Modular construction mold apparatus and method for constructing concrete buildings and structures

A modular stay-in-place construction mold apparatus comprising:

• (a) a stay-in-place panelized encasement assembly for shaping concrete poured therein and configured in contiguous horizontal foundation, vertical cavity wall and roof deck slab void space portions so that concrete poured therein and cured creates such foundation, walls and slabs, said panelized encasement assembly,
• (b) comprising arrays of hollow core fiber reinforced polymer panels with longitudinal edges, said edges having key extensions and
• (c) said assembly further comprising a first set of brackets of hollow core fiber reinforced plastic with keyways for attachment to said key extensions of said panels and said brackets also comprising extension arms extending into void space;
• (d) a stay-in-place structural steel grillage located within said void spaces and spaced from said panels and further comprising a second set of brackets integrally attached to said grillage and to brackets of said first set;
• and
• (e) the structural steel grillage is within the encasement assembly and spaced from said stay-in-place panelized encasement assembly.

A stay-in-place construction mold apparatus for forming, contiguous void spaces that define, horizontal foundation, vertical walls and horizontal roof deck slab elements of monolithically constructed structures in site on dry land or underwater comprising:

• a stay-in-place panelized encasement assembly comprising one in a plurality of pairs of spaced opposing encasing arrays of panels forming each of said contiguous foundation void spaces, cavity wall void spaces and roof deck void spaces for accepting, containing and shaping wet concrete fill cast into said void spaces to form contiguous foundation, wall and deck portions,
• a stay-in-place structural steel grillage located within said horizontal and vertical void spaces of said stay-in-place panelized encasement assembly in such spatial relation to said encasement assembly as to become embedded fully in concrete when concrete is poured into said encasement assembly, and
• first and second sets of connecting means for tying panel arrays of said stay-in-place panelized encasement assembly to said stay-in-place structural steel grillage, said first set of connecting means comprising keyways attached to key extensions of said panelized encasement assembly and being located between edges of adjacent panels in said panel arrays and also extending inward in said void spaces formed between said spaced opposing panels toward said structural steel grillage therewithin and said second set of connecting means being attached to said grillage and also connected to said first set of connecting means;
• said stay-in-place structural steel grillage and said stay-in-place panelized encasement assembly and said second set of connecting means being constructed and arranged to enable said stay-in-place grillage and said second set of connecting means to be within said void spaces to become-fully embedded in concrete fill during casting of concrete.

A stay-in-place construction mold apparatus for forming, contiguous void spaces that define, horizontal foundation, vertical walls and horizontal roof deck slab elements of monolithically constructed structures in situ on dry land or underwater comprising:

• a stay-in-place panelized encasement assembly comprising one in a plurality of pairs of spaced opposing encasing arrays of panels forming each of said contiguous foundation void spaces, cavity wall void spaces and roof deck void spaces for accepting, containing and shaping wet concrete fill cast into said void spaces to form contiguous foundation, wall and deck portions,
• a stay-in-place structural grillage made of material selected from the group consisting of metals and fiber-reinforced polymer and located within said horizontal and vertical void spaces of said stay-in-place panelized encasement assembly in such spatial relation to said encasement assembly as to become embedded fully in concrete when concrete is poured into said encasement assembly, and
• first and second sets of connecting means for tying panel arrays of said stay-in-place panelized encasement assembly to said stay-in-place structural steel grillage, said first set of connecting means comprising keyways attached to key extensions of said panelized encasement assembly and being located between edges of adjacent panels in said panel arrays and also extending inward in said void spaces formed between said spaced opposing panels toward said structural grillage therewithin and said second set of connecting means being made of material selected from the group consisting of metals and fiber reinforced polymer and attached to said grillage and also connected to said first set of connecting means;
• said stay-in-place structural steel grillage and said stay-in-place panelized encasement assembly and said second set of connecting means being constructed and arranged to enable said stay-in-place grillage and said second set of connecting means to be within said void spaces to become-fully embedded in concrete fill during casting of concrete.

A modular stay-in-place construction mold-apparatus for forming, casting and encasing horizontal concrete foundation, vertical walls and horizontal roof deck slab contiguous structural elements of monolithically constructed structures in situ on dry land or underwater comprising:

• a stay-in-place panelized encasement assembly comprising arrays of encasing panels, with adjacent longitudinal edges, forming a plurality of contiguous horizontal foundation, vertical wall and horizontal roof deck void spaces for accepting, containing and shaping wet concrete fill cast into said void spaces to form said contiguous horizontal foundation, vertical wall and roof deck elements and a horizontal deck array of panels to form the underside of the roof deck slab element, the panels being made of fiber reinforced polymer material,
• a stay-in-place structural grillage comprising structural materials selected from the group consisting of metals and fiber reinforced polymer and located within said void spaces of said stay-in-place panelized encasement assembly and spaced from said panels of said encasement assembly, the grillage having a horizontal foundation portion, multiple vertical wall portions and a horizontal roof deck portion, the foundation portion and roof deck portions being integrally joined to the wall portions,
• first and second sets of panel connector brackets for tying panels of said panelized encasement assembly and said structural steel grillage together so that the grillage supports said encasement assembly,
• said brackets of said first set of brackets being made of fiber reinforced polymer material and being attached to said panels at adjacent longitudinal edges thereof and each bracket having a base portion for connecting a longitudinal edge of each said panel to a next adjacent panel, also having extension arm portions extending from said base portions inward into said void spaces toward said structural grillage and wherein said second set of brackets are made of structural materials selected from the group consisting of metals and fiber reinforced polymer and are integrally attached to said structural grillage, and also attached to said first set of brackets,
• said stay-in-place structural steel grillage and said second set of brackets being constructed and arranged in said spatial relation to said encasement assembly to become fully embedded in concrete fill during casting of concrete into said encasement assembly, and
• wherein said panelized encasement assembly panels comprise keys at the longitudinal edges extending therefrom and brackets of said first set of brackets comprise keyways on one longitudinal edge of a base portion of a panel connector bracket configured to interlock and connect to a key formed along the corresponding longitudinal edge of a first stay-in-place encasement panel and a keyway configured on a second longitudinal edge of the said bracket configured to interlock with a key formed along the longitudinal edge of the base portion of a second stay-in-place encasement panel,
• and further comprising, U-shaped cap connectors with two parts of dual channel form with each channel part forming part having two parallel opposing legs with a first one of said channel form parts sized and configured to fit over exposed ends of vertically oriented panels of said encasement assembly, and a second of said channel form parts configured to connect the upper butt end of said vertically oriented encasement panel assembly to the butt end of a second horizontally oriented roof deck encasement panel assembly intersecting at 90° to the longitudinal axis of said vertical panel assembly, with a key on said second channel form part of said cap connector slidably interlocking and connecting to said panel connector bracket.