Modular system of permanent forms for casting reinforced concrete buildings on site

Abstract

A lightweight, permanent form system includes a plurality of GRC forms having a one or more open cavities that form a continuous interconnecting void within and throughout the plurality of GRC forms when assembled on-site to form a permanent form assembly. The continuous interconnecting void is configured to receive pourable concrete which creates a support structure for the plurality of GRC forms when the concrete hardens and to permanently join the plurality of GRC forms together.

1 . A lightweight, permanent form system comprising a plurality of pre-cast GRC forms having a plurality of open cavities wherein said plurality of open cavities forms a continuous interconnecting void within and throughout said plurality of pre-cast GRC forms when said pre-cast GRC forms are assembled on-site to form a permanent form assembly, said plurality of pre-cast GRC forms being a combination of GRC panels designed for a predetermined application, said continuous interconnecting void configured for receiving pourable concrete to create a support structure for said plurality of GRC forms on-site when said pourable concrete hardens and to permanently join said plurality of pre-cast and assembled GRC forms together forming said permanent form assembly.  
   
   
       2 . The system of  claim 1  further comprising a reinforcement structure for insertion within said continuous interconnecting void prior to filling said continuous interconnecting void with pourable concrete when said pre-cast GRC forms are assembled on site to form said permanent form assembly.  
   
   
       3 . The system of  claim 1  further comprising instructions to assemble said plurality of GRC forms in order to create said continuous interconnecting void within and throughout said plurality of GRC forms when said plurality of GRC forms are assembled.  
   
   
       4 . The system of  claim 1  wherein each of said plurality of GRC forms has an integrated seal structure along one edge and along an opposite edge wherein said one edge is configured to mate with said opposite edge of an adjacent GRC form.  
   
   
       5 . The system of  claim 1  wherein said plurality of GRC forms further includes wall panels, floor panels and roof panels.  
   
   
       6 . The system of  claim 5  wherein said floor panels have at least two hollow core regions and at least one U-shaped rib.  
   
   
       7 . The system of  claim 5  wherein said wall panels have a single skin configuration.  
   
   
       8 . The system of  claim 5  wherein said wall panels have a double skin configuration defining one or more cavities.  
   
   
       9 . The system of  claim 8  wherein said wall panels have openable apertures located adjacent a top edge and a bottom edge, said apertures communicating said one or more cavities with the outside air.  
   
   
       10 . A method of using a lightweight, permanent form system comprising: 
 forming a plurality of concrete forms using GRC material, said plurality of GRC concrete forms has a plurality of open cavities wherein said plurality of open cavities forms a continuous interconnecting void within and throughout said plurality of GRC concrete forms when said plurality of GRC concrete forms are assembled on-site to form a permanent form assembly;    assembling said plurality of GRC concrete forms; and    disposing pourable concrete within said interconnecting void forming a permanent support structure for said permanent form assembly.    
   
   
       11 . The method of  claim 10  further comprising constructing a steel reinforcement structure configured for placement within said interconnecting void.  
   
   
       12 . The method of  claim 11  further comprising disposing said steel reinforcement into said interconnecting void before disposing said pourable concrete into said interconnecting void.  
   
   
       13 . The method of  claim 10  further comprising disposing a steel reinforcement structure into said interconnecting void before disposing said pourable concrete into said interconnecting void.