CA1154278A - Dry stack form module - Google Patents

Abstract

ABSTRACT OF THE DISCLOSURE
A dry stack form module is disclosed for use in con-struction of a wall comprising a plurality of dry stacked modules which may be filled with concrete. In one aspect, the invention provides modules whereby adjacent an outer face of the module substantially throughout the perimeter of the outer face a seal is formed between neighbouring modules resistant to water penetration by the steps of dry stacking of modules and filling cavities in the modules with concrete. In a second aspect, a module is provided having a sandwich-like construction and comprising a block-like concrete portion, an insulative portion and a facing portion, whereby by the steps of dry stacking of a module a structural, insulated wall may be formed having one decorative and protective outer surface. The modules according to the present invention advantageously allow walls to be constructed by dry stacking at low cost using unskilled labour as compared to costs of conventional mortared brick and block walls.

Description

~S~2~7~3 BA,CKGROUND OF T~IE INVENTION
___ This invention relates to the construction of walls by the dry stacking of form modules to provide a modular concrete retaining form and, more particularly, to a dry stack form module for a wall comprising a modular retaining form consisting of a plurality of similar form modules wherein said modular retaining form is adapted to be filled with concrete.
In the past, conventional walls have included mortared brick or concrete block walls, constructed from a plurality of similar bricks or cement blocks wherein mortar joins ancl spaces neighbouring bricks or concrete blocks. The mortar bonds the bricks or blocks together thereby providing a seal resistant to water penetration~ The mortar also provides an adjustable medium whereby, in construction, the bricks or blocks may be leveled and orientated with respect to one another.
Mortared concrete brick and block walls have the disadvantage that they are time consuming and labour intensive to construct requiring the placement, levelling and adjustment of each block to be laid. Mortared brick and concrete block walls have the further disadvantage that the mortar bond is not of sufficient strength to provide the wall with the structural strength required for many applications.
Recently, mortared concrete block walls have been provided to have increased structural strength by utilizing a concrete block with a vertically extending cavity therethrough.
In construction, the block may be located in place with mortar followed by the cavity being filled with concrete. With the cavity of one block being in communication with the cavities of neighbouring blocks, the concrete increases the structural strength of the completed wall. Such a construction retains the disad-vantayes inherent in time consuming mortar construction.

`~ .

~L1S~2~3 1 Further, in proYiding the block w~th surraces adapted to receive the morta~r and provide satisf~ctory mor~ar le~eLling and bonding, the cross-sectional area o~ the block which can comprise the concrete receiving cavity is reduced, thereby reducing the ultimate strength of the wall. Another disadvantage is that as the mor-tar provides a seal between blocks, it is extremely difficult to eliminate the entrapment of air within the blocks when concrete is to be poured into a mortared wall comprising a plurality of vertically stacked mortared courses of blocks.
The construction of walls by the dry stacking of conventional concrete blocksl without mortar, and then filling cavities within the blocks with concrete has numerous disadvantages.
While the concrete in the cavities may provide structural strength to the wall, conventional concxete blocks which have been dry stacked and concrete filled provide no means which substitute for the moisture resistant junction therebetween typically pro-vided by mortar in mortared walls. Dry stacked walls have the disadvantage that abutting surfaces between neiyhbouring blocks which are exposed to climatic conditions have no means for pre-venting water seepage therethrough or collection therein and for minimizing destruction due to expansive forces of water freezing and thawing.
While horizontal foundations may be provided for a wall to be formed by dry stacking of concrete blocks, the levelling and alignment of blocks which are dry stacked depends upon the abuttment between neighbouring blocks. Conventional blocks suffer the disadvantage that they are not adapted for placement in accurate or stable abutting relation with neighbouring blocks, nor are they adapted to facilitate manufacture such that 3~ the blocks may be provided with precise dimensional relationships.
Conventional walls also include walls constructed by ~S~2~7~
1 pouring concrete into ~oncrete retaining forms typically con-sisting of spaced barriers, braced and supported to retain wet flowable concrete until setting or solIdi-fication, at which time the orms are removed pro~iding a solidified concrete wall.
The construction of such concrete walls from conventional retain-ing ~orms has the disadvantages of requiring means ~or raising and supporting the forms to retain the concrete as well as re-quiring the removal of the forms after solidification.
Recent advances in concrete wall construction have included the use of pre-fabricated concrete wall sections which are manufactured off the construction site, transported to the site,and are incorporated at the site into a given structure.
Pre-fabricated sections of walls have the disadvantages of re-quiring specialized engineering and construction planning to adapt the site for the pre-fabricated modules, requiring specialized transportation and handlingl and requiring skilled labour during erection of the pre-fabricated concrete wall sections.
Conventional methods of constructing walls has typically involved a first step of constructing a structural load bearing wall followed by finishing of the structural wall to provide, for example, insulative, protective and decorative qualities to the wall as desired. Typical mortared brick walls while having decorative and protective surfaces typically require at least the addition of insulation and a vapour barrier for many ap-plications. Concrete block walls and concrete walls constructed by use of concrete retaining forms suffer similar disadvantages and in addition typically do not have the asthetically pleasing decorative features of brick walls~ Pre-fabricated concrete wall sections have been provided to meet a variety of structural, insulative, protective and decorative requirements~ however, to increase the extent to which these requirements may be satisfied, ~154Z7B
1 the difficulties o~ eonstxucti~on~ transpor-t~tion and insulation of the pre-fabrieated eonerete wall seetions also inereases.
Accordingly, conven-tional buIlding components and conventional eonstruetion techniques have the disadvantage that they do not provide a component or a method for simplified eonstruetion of a wall with structural, insulative, protective and deeorative qualities as are frequently required in the eonstruction industry.
SUMMARY OF ~HE INVENTION

