Building system including concrete formwork using concrete shells

A building system for a building structure, the building system comprising:

• at least one wall assembly including a mold cavity arranged to receive poured concrete therein, the at least one wall assembly comprising:
• (i) an inner shell including (a) a panel of concrete having a first side defining an inner surface of the at least one wall assembly and a second side at an interior of the at least one wall assembly and (b) a plurality of stiffener members embedded in the panel of concrete so as to be at least partly exposed at the second side of the panel of concrete such that the plurality of stiffener members of the inner shell protrude from the second side of the panel of the inner shell into the mold cavity;
• (ii) an outer shell including (a) a panel of concrete having a first side defining an exterior surface of the at least one wall assembly and a second side at an interior of the at least one wall assembly and (b) a plurality of stiffener members embedded in the panel of concrete so as to be at least partly exposed at the second side of the panel of concrete such that the plurality of stiffener members of the outer shell protrude from the second side of the panel of the outer shell into the mold cavity;
• and
• (iii) a mechanical coupling connected between the plurality of stiffener members of the inner shell and the plurality of stiffener members of the outer shell such that (a) said mold cavity is defined between the second side of the inner shell and the second side of the outer shell, (b) the mechanical coupling within the mold cavity supports the inner shell and the outer shell at a fixed spacing such that the inner and outer shells are immovable relative to one another, and (c) the at least one wall assembly is able to be transported in an assembled form to a location of the building structure from a separate manufacturing location prior to receiving the poured concrete therein;
• wherein the stiffener members span a height of the mold cavity of the at least one wall assembly.

A building system for a building structure, the building system comprising:

• at least one wall assembly including a mold cavity arranged to receive poured concrete therein, the at least one wall assembly comprising:
• (i) an inner shell including (a) a panel of concrete having a first side defining an inner surface of the at least one wall assembly and a second side at an interior of the at least one wall assembly and (b) a plurality of stiffener members embedded in the panel of concrete so as to be at least partly exposed at the second side of the panel of concrete such that the plurality of stiffener members of the inner shell protrude from the second side of the panel of the inner shell into the mold cavity;
• (ii) an outer shell including (a) a panel of concrete having a first side defining an exterior surface of the at least one wall assembly and a second side at an interior of the at least one wall assembly and (b) a plurality of stiffener members embedded in the panel of concrete so as to be at least partly exposed at the second side of the panel of concrete such that the plurality of stiffener members of the outer shell protrude from the second side of the panel of the outer shell into the mold cavity;
• and
• (iii) a mechanical coupling connected between the plurality of stiffener members of the inner shell and the plurality of stiffener members of the outer shell such that (a) said mold cavity is defined between the second side of the inner shell and the second side of the outer shell, (b) the mechanical coupling within the mold cavity supports the inner shell and the outer shell at a fixed spacing such that the inner and outer shells are immovable relative to one another, and (c) the at least one wall assembly is able to be transported in an assembled form to a location of the building structure from a separate manufacturing location prior to receiving the poured concrete therein;
• wherein the mechanical coupling comprises a plurality of mating profiles arranged to be coupled between the stiffener members of the inner and outer shells by longitudinal sliding connections oriented in a direction of a height of the at least one wall assembly.

A building system for a building structure, the system comprising:

• at least one wall assembly comprising:
• (i) an inner shell including (a) a panel of concrete having a first side defining an inner surface of the wall assembly and a second side at an interior of the wall assembly and (b) a plurality of stiffener members embedded in the panel of concrete so as to be at least partly exposed at the second side of the panel of concrete;
• (ii) an outer shell including (a) a panel of concrete having a first side defining an exterior surface of the wall assembly and a second side at an interior of the wall assembly and (b) a plurality of stiffener members embedded in the panel of concrete so as to be at least partly exposed at the second side of the panel of concrete;
• and
• (iii) a mechanical coupling arranged to be connected between the inner and outer shells so as to define a mold cavity between the second sides of the inner and outer shells arranged to receive poured concrete therein;
• wherein the mechanical coupling comprises a plurality of coupling pins at least partly embedded within a first shell among the inner and outer shells and a plurality of receivers at least partly embedded within a second shell among the inner and outer shells, the coupling pins being arranged to mate with the receivers in a manner that retains the coupling pins within the receivers when the coupling pins are inserted into the receivers along an axis oriented perpendicularly to the inner and outer shells.

A building system for a building structure, the building system comprising:

• at least one wall assembly including a mold cavity arranged to receive poured concrete therein, the at least one wall assembly comprising:
• (i) an inner shell including (a) a panel of concrete having a first side defining an inner surface of the at least one wall assembly and a second side at an interior of the at least one wall assembly and (b) a plurality of stiffener members embedded in the panel of concrete so as to be at least partly exposed at the second side of the panel of concrete such that the plurality of stiffener members of the inner shell protrude from the second side of the panel of the inner shell into the mold cavity;
• (ii) an outer shell including (a) a panel of concrete having a first side defining an exterior surface of the at least one wall assembly and a second side at an interior of the at least one wall assembly and (b) a plurality of stiffener members embedded in the panel of concrete so as to be at least partly exposed at the second side of the panel of concrete such that the plurality of stiffener members of the outer shell protrude from the second side of the panel of the outer shell into the mold cavity;
• and
• (iii) a mechanical coupling connected between the plurality of stiffener members of the inner shell and the plurality of stiffener members of the outer shell such that (a) said mold cavity is defined between the second side of the inner shell and the second side of the outer shell, (b) the mechanical coupling within the mold cavity supports the inner shell and the outer shell at a fixed spacing such that the inner and outer shells are immovable relative to one another, and (c) the at least one wall assembly is able to be transported in an assembled form to a location of the building structure from a separate manufacturing location prior to receiving the poured concrete therein;
• the stiffener members on a first shell among the inner shell and the outer shell comprising truss members arranged to span at least partway across the mold cavity between the panels of the concrete;
• the stiffener members on a second shell among the inner shell and the outer shell comprising channel members arranged to receive respective portions of the truss members therein;
• and
• the mechanical coupling being arranged to retain said portions of the truss members within the channel members such that the inner and outer shell are held at a fixed spacing relative to one another.

A method of forming a wall assembly for a building structure, the method comprising:

• forming an inner shell using a first mold to cast a first panel of concrete having a first side at the bottom of the first mold, a second side at a top of the first mold, and a plurality of stiffener members embedded in the concrete so as to be at least partly exposed at the second side of the panel of concrete corresponding to the top of the first mold;
• forming an outer shell using a second mold to cast a second panel of concrete having a first side at the bottom of the second mold, a second side at a top of the second mold, and a plurality of stiffener members embedded in the concrete so as to be at least partly exposed at the second side of the panel of concrete corresponding to the top of the second mold;
• subsequent to forming and curing the inner shell and the outer shell, pivoting the inner shell and the outer shell 180 degrees relative to one another and using a mechanical coupling to mechanically couple the inner shell and the outer shell at a fixed spacing relative to one another so as to define a mold cavity between the second sides of the inner shell and the outer shell and such that the inner shell and the outer shell are immovable relative to one another;
• transporting the assembled wall assembly comprising the inner shell and the outer shell, while the inner shell and the outer shell are mechanically coupled immovably relative to one another by the mechanical coupling from a manufacturing location to a separate building location;
• and
• casting field concrete into the mold cavity between the inner and outer shells after transporting the assembled wall assembly from the manufacturing location to the building location.