Stay-in-place concrete form

Abstract

A stay-in-place concrete form includes masonry shells layered with rigid insulation tied with plastic cross tie assemblies. The masonry shells can be connected with plastic dovetail connectors that compensate for the variation in height of the shells. This allows for the shells, together with the connectors, to be a consistent height and allows for dry stacking. The masonry shells can be bonded together with a layer of lightweight concrete poured in a cavity behind the masonry shells and/or 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 form system with interior and exterior cementitious segmental shells for assembly on site within a predetermined grid course pattern that is properly spaced by telescoping plastic friction connectors comprising of:
 Cementitious shell channels formed along a height of cementitious shells, the cementitious shell channels spaced apart by a spacing;   A plastic friction connector assembly having a first protrusion on a bottom half of the connector and a second protrusion on a top half of the plastic connector, the first protrusion operable to fit into the cementitious shell channels below and the second protrusion operable to fit into the cementitious shell channels above and the assembly operable to accept a cross tie member;   A cross tie member operable to disposed on plastic friction connector assembly fitting attached to an exterior shell assembly and the opposite end operable to disposed on plastic friction connector assembly fitting attached to an interior shell assembly; and   First and second rigid insulation form liners operable to disposed on each end of the cross tie members.   
     
     
         2 . The stay-in-place concrete wall system of  claim 1 , further comprising an plastic pipe disposed on the plastic friction connector assemblies to retain the first and second rigid insulation form liners. 
     
     
         3 . The stay-in-place concrete wall system of  claim 1 , wherein the cementitous shell channels are dovetail shaped channels. 
     
     
         4 . The stay-in-place concrete wall system of  claim 1 , where the cementitious shells are concrete masonry units. 
     
     
         5 . The stay-in-place concrete wall system of  claim 1 , further comprising a spacer stop adapted to space a cavity between the rigid form liners and the the cementitous shells to allow for mortaring behind the cementitous shells. 
     
     
         6 . The stay-in-place concrete wall system of  claim 1 , further comprising plastic friction connector assemblies made of multiple plastic parts that attach together. 
     
     
         7 . The stay-in-place concrete wall system of  claim 1 , further comprising of metal form ties contained within the plastic cross ties to restrain the shells against hydraulic pressure of poured concrete. 
     
     
         8 . 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. 
     
     
         9 . A method for forming a stay-in-place concrete wall system comprising:
 disposing cementitious shells where a concrete wall is desired, the cementitious shells having channels at a spacing to accept plastic connectors, the cementitious shells arranged to form an interior and exterior wall of a stay-in-place form;   assembling plastic connectors in pairs with plastic cross ties, sliding the assembly into the shell channel in the exterior cementitious shell while simultaneously sliding the assembly into the shell channel in the interior cementitious shell, a force is applied upon the plastic connectors until bottom half of plastic assembly is embedded into the shell channel.   securing first and second rigid insulation form liners on each end of uniform plastic cross tie assembly, the rigid insulation restrained between a grid of cross ties spanning between the exterior cementitious shell and the interior cementitious shells, uniform cross tie geometry allows rigid insulation to be position as required along its length;   sliding a cementitious shell onto an exterior side of the plastic cross tie assembly, the cementitious shell having cementitious shell channels formed along a height of the cementitious shell, the cementitious shell channels spaced apart by a spacing and adapted to receive the top half of the protrusion, a force is applied until the cementitious shell is properly spaced within a predetermined grid dimension pattern;   sliding a cementitious shell onto an interior side of the plastic cross tie assembly, the cementitious shell having cementitious shell channels formed along a height of the cementitious shell, the cementitious shell channels spaced apart by a spacing and adapted to receive the top half of the protrusion, a force is applied until the cementitious shell is properly spaced within a predetermined grid dimension pattern; and   repeating steps above on course by course grid level until exterior and interior wall assemblies are stacked to the required height.   
     
     
         9 . The methods of  claim 8 , further comprising of patching or pointing the cementitious shell joints after the shells are positioned onto the plastic cross tie assemblies. 
     
     
         10 . The method of  claim 8 , wherein the rigid insulation liners are positioned with a cavity between the liners and the cementitious shells to accept course by course mortar from behind. 
     
     
         11 . The methods of  claim 8 , wherein the cementitious shells are concrete masonry units. 
     
     
         12 . The methods of  claim 8 , wherein the masonry shell channels are dovetail shaped channels. 
     
     
         13 . The methods of  claim 8 , wherein the uniform cross ties are plastic piping. 
     
     
         14 . The methods of  claim 8 , wherein plastic connectors consist of multiple plastic parts that attach together. 
     
     
         15 . The methods of  claim 8 , wherein metal form ties can be threaded through the plastic ties to supplement the plastic cross ties. 
     
     
         16 . The method of  claim 6 , further comprising pouring concrete in a central region, between the first and second rigid insulation form liners.