_ Accordingly, it is an object of the present invention to at least partially overeome these disadvantages by providiny a dry stack for~ module for use in construetion of a wall by the dry stacking of similar form modules to provide a modular concrete retaining form adapted to be filled with flowable eonerete.
A further objeet of the present applieatiorl is to pro-vide a method of eonstrueting a wall from a dry staek form module by the steps of dry staeking of similar form modules to produee a modular eoncrete retaining form and filling the form with a flowable eonerete material.
A further obieet of this invention is to provide a dry staek form module for a wall comprising a modular eonerete retaining form eonsisting of a plurality of modules wherein by filling of the form with eoncrete, a seal is formed between neighbouring modules proximate one surface of the wall which is resistant to water penetration.
A fur-ther object is to provide a module adapted to construct a eomplete structural wall which is insulated and has an interior decorative and proteetive surfaee merely by the dry staeking of similar modules and filling the modules with concrete.
A further object is to provide a form module for dry staeking whieh is adapted to faeilitate dimensionally accurate manufacture by press molding, easting, and grinding of 'he form modules.

27~

1 A further ob~ect is to provide a dry stack form module which is self leyelling and self aligning wt.th respect to neighbourin~ modules to be stacked ~nto a modular reta;ning form.
A further ob~ect is to pr~ide a dry stack form module for a wall comprising a modular concrete retaining form compri.sing a plurality of modules wherein upon filling the form with concrete only interfaces o~ narrow width are left between opposing sur~
faces of modules which are exposed to weathering conditions where-by the affects of weathering will not substantially affect the structural integrity of the wall~
A further object is to provide a dry stack foxm module for a wall comprising a modular concrete retaining form com-prising a plurality of modules wherein, by the filling of the form with concrete, spaces between opposing surfaces of modules into which water may otherwise collect and upon freezing subject the wall to destructive expansion forces are filled with concrete and thereby eliminated.
To this end, in a first of its aspects of the invention provides a dry stack form module ~or a wall comprising a plurality of dry stack courses of modules, each module having:
a) a vertically extending cavity therethrough adapted to.communicate with cavities of subjacent and superjacent modules;
b) an outer face with a perimeter bounded by perimeter surfaces comprising upper and lower surfaces and two end surfaces, one of the upper and lower surfaces and an end surace adjacent thereto being adapted to mate wi-th complementary pe:rimeter surfaces of adjacent, subjacent and superjacent modules to form a space therebetween adjacent the outer space substantially through a portion of the perimeter of the outer face bordered by said one of the upper and lower su~faces and the end surface adj~cent thereto; and c) commun~cating means for pro~idin~ ~low o:E flowable cementitious binding m~terial from the cavity to the space whereby the binding material to be introduced into the cavity ma~ flow from the communicating means through the space to proximate the outer surface substantially througho~t the portion of the perimeter of the outer face to provide, on solidification of the binding material, a seal between modules proximate the outer face;
the space having a distance between complementary perimeter surfaces: sufficiently small at least proximate the outer face to restrict flow of the flowable cementitious binding material therethrough.
In a second of its aspects the invention provides a dry stack form module for the construction of a structural, insulated wall by the steps of dry stacking of courses of similar adjacent modules longitudinally off-set with respect to subjacent and superjacent modules and insertion of flowable concrete into cavities vertically extending through the modules, each module comprising:
a) a vertically extending cavity therethrough adapted to communicate with cavities of subjacent and superjacent modules;
b) a pair of spaced parallel wall portions coupled together with the cavity therebetween, each wall portion having upper and lower surfaces and end surfaces adapted to mate with complementary surfaces on adjacent, subjacent and superjacent modules with distances therebetween sufficiently small to restrict flow of concrete inserted into the cavity therehetween;
c) an insulative portion coupled to the module with a first of the wall portions intermediate the cavity and the in-sulative portion, having insulative upper and lower surfaces 1~5~27B

1 and insulative end surfaces ad~pted to mate with complementary surfaces of insu~atiYe po~tions on ad~acent, sub~acent and super-jacent modules~ in a~utt~ng relation throughout;
d) a facing portion coupled to t~e module with the insulative portion intermediate the first wall portion and the facing portion, the facing portion pro~iding a decorative and protective outer surface of the wall; and e) alignment means provided on each module for alignment thereof with respect to subjacent and superjacent modules by mating engagement with complementary alignment means thereon.
In dry stack construction of walls according to the present invention, modules are preferabl~ to be used which have abutting surfaces which canwith precision locate and orient the modules with respect to one another~
In dry stack construction according tothe present invention, a first course o modules may be ~aid and secured to provide, for example, a straight horizontal first course of modules. Subsequent modules may then be dry stacked onto the modules of the first course to build successive courses. The modules may preferably be offset with respect to subjacent modules although offsetting may not be required. Dry stacking necessarily means stacking of the modules without providing typical adjustable locating means such as mortar between the modules. Accordingly, the modules may be vertically stacked with a portion o~ the upper and lower surfaces in abuttment.
Preferably end surfaces of the modules will be in abuttment al-though other means may be provided to locate complementary end surfaces of adjacent modules in suitable juxtaposition. Preferably, means are provided to align the modules with respec-t to neighbouring modules.

