Patent ID: 9388561
Filing Date: 2016-07-12
CPC Classification: B28B,E02D,E04B,E04C

Claim Text:
1. 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 lands 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 when cast into said void spaces, to form the said contiguous horizontal foundation, vertical wall and roof deck slab elements and a horizontal deck array of panels to further define the underside of the roof deck slab element, the panels being made of fiber reinforced polymer material, a stay-in-place structural steel grillage located within all 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 of said first set of said bracket having a base portion for connecting a longitudinal edge of each such panel to a next adjacent panel, and also having extension arm portions extending from said base portions inward into said void spaces toward said structural steel grillage and wherein said second set of brackets are made of steel and are integrally attached to said structural steel grillage, and are 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 their 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 on a second longitudinal edge of the base portion of said bracket configured to interlock with a key formed along the longitudinal edge of a second stay-in-place encasement panel and further comprising, U-shaped cap connectors with two parts of channel form, with each channel form 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 interlocking and connecting to a panel connector bracket.