the vertical trim members  166  of the panel  150  are substantially uniform, and that gaps between the outermost vertical trim members  166  and outermost vertical trim members  166  of other panels substantially match the gaps between the adjacent vertical trim members  166  of the panel  150 . Thus, trim members are fixed to the precast wall structure at various points, and are prevented from warping or other such unwanted movement. The extended anchoring members  174 , 182  may be provided in a number of forms and configurations. For example, the anchoring members may be formed of the same composite material as the trim members, and formed at the same time as the trim members. In other example embodiments, the anchoring members may be attached to the trim members after the production of the trim members. In the example embodiment of the present general inventive concept, the anchoring members may be panhead screws that are screwed partially into the trim members such that the head of the panhead screws may be embedded in the poured concrete of the precast wall structure to provide anchoring of the trim members to the precast wall structure. In other various example embodiments, the anchoring members/extensions may be formed with barbs, ribs, annular flanges, one or more tapering portions, etc., or any combination of such protrusions and/or open spaces in the anchoring members, which allows the wet concrete to surround, fill, etc., one or more portions of the anchoring members to provide an anchoring action. The quantity and/or configuration of the anchor members  174 , 182  may vary according to various example embodiments of the present general inventive concept. 
     As illustrated in  FIG. 23D , when the concrete is ready, such as being firm enough to hold the shape imprinted by the brick stamps  186  but not completely firm, the brick stamps  186  may be lifted straight up from the upper surface of the concrete  154 , leaving the brick pattern  158  formed in the curing concrete. After the concrete  154  is completely dried, the panel  150  may be stood up to a vertical position, resulting in the panel  150  illustrated in  FIG. 19 . 
     Various example embodiments of the present general inventive concept may provide a method of forming the panel to be used as a floor, wall, or roof structure including positioning one or more forming members within a casting bed having a plurality of upright surfaces defining a generally rectangular interior area, the one or more forming members comprising an insulating material extending along a length dimension of the one or more forming members to define a plurality of rectangular-shaped channels in a parallel and spaced-apart relationship, placing uncured concrete within the casting bed and allowing the concrete to cover the one or more forming members and substantially fill the channels, and allowing the concrete to cure. The method may further include positioning a plurality of nailer strips within the casting bed, wherein the one or more forming members may include a plurality of components separated from one another on at least one side by one of the nailer strips. The one or more forming members may include a plurality of nailer strips respectively provided adjacent to a bottom of a plurality of the channels. The nailer strips may be respectively provided to every other one of the channels. The method may further include at least one channel provided across a width of the forming member. The one or more forming members may include a layer of insulating material defining a plurality of integrally-formed rectangular protrusions extending along the length dimension of the one or more forming members in a parallel and spaced-apart relationship to one another to define the plurality of rectangular-shaped channels therebetween. The method may further include placing uncured concrete within the casting bed before positioning the one or more forming members therein, and allowing the concrete to cure. The one or more forming members may be completely encased in the concrete after the placing of the uncured concrete within the casting bed and allowing the concrete to cover the one or more forming members and substantially fill the channels. A protrusion may be formed along an inner surface of each of two lengthwise members of the casing bed such that a grout keyway is formed in lengthwise sides of the panel. The method may further include positioning a plurality of reinforcing members within the casting bed prior to placing the uncured concrete over the forming member. 
     Various example embodiments of the present general inventive concept may provide a panel to be used as a floor, wall, or roof structure, the panel including a concrete portion including a face portion and a plurality of joists extending inwardly from the face portion, and a plurality of insulating portions configured between each adjacent pair of the joists. The insulating portions may be configured to extend further from the face portion than the joists. The panel may further include a plurality of nailing strips provided respectively at ends of at least a plurality of the joists. Each of the insulating portions may be integrally formed with at least one adjacent insulating portion. The concrete portion may further include a back portion contacting ends of the joists opposite the face portion such that each of the insulating portions provided between the joists is completely surrounded by concrete. 