27~1 1 In ordex that successlYe courses o~ modules may accurately repe~t a straight and horizontal orientation of the first course, the abutting surfaces of the modules are pre-ferably precisely located on each module requiring ~or example that each module have a precise he;ght dimens~on between abutting upper and lower surfaces. S;milarly, the abutting surfaces are preferably orientated in a plane to be accurately horizontal or vertical.
Known techniques for a manufacture of rectangular brick or block-like modules from conventional concrete or clay aggregate materials include pressing of aggregate into molds or molding of modules in forms whereby two or three precisely formed mutually ad~acent surEaces may be provided. Grinding techniques are known for grinding of such conventional brick and block surfaces however grinding is typica~ly expensive. The present invention provides dry stack modules which may be manu-factured, for example, using known molding techniques to provide a precisely formed bottom surface and a precisely formed first end surace and at the same time providing an upper surface and sometimes a second end surface which is adapted to facilitate economical grinding into precise~y formed abutting surfaces. The present invention provides for dry stack modules with abutting surfaces which preferably are of narrow width to thereby facilitate and reduce the cost of grinding. Another method of providing accurate surfaces according to the present invention is to pro-vide raised portions of small cross-sectional area which abut with portions of complementary surfaces, Such raised portions may easily be ground to have precisely located and orientated abutting surfaces. Optionally the raised portions may be made of easily machinable or easily formable material such as plastic, to be affixed to a surface of the module.

2'7~

1 In many wall~ to be ~ormed by dry stacking o~ modules it may be advantageous to provide the wall with an exterior sùr-face which is res~stant to water penetrat~on and which does not have cracks or spaces between modules into which water can collect and on freezing or thawing subject the wall to destructive expansive forces. According to a first aspect of the present invention a module is provided whereby a seal which is resistant to water penetration may be formed between modules which seal is preferably located suf~iciently close to an outer face oE the module so that there do not exist locations between neighbouring modules outbound of the seal where water may collect, freeze, and subject the wall to forces due to water expansion.
As is known to persons skilled in the art r conventional bricks and concrete blocks are not, strictly speaking, water impermeable but typically to at least some extent breathe and may absorb water. While the seal to be formed according to the present invention between modules may be water impermeable, the seal may only be resistant to water penetration to a similar extent to which conventional brick and concrete block and conven~
tional mortar and concrete may be appreciated to be resistant to water penet~ation.
In a first aspect, the present invention provides a dry stack form modules whereby adjacent an outer face of the module substantially around a perimeter of the outer Eace, a seal which is resistant to water penetration may be formed bet-ween neighbouring modules. This is advantageously accomplished by providing the module with perimeter surfaces adjacent the outer surface of the module which are adapted, when the module is located in abutting engagement with neighbouring modules, to provide a space between the modules substantially around the entire perimeter of the module and preferably adjacent the outer ~S~27~

