Stay-in-place concrete form

Abstract

A stay-in-place concrete form includes masonry shells layered with lightweight concrete and rigid insulation tied with plastic ladders. The masonry shells can be capped with plastic shims that compensate for the variation in height of the shells. This allows for the shells, together with the shims, to be a consistent height and allows for dry stacking. The masonry shells are bonded together with a layer of lightweight concrete poured in a cavity behind the masonry shells instead of being bonded together by mortar joints. This dry stacking method can result in labor time and training savings over conventional masonry mortar construction.

What is claimed is: 
     
         1 . A stay-in-place concrete wall system comprising:
 a masonry shell forming an exterior of a concrete wall;   masonry shell channels formed along a height of the masonry shell, the masonry shell channels spaced apart by a spacing;   a concrete shell forming an interior of the concrete wall;   concrete shell channels formed along a height of the concrete shell, the concrete shell channels spaced apart by the spacing;   a form tie ladder having a first protrusion on a first end of the form tie ladder and a second protrusion on a second, opposite end of the form tie ladder, the first protrusion operable to fit into the masonry shell channels and the second protrusion operable to fit into the concrete shell channels; and   first and second rigid insulation form liners operable to disposed on each end of the form tie ladder with a space formed between the rigid insulation form liners and the masonry shell and the concrete shell, the space adapted to receive lightweight concrete.   
     
     
         2 . The stay-in-place concrete wall system of  claim 1 , further comprising an I-strut disposed on the form tie ladder to retain the first and second rigid insulation form liners. 
     
     
         3 . The stay-in-place concrete wall system of  claim 1 , wherein the masonry shell channels and the concrete shell channels are dovetail shaped channels. 
     
     
         4 . The stay-in-place concrete wall system of  claim 1 , further comprising a plastic cap shim adapted to fit on the masonry shell to adjust a height of the masonry shell. 
     
     
         5 . The stay-in-place concrete wall system of  claim 1 , further comprising concrete poured in a central region, between the first and second rigid insulation form liners. 
     
     
         6 . A method for forming a stay-in-place concrete wall system comprising:
 disposing form tie ladder where a concrete wall is desired, the form tie ladder having a first protrusion on a first end of the form tie ladder and a second protrusion on a second, opposite end of the form tie ladder;   sliding a masonry shell onto an exterior side of the form tie ladder, the masonry shell having masonry shell channels formed along a height of the masonry shell, the masonry shell channels spaced apart by a spacing and adapted to receive the first protrusion;   sliding a concrete shell onto an interior side of the form tie ladder, the concrete shell having concrete shell channels formed along a height of the concrete shell, the concrete shell channels spaced apart by the spacing and adapted to receive the second protrusion; and   securing first and second rigid insulation form liners on each end of the form tie ladder with a space formed between the rigid insulation form liners and the masonry shell and the concrete shell, the space adapted to receive lightweight concrete.   
     
     
         7 . The method of  claim 6 , further comprising pouring the lightweight concrete into the space to a height approximately one-half the way up a top course during wall construction. 
     
     
         8 . The method of  claim 6 , further comprising securing the first and second rigid insulation form liners with an I-strut formed on the form tie ladder. 
     
     
         9 . The method of  claim 6 , wherein the masonry shell channels and the concrete shell channels are dovetail shaped channels. 
     
     
         10 . The method of  claim 6 , further comprising adjusting a height of the masonry shell by securing a plastic shim cap on the masonry shell. 
     
     
         11 . The method of  claim 6 , further comprising pouring concrete in a central region, between the first and second rigid insulation form liners.