Modular concrete form panel

Abstract

A modular form panel for assembling a cast-in-place concrete structure includes an inner panel section and an outer panel section. A filling gap is defined between the inner and outer panel sections. The filling gap is configured to receive concrete poured on-site to form a concrete wall or roof section. One or more tie members span the filling gap interconnecting the inner and outer panel sections. The panel includes an integral side flange in some embodiments. When multiple panels are positioned adjacent one another, the adjacent side flanges form an end gap on each lateral side of the panel. The end gap has a thickness greater than the filling gap thickness. Concrete disposed in each end gap forms an integrated support column on each side of the panel. A bond beam gap is defined along the top edge of the panel having a greater thickness than the filling gap.

What is claimed is: 
     
         1 . A modular panel apparatus for forming a concrete structure, comprising:
 a first panel section;   a second panel section comprising foam;   a filling gap defined between the first and second panel sections;   one or more support ties spanning the filling gap between the first and second panel sections; and   a barrier layer disposed on the first panel section   
     
     
         2 . The apparatus of  claim 1 , further comprising the second panel section having an exterior side facing away from the filling gap, and a cover layer disposed on the exterior side. 
     
     
         3 . The apparatus of  claim 1 , further comprising one or more stud members disposed on the first panel section, wherein barrier layer is positioned between the one or more stud members and the filling gap. 
     
     
         4 . The apparatus of  claim 3 , wherein at least one of the support ties is secured to at least one of the stud members. 
     
     
         5 . The apparatus of  claim 4 , wherein at least one of the support ties extends at least partially through the second panel section. 
     
     
         6 . The apparatus of  claim 4 , further comprising an outer tie fastener disposed on the second panel section, the outer tie fastener engaging at least one of the support ties. 
     
     
         7 . The apparatus of  claim 4 , further comprising:
 the second panel section including an inner foam layer and an outer foam layer, the inner foam layer positioned between the outer foam layer and the filling gap; and   a side flange protruding laterally outwardly from the outer foam layer.   
     
     
         8 . The apparatus of  claim 7 , wherein the outer foam layer has a greater lateral width than the inner foam layer. 
     
     
         9 . The apparatus of  claim 2 , wherein the cover layer comprises at least one plastic sheet. 
     
     
         10 . A modular panel apparatus for forming a concrete structure, the concrete structure having a concrete wall and an integral concrete support column, the apparatus comprising:
 a first panel section;   a second panel section;   a filling gap defined between the first and second panel sections; and   a side flange protruding from the second panel section in a lateral direction, the side flange having a distal flange edge extending beyond the first panel section in the lateral direction,   wherein the side flange forms a boundary for the integral concrete support column.   
     
     
         11 . The apparatus of  claim 10 , wherein the second panel section comprises an inner foam layer and an outer foam layer, and the side flange is integrally formed on the outer foam layer. 
     
     
         12 . The apparatus of  claim 11 , wherein the side flange protrudes laterally beyond the inner panel layer. 
     
     
         13 . The apparatus of  claim 11 , further comprising a cover layer disposed on the outer foam layer. 
     
     
         14 . The apparatus of  claim 13 , wherein the cover layer comprises metal wire mesh or a plastic sheet. 
     
     
         15 . The apparatus of  claim 14 , further comprising one or more rigid support ties spanning the filling gap between the first panel section and the second panel section. 
     
     
         16 . The apparatus of  claim 10 , further comprising an end gap defined on at least one lateral edge of the panel apparatus, the end gap open to the filling gap such that concrete poured into one of the end gap and filling gap may flow into the other, wherein the end gap includes a greater thickness dimension than the filling gap. 
     
     
         17 . A modular concrete form panel apparatus, comprising:
 a first panel section;   a second panel section;   a filling gap defined between the first and second panel sections, the filling gap having a filling gap thickness;   one or more support ties spanning the filling gap between the first panel section and the second panel section, each support tie interconnecting the first panel section and second panel section;   one or more stud members disposed on the first panel section;   a barrier layer disposed on the first panel section between the one or more stud members and the filling gap;   a side flange protruding laterally outwardly from the second panel section;   a first top flange protruding upwardly from the first panel section; and   a second top flange protruding upwardly from the second panel section, the first and second top flanges defining a bond beam gap having a bond beam thickness therebetween,   wherein the bond beam thickness is greater than the filling gap thickness.   
     
     
         18 . The apparatus of  claim 17 , wherein the barrier layer comprises a vapor barrier material. 
     
     
         19 . The apparatus of  claim 17 , wherein each support tie extends at least partially through one of the stud members. 
     
     
         20 . The apparatus of  claim 17 , further comprising:
 an end gap defined adjacent the filling gap along a vertical edge of the panel apparatus, the end gap having an end gap thickness greater than the filling gap thickness,   wherein the side flange forms a partial boundary for an integrated support column.