1 face through substantially the entire perimeter. Vertically extendin~
cavities or passageways may be provided in each module to com-municate with cavities of subjacent and superjacent modules and with means to communicate flowable cementitlous binding material from each cavity to the space extending around the entire perimeter of the module. The space is provided to have a distance hetween complementary perimeter surfaces of neighbouring modules such that flow of the binding material through the space is restricted at least proximate an outer face of one of the modules. Thus, the binding material to be introduced into the cavity of one module may flow to neighbouring modules, fill the spaces between modules, and ~ill the cavities, being retained within the spaces due to the restriction of flow through the space proximate an outer face of one of the modules.
Dry stack modules according to the present invention may be adapted to provide a wall resistant to water penetration having an inner cavity which is adapted only to provide for the flow therethrough of small amounts of binding materials such as mortar as may be required after dry stacking of the ma-terials to ~O merely ~ill the spaces surrounding the perimeter of the outer face and provide for a seal. Preferably, the cavity may be of sufficient size to receive binding materials such as concrete and to provide substantial strength to the wall.
The present invention in the second aspect provides a dry stack form module with which, by the dry stacking of modules, a structural, insulated wall may be formed preferably with a protective and decorative inner surface. In this aspect the modules may comprise a sandwich-like construction including a building block-like portion and an insulative portion as well as, preferably, a facing portion to form oresurface of the wall.
Optionally another decorative and protective face plate may ~5~
1 be provided to form the other surface of the wall. Further, means may be provided in each module so as to provide a vapour barrier through a wall made from the modules. The modules have suitable abutting surfaces for dry stacking and preferably have means for alignment.
The combined use of typical building block materials such as concrete with insulative ma-terials such as high density urethene foam in dry stack modules provides advantages which are not available,to dry stack modules produced from merely concrete.
Insulative materials may be chosen which are easily molded and formed into dimensionally accurate shapes facilitating the use of insulative materials in providing at least part o the abuttin~3 surfaces between stack`modules and in providing alignment means.
The' accurate attachment of insulative materials to portions of modules made from conventional building materials such as concrete can reduce manufacturing costs in construction of the modules. Insulative materials may be selected which are slightly compressive soas to provide definite sealing engagement between neighbouring insulative sections, ~o Modules according to the second aspect of the present invention comprising a sandwich-like construction including an insulative layer may preferably have a vertically extending cavity therethrough to receive flowable cement and thereby pro-vides support to the wall. Such modules may also utilize the first aspect of the present invention whereby an outer surface may be formed to be resistant to water penetration by the in-sertion of concrete into the modulesO -The pxesent invention also provides methods of con-struction of walls using dry stack modules of forms according to the present inven~ion, preferably by the laying of a first course of modules, dry stacking additicnal courses of modules ~1S~27~
1 thereon to build a concrete retaining form and filling the form, as required, with flowable cementitious binding material.
While the present application is preferably applicable to brick-like modules having a generally rectangular form, the invention is not so limited and is equally applicable to modules having any form whereby complementary surfaces are formed with respect to neighbouring modules.
The dry stack form modules and method of construction of walls usin~ dry stack form modules according to the present invention provides for modules which may be entirely prefabricated at a plant location and easily transported to a construction site as is the manner with known bricks and cement blocks. The modules according to the present invention may easily be stacked to form a retaining form by unskilled labour in a minimum of time.
~ere required, such a retaining form may be filled with concrete thereby forming a structural wall at substantially reduced cost.
Another aspect of the present invention is based on the applicant's recognition that many conven-tional bricks and concrete blocks are not, strictly speaking, water impermeable but that the bricks and blocks are typically to a greater or lesser extent porous and absorb water at least to some small extent. The ap-plicant has appreciated that due to the ability of water to pass through the bricks and blocks, water may collect in cracks and spaces between modules within the interior oi a wall constructed from dry stacked modules. Where such water may collect, on fre-ezing the wall may be subjected to destructive expansive ~orces.
In another aspect the present invention at least partially over-comes the problem of water collection between dry stacked modules by providing modules wherein surfaces of the module which abut ~s~z~
1 with surfaces o-E neighbouring modules r abut therewi~h over areas which are preferably as small as possible. Accordiny to this aspect, surfaces and, particularly, load bearing upper and lower surfaces of dry stack modules~ which abut with surfaces o neigh-bouring modules, are adapted to have abutting interfaces there-between which are of small area, preferably being narrow elongate interfaces. Minimizing the area of the abutting interfaces between modules minimizes the area upon which the expansive forces due to freezing of water can act and, in addition, can aid ~ the flow of concrete introduced into cavities in the modules,to more completely fill between modules,reducing locations in which water may collect.
BRIEF DESCRIPTION ~F THE DRA~INGS
Further objects and advantages of the invention will appear from the following description taken together with the accompanying drawings in which:
Figure 1 is a pictorial bottom view of an embodiment of an insulated form module according to the invention.
Figure 2 i9 a pictorial top view of the insulated form module shown in Figure 1~
Figure 3 is a bottom view of the insulated form module shown in Figure 1.
Fi~ures 4 and 4A are top views o the insulated form modules shown in Figure 1.
Figure 5 is an end view of three substantially identical insulated form modules similar to the module shown in Figure 1 wherein the three form modules are shown dry stacked one upon the other.

Figures 6 and 7 are a cross-sectional end view of two identical insulated form modules similar to the module shown in Figure 1 taken along a cross-section shown as line 2-2' in in Figure 8, with concrete between the two modules.

3L~S~7~3 1 Figure 8 is a top view of an end of a course of in-sula-ted form modules comprising two modules similar to the form module of claim 1 in line with a half-sized form module. Figure 8 shows vertical and horizon-tal reinforcing rods in conjunction with the Eorm modules and schematically shows the ~low paths which concrete poured into the module may take as well as a portion of one of the modules filled with concrete.
Figures 9 to 13 show an end view of the plurality of insulated Eorm modules similar to the form modules shown in Figure 1 dry stacked one upon the other and with diferent modules in the stack varying in minor respec-ts with respect to one another so as to illustrate in a schematic manner different aspects of the invention nf the present application.
~ ure 14 is a top view showing a portion of a course of modules including two corners and comprising modules similar to the module shown in Figure 1 in conjunction with right and left turning modules.
Figure 15 shows a pictorial view oE two identical in-sulated form modules according to another embodiment of the pre-sent invention located in schematic opposing relation.
Fi~ure 16 is an end view of two identical insulatedform modules similar in only some respects to khe orm module shown in Figure 1.
Figure 17 is a top view of an insulated form module showin~ an another embodiment of the invention.
Fiyure 18 is a top view of an insulated form module according to the invention adapted for use at the end of a course of modules sim:ilar to the modules shown in Figure 1.
Figure 1~ is a top view of an insulated form module

3~ accordin~ to the present invention to be used to support joists or beams in a wall.