     Various example embodiments of the present general inventive concept may provide a method of forming a wall structure, the method including positioning a frame within a casting bed having a plurality of upright surfaces defining a generally rectangular interior area, the frame including first and second spaced apart members extending fully along a width dimension of the casting bed and a plurality of studs interconnecting the first and second spaced apart members, the studs each extending fully along a length dimension of the frame, positioning a forming member in overlying relation above the frame, the forming member including a one-piece layer of insulating material sized to extend fully along the width dimension of the casting bed and fully along a width dimension of the frame and to fully cover and encapsulate the frame within the casting bed, the forming member defining a plurality of integrally-formed rectangular protrusions, each said integrally-formed rectangular protrusion having a length dimension extending fully along a length dimension of the forming member and fully along the length dimension of the frame in a parallel and spaced-apart relationship to one another to define a plurality of rectangular-shaped channels therebetween, placing uncured concrete within the casting bed and allowing the concrete to cover the forming member and substantially fill the channels, and allowing the concrete to cure. The method may further include positioning the frame within the casting bed to provide a first space between the frame first member and a first upright surface of the casting bed and to provide a second space between the frame second member and a second upright surface of the casting bed. The method may further include positioning the forming member above the frame to provide a third space between the forming member and the first upright surface of the casting bed, and to provide a fourth space between the forming member and the second upright surface of the casting bed. The method may further include allowing uncured concrete to fill the first and third spaces to form a top beam portion of the wall structure and wherein uncured concrete is allowed to fill the second and fourth spaces to form a toe portion of the wall structure. The method may further include positioning a spacer between the frame first member and the third upright surface of the casting bed to form the first space. The spacer may be a strip of insulating material. The first and second upright surfaces of the casting bed may define structures shaped to allow the concrete to form matingly-shaped portions of a joint along opposite sides of the wall structure. The first upright surface may define a ridge extending along a length thereof and the second upright surface may define a matingly-shaped groove extending along a length thereof. The method may further include positioning a plurality of reinforcing members within the casting bed prior to placing the uncured concrete within the casting bed. The positioning of a plurality of reinforcing members may further include placing at least one reinforcing member along each channel. The method may further include positioning one or more trim members, configured to be anchored to the concrete, on an upper surface of the concrete. The method may further include positioning one or more pattern stamps at least partially into an upper surface of the concrete. 
     Various example embodiments of the present general inventive concept may provide a method of forming a wall structure, the method including positioning a wall structure frame within a casting bed, placing uncured concrete within the casting bed and allowing the concrete to cover the wall structure frame, positioning one or more trim members, configured to be anchored to the concrete, on an upper surface of the concrete, and allowing the concrete to cure. The positioning of the one or more trim members may include pressing a plurality of anchoring extensions extending from a back surface of the one or more trim members into the concrete. The anchoring extensions may be configured as screws that are partially screwed into the back surface of the one or more trim members, the screws having screwheads with a larger diameter than a body of the screws. At least a portion of the anchoring extensions may be respectively positioned adjacent each edge of the one or more trim members. The one or more trim members may be formed of a composite material which is cut to a desired size for the wall structure, and may be covered with a sealant before being placed on the upper surface of the concrete. 
     Various example embodiments of the present general inventive concept may provide a method of forming a wall structure, the method including positioning a wall structure frame within a casting bed, placing uncured concrete within the casting bed and allowing the concrete to cover the wall structure frame, positioning one or more pattern stamps at least partially into an upper surface of the concrete, and allowing the concrete to cure. The method may further include removing the one or more pattern stamps from the upper surface of the concrete after the concrete has partially cured. The one or more pattern stamps may be configured to form a brick pattern, and the one or more pattern stamps may each be configured as a skeletal structure in which open spaces of the skeletal structure correspond to bricks of the brick pattern, and solid portions of the skeletal structure correspond to mortar between the bricks of the brick pattern. 
     It is noted that the simplified diagrams and drawings included in the present application do not illustrate all the various connections and assemblies of the various components, however, those skilled in the art will understand how to implement such connections and assemblies, based on the illustrated components, figures, and descriptions provided herein. Numerous variations, modification, and additional embodiments are possible, and, accordingly, all such variations, modifications, and embodiments are to be regarded as being within the spirit and scope of the present general inventive concept. Furthermore, while the present invention has been illustrated by description of several embodiments and while the illustrative embodiments have been described in detail, it is not the intention of the applicant to restrict or in any way limit the scope of the appended claims to such detail. Additional modifications will readily appear to those skilled in the art. The invention in its broader aspects is therefore not limited to the specific details, representative apparatus and methods, and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of applicant&#39;s general inventive concept.