1Figure 20 is a schematic pictorial view of the wall constructed from form modules in accordance with the present invention and including bracing and positioning posts for use in construction of the wall.
Figure 21 is a pictorial view of a non-in~ulated form module according to the present invention.
Figures 22 to 26 show an end view of a plurality of non-insulated form modules according to the present invention stacked one upon the other and differing from each other and from the form module shown in Figure 21 so as to,in simplified form, shows different aspects of the presen-t invention.
Figures 27A to 27C show a dry stack form module accordin~
to the present invention with FicJure 27A comprising a pictorial view of three identical modules, Figure 27B showing an end section through line B-B' of Figure 27A and Figure 27C showing a top section through line C-C' of Figure 27A.
Figures 28A to 28D show three identical dry stack form modules according to the present invention with Figure 28A
showing a pictorial view of the modules, Figure 28B showing an end section through line B-B' of Figure 28A and Figure 28C showing a top section through line C-C' of Figure 28A. Figure 28D
shows an exploded view of area D circled in Figure 28A with an alternative recessed portion thereon.
Figures 29A to D show three identical dry stack form modules according to the present invention with Figure 29A
showing a pictorial view, Figure 29B showing an end section through line B-B' of Figure 29A, Figure 29C showing a top section through line C-C' of Figure 29A and Figure 23D showing a front view of Figure 29A~
30Figures 30A to C show three identical form modules according to the present invention with Figure 30A showing a -14a- }

1 pictorial view of the modules, Figure 30B showing an end section through line B-B' of Figure 30A and Figure 30C showing a top section through line C-C' of Figure 30A.
Figure 31 is a schematic front view of a portion of a wall formed from dry stack form modules according to the present invention, shown with a template used to assist external mortaring of junctures between modules.
Referring first to Figure 27, Figures 27A to 27C show three identical dry stack form modules 701, 702 and 703 embodying a first aspect of the invention of the present application.
Figure 27~ shows a portion of a concrete retaining form which comprises stacked aourses of similar modules. Module 701 is an adjacent module to module 702. Module 703 is a superjacent module to module 702, while module 702 is a subjacent module to module 703.
As shown, the modules are stacked to be loca-ted with respect to one another by abutting engagement over portions thereof. Each module has a cavity 704 vertically ex-tending there-through to communicate with cavities 704 of subjacent and super-; 20 jacent modules as shown in Figure 27A.
As seen in Figure 27A, each modùle has an outer face 7~6 shown to have a rectangular perimeter bounded by perimeter surfaces comprising upper surface 710~ first end surface 712, lower surface 714 and second end surface 716.
With the modules located with respect to one another to make up the retaining form, the perimeter surEaces of each module are separated from complementary perimeter surfaces of subjacent, superjacent and adjacent modules to form a space 718 between complementa~y surfaces adjacent each outer face 706 throughout the entire perimeter of the outer face 706, As may be seen in Figure 27B, the upper surface 710 of module 702 and ~5~7~3 1 complementary lower surface 714 o~ module 703 are located in spaced relationship throughout the surfaces defining space 718 along the entire length of the modules, ~s seen in F~gure 27C, the first end sur~ace 712 of module 701 and complementary second end surface 716 of module 703 are located in spacedrelation throughout the surfaces defining space 71~ along the entire length o$ the module. As is apparent from the drawings, for a module surrounded by adjacent, subjacent and superjacent modules, space 718 will extend around the entire perimeter of outer ace 706 with the portion of the space defined between complementary upper surfaces 710 and lower surfaces 714 communicatin~ with the portion of the space defined between complementary first end surface 712 and second end surfaces 716. Opening 720 is pro-vided through module between space 718 and cavity 704 whereby a flowable cementitious binding material such as concrete which is introduced into cavity 704 may flow from the cavity 704 through opening 720 to the portion of space 718 near opening 720 and then through space 718 to entirely fill space 718.
Space 718 may be seen to be formed between complemenkary ~0 perimeter surfaces adjacent outer face 706 due -to outer face 706 having a length Ll and a height Hl which are smaller by distances L2 and ~2 than the effective length L3 and height H3 o each module when located in abutting stack arrangement in the retaining form. That is, distances L2 and ~I2 represent the width of the spa~e adjacent outer face 706 and its perimeter.
Distances L2 and EI2 are to be selected having regard to the nature of the flowable concrete to be introduced into cavity 704 whereby the distances are sufficiently small so as to restrict flow of concrete between complementary perimeter surfaces thereby sub-stantially retaining the concrete within space 718 such that aseal resistant to water penetration may be formed upon solidifica-tion of the concrete between complementary perimeter surfaces 1 throughout the perimeter o~ outer face 7060 It is contemplated that some concrete may.flo~ out of ~pace 718 and down the outer face 706, -16a-~L~S~7~

1 however, provided the flow out of space 718 is not so excessi~e that space 718 is not entIxel~ ~illed with concrete, the flow out of space 718 may not be unexceptable, Prefera~ly, the flow of concrete out of space 718 is minimized so as to allow its removal by simple wiping away o~ excess concrete as is necessary.
As shown, upper surface 710 and end surEace 712 are sloped inwardly away from the perimeter of outer space 706 so as to provide space 718 with greater distances ~etween complemen-tary surfaces inward from the perimeter of outer face 706 where-by flow of concrete through space 718 to completely fill the space is aided.
Opening 720 aids the filling of cavity 704 with concre~e,involving the flow of concrete from cavity 704 of one module to cavities of superjacent and subjacent modules,by al-lowing the escape-of air from each cavity 704.
The form module shown in Figure 27 allows for the construction of a wall by the dry stacking of form modules as shown in Figure 27A to form a concrete retaining form of re-~ quired height. Concrete is then introduced into cavity 704of the upper course of modules~ flows successively through the communicating cavities of the courses of modules and out openings 720 to fill spaces 718. In this manner, a wall with an outer surface which is resistant to water penetration may be formed merely by dry stacking modules and pouring of flowable con-crete into the cavities thereof.
Referring next to Figure 28, Figures 28A to 28C show three identical modules 801, 802, 803 embodying another form of the first aspect of the present invention whereby a wall having water resistant inner and outer surfaces may be formed merely by dry stacking modules and pouring of flowable concrete ~5~
1 into cavities 804 thereofO
As seen in Figure 28A, each module has a pair o~ parallel wall portions 805 spaced by br~d~i~ng member 826 to form cavities 804 therebetween. Each wall portion 80~ has an outer face 806 having a rectangular perimeter bounded by perimeter surfaces comprising upper surface 810, first end surface 812, lower sur--face 814 and second end surEace 816~ The upper surface 810 and first end surfaces 812 are provided with raised portions 822.
In dry stacking of the modules, raised portions 822 on each module abut correspond;ng perimeter surfaces of adjacent, subjacent and superjacent modules whereby complementary surfaces are located in opposing, mating relation with spaces 818 there-between as b~st shown in cross-sectional Fiyures 28B and C. As may be seen,spaces 818 are adjacent both outer faces 806 sub-stantially through the perimeter of each outer face. Spaces 818 are not formed in this embodiment between complementary perimeter surfaces wherein the raised portion 822 are shown. Reducing the cross-sectional area of raised portions 822 advantageously increases the extent to which space 818 completely surrounds ~ outer face 806.
Spaces 818 are open to cavity 804 as well as to each outer face 806 and concrete inserted into cavity 804 may flow from the cavity to fill space 818. Having regard to the nature of the concrete to be introduced into a retaining form comprising a plurality of stacked modules, the hei~ht of raised portions 322 and thereEore distances Dl and D2 between complementary perimeter surfaces may be selected so that flow of concrete there-between through space 818 is restricted,effectively retaining concrete introduced into cavity 804 so as to fill space 818 to form a seal between complementary surfaces proximate the outer face substanti~lly throughout the perimeter of the outer ~5~2~
1 face and to allow~ cayity 8Q4 to become filled with concrete.
In choosing the dis-tance between complementa~y perimeter surfaces so as to restrict concrete flow through the space 818, the thick-ness T of wall portion 805 may be kept in mind so that, advan-tageously, the concrete flows throuyh space 818 to proximate outer face ~06 thereby minimizing portions of space 818 adjacent outer face 806 which may not be completely filled with concrete.
The modules shown in Figure 28 are advantageous in that the perimeter surfaces are of narrow width and facilitate accurate manufacture of the module as, for example, by grinding of the perimeter surfaces to within small tolerances as is re~uired for advantageous dry stack modules.
Figure 28D shows an exploded view of a wall portion 805 of module 801 of Figure 28A showing upper surface 810 and outer face 806. Raised portion 828 shown in Figure 28 is provided as a substitute for raised portion 822 of Figure 2BA.
Raised poxtion 828 is provided inwardly recessed from the perimeter of outer face 806 whereby a space may be formed outbound of raised portion 828 adjacent outer Eace 806 between upper surface 810 and a complementary lower surface of a super~acent module.
Raised portion 8?8 is also provided to taper toward the perimeter of outer ace 806 whereby flow of concrete to fill the space to be formed outbound of raised portion 828 is facilitated as.
shown for example by the arrows in Figure 28D.
Referring now to Figure 29, Figures 29A to D show three identlcal modules 951, 952 and 953 whereby a wall having an outer surface which is resistant to water penetration may be formed merely by dry stacking modules and pouring of flowable concrete into cavities 954, As seen, each module h.as an exterior wall portion 956 spaced from interior wall portion 958 by bridging members 960 to form cavitles 954 therebetween. Ext:erior wall 7~
1 portion 956 has an outer face comprising surfaces 962, 964 and 966 and a rectangular perime.ter bounded by perimeter surf~ces com-prising upper sur~ace ~68, ~irst end surface 970, lower surface 972 and second end sur~ace ~74, ExterioE upper surface 968 and exterior first end surface 970 are provided wlth raised portions 976. Interior wall port~on 958 ~as upper surface 978, first end surface 980, lower surface 982 and second end surface 984.
In dry stacking of the modules, complementary perimeter surfaces of the interior wall portions of adjacent, subjacent and superjacent modules mate in abutting relation throughout while raised portions 976 on perimeter surEaces of ex-terior wall por-tions 956 abut with complementary peri.meter surfaces forming space 986 therebetween. As may be seen, space 986 is adjacent the outer face at a portion of the perimeter thereof along exterior upper surface 968 and first end surface 970. With the distances bet-ween complementary perimeter surfaces sufficiently small to restrict flow of concrete therethrough, concrete introduced into cavity 954 will flow into space 986 to form a seal between modules throughout the perimeter of the outer face and adjacent the outer ~ face alon~ its~ bQundarx wi~th uppeX s.ur~ace 968 and f~ s~ e~d surface 970..
The embodiment of Figure 29 may be contrasted with the embodiment of Figure 27. In the embodiment of Figure 29 the seal is formed between modules adjacent the outer face along two sides of the perimeter of the outer face whereas in Figure 27 the seal is adjacent the outer face along all four sides of the perimeter.
In providing outer surfaces in a wall which are resistant to water penetration according to the first aspect of the present 3~ invention, the sea~ between modules is preferably formed at a location near the exterior surface oE the wall whereby outbound 1 of the seal there do not exist portions ~e-tween modules wherein water may collect, freeze and su~ject the wall to forces due to water expansion.
Referrin~ now to Figure 30, Figures 30A to C show three identical dry stack form modules 901, 902 and 903 embodying a second aspect of the invention.
Each module comprises a block por-tion 907, an insulative portion 90q and a facing portion 911. The block portion com-prises parallel wall portions 905 spaced by bridging me~ers 926 to provide inner cavities 904 therebetween, Each wall portion 905 has upper surface 910, first end surface 912, lower surface 914 and second end surface 916 adapted to mate, when the modules are stacked as shown in Figure 29, with complemen-tary surfaces of adjacent, subjacent and superjacent modules~ Flowable concrete to be introduced into cavities 904 i.s retained between wall portions 905 due to complementary surfaces, having distances therebetween, throughout the surfaces, sufficiently small to restrict concrete flow therebetween. For example, complementary surfaces may abut or be spaced one from the other a small distance.
~0 Upon solidification, the concrete which has filled cavity 904 bonds the modules together giving the wall structural strength.
Insulative portion 90~ and facing portion 911 are coupled to the building block gO7, as for example, by suitable adhesives or known mechanical attachment means.
Insulative portion 909 serves to insulate the wall formed by the modules reducing thermal transfer therethrough and may be made from known, substantially shape retaining, in-sulative materials. Insulative portion 909 has an insulative upper surface 930, insulative first end surface 932, insulative lower surface 934 and insulative end surface 936 which abut with complementary insulative surfaces to provide a continuous 1 insulative laye~ along the wall~ In~ulatiYe po~tion 909 has a longitudinally extendin~ key 938 ~n ~ts upper surface ~30 and a complementary key-way 940 in i:ts lower s.urface which are adapted to align each module with respect to subjacent and superjacent modules.
Facing portion 911 provides a protective and decorative cover to the insulative portion 909 thereby forming substantially and interior surface 942 of the wall. Facing por~ion 911 is shown to have edges bevelled at 944 which may be advantageous in ~ assembly ~hen acing portions 911 a~e not intended to be load bearing l~embers~
The form modules shown in Figure 30 allow for the construction of a structural, insulated wall including a pro-tective and decorative interior surface m~rely by the steps of dry stacking courses of modules and introducing cemen-t into cavities 904 of the modules which may then ~low into and fill the other cavities of the remaining modules, Where a module as shown in Figures 27 or 29 may be substituted for building block 907 of Figure 30, the resultant wall may without additional steps ~ be formed with an exterior surface which is resistant to water penetration, Alternately, if an exterior wall is required which is resistant to water penetration when using the module as shown in Figure 30 with building block 907, the junctures between modules may be sealed by known means,as for example, by parging or caulking in an additional step.
Further illustrative embodiments of the insulative form module of the invention will now be described with reference to Figures 1 to 27. Like reference numerals will refer to like elements throughout the following description.
. ~ 30 The insulated form.module 10 shown in Figure 1 is .. generally a box shaped module which may in a particular 1 embodiment haYe a length dimension "L" on the order of 12 inches, a height dimension "H." on the orde~ of 3 inches ! and a depth or thickness dimension "~" on the order of 12 inches while it may be appreciated the invention may range outside these dimensional limits. Different sizes may be more useful and practical than the dimensioned preferred embodiment adapted for use with con-crete as the preferred material of construction. While many alternate materials of construction wil~ occur to persons skilled in the art incorporating combinations.of materials particularly lightweight materials and insulation materials such as light expanded clay aggregate, hollow plastic beads, polyurethene and polystyrene beads and pozzoliths, shale, slag, vermiculite, hay-dite, wood chips and fiber glass, ma~ be used.
The insulated form module 10, includes a top surface 12 including surfaces 24 and 55, (Figures 2, 4 and 5); a bottom surface 14, (Figures 1, 3, and 5); :Eirst end surface 16 including surfaces 25 and 52 (Figures 1, 4 and 5); and second end surface - 18 including surfaces 31 and 54 (Figure ~).
An exterior wall portion or plate 23 ~Figures 2, 4A and 5) forms exterior wall outerface 22 (Figures 1, 4 and 5), exterior opening surface 17 (Figures 1 and 4) and exterior top surface 24 (Figures 2, 4A and 5). The exterior waIl plate 23 further forms a horizontal exterior chamfer 72 (Figures 1, 4A
and 5) adjacent top surface 24. The exterior wall plate further forms vertical exterior chamfers.70 and 74 (Figures 1 and 4A) adjacent exterior end surfaces 25 and 31 (Figures 1 and ~A).
This causes a patterned shadow ef~ect on the exterior surface which imitates a brick and mortar appearance as shown schematically at 700 in Figure 31. The exterior wall plate 23 as well forms a horizontal exterior opening chamfer 67 ~Figure 4A) adjacent exterior top surface 24 and vertical exterior opening chamfers 1~427B

1 68 and 6~ ~Figure 4A) adj~cent exterior end sur-~aces 25 and 31 respectively.
An inter~or wall plate 5Q (Fi~ures 2, 4A and 5) forms interior insulation surface 11 r (F~gures 1, 4 and 5~ interior opening surface 19 (,Figures 2 and 4~, interior top surface 55 (Figures 2, 4B and 5) and inter:~or top surface central recession 58 (Figures 2 and 4B). Said 1nterior wall plate 50 further forms hoxizontal interior opening chamfer 71 (Figures 2 and 4A) adjacent interior top surface 55 and interior top surface central 1~ recession 58. The interior wall plate 50 as well forms vertical interior opening chamfers 73 and 75 (Figures 2 and 4A) adjacent interior end surfaces 52 and 54 (Figures 2 and 4A) All of the horizontal and vertical openi.ng chamfers allow concrete to pass quickly into the gaps to be formed between complementary opposing surfaces of subjacent, superjacent and adjacent modules after concrete has been introduced into the vertical cavities or openings and communicating horizontal openin~s described hereinafter. A further advantage o the multiple chamfers is to cause each from module to be of a robust nature 2~ whereby chipping is less likely to occur during handling.
Optionally the horizontal interior opening chamfer 71 may replace the interior opening surface 19 by extending all the way to the bottom surface 14 (not shown). As well, the hori~ontal exterior opening chamEer could optionally replace the exterior opening surface 17 by extending to the bottom surface 14 (no-t shown). Further variable exterior and interior opening surface configuratlo~.may be incorporated to allow quick, easy and complete filling of the internal openin~s of the wall form.
The in~erior opening surface 19 and exterior opening surface 17 are preferably subs-~antially flat surfaced as shown ~5~278 1 in tFi~ures 2 and 4) The extexior wall surface 22 is preferably ~orn~ed to have a rust~c appearance and may be~ etched or texturized as shown at 13 (Fi~ure 61 and 701 ~Fi~ure 27~, ~ny of the interior and exterior opening surfaces and any of the exterior or insulation surfaces ~.22 and 11, respectively~ may be flat, coarse,et~hed, coated, grooved, texturi~ed, coloured, or patterned.
Further, they may be adapted to rece;ve attachments as various manufacturing and construction needs re~uire. A ew examples follow:
a) The interior insulation surEace 11 may optionally have numerous interior vertical grooves 56 (Figure 4) to aid in grinding to size of the surface 11 adhesive bondingOf the insulation section, and as vapour vents in the inner module;
b) Etched or grooved interior and exterior opening surfaces may be provided for a superior concrete bond to the orm module especially where the form module is made of clay or o~her similar materials; and c) A flat or patterned exterior wall surface may be desirable to provide a commercial austere look or for purposes ~ of aiding the applying and adhesion of stucco.
Adjoining and perpendicular to the exterior wall plate 23 and the interior wall plate 50 are the first and second recessed bridging members or.partitions 60 and 62 ~Figures 2 and 4A), creating central vertical cavity or opening 30, first vertical cavity or opening 32, second vertical cavity or opening 34.
tFigures 1, 2 and 4), and a horizontal opening 100 (Figure 5), The vertical openings 30, 32 and 34 are adapted to align with vertical openings of other form modules when multiple orm modules are assembled in a designed 50% overlapping manner whereby vertical openings in underlying and overlapping Eorm modules will.define an internal series of vertical paths throughout the height of the 27~

1 wall form. The in~ention may ~urther define alternate ~ertical path patterns when alternate recessed partition arrangements are used or when the form modules are stacked in different wall patterns. In alternate partition arrangements, one or more partitions may be employed adjoining the exterior and interior wall plate to decrease or increase the resultant vertical openings per form module thus changing the internal series of vertical paths. Decreasing the number of vertical openings makes filling easier when pouring concrete due to less interference from the 1~ partitions. Increasing the number of vertical openings allows the form module to be more robust as is needed when the form module is made of fragile or weaker materials such as clay or slag.
In the preferred dimensioned embodimen-ts the partitions 60 and 62 are recessed 1 to l l/2 inches next to the location of the exterior opening surface 17 and are recessed l l/2 inches next.to the location of the interior opening surface 19 which forms the base of horizontal opening lO0 ~Figure 5).
The horizontal opening lO0 ensures that concrete easily flows around anchor member 95 ~Figures 2, ~A and 5) described hereinafter and covers the top surface of the recessed partitions 60 and 62 once the concrete has been poured into vertical openings 30, 32 and 3~. The horizontal opening lO0 and vertical openin~s 30, 32 and 34 communicating therewith ensure complete filling of all the vacant internal vertical and horizontal openings within the wall form~ The extent of the recession of the partitions and the area of contac-t between the partitions and the interior and exterior wall plates may be selected to provide a sufficiently strong module to withstand handling. An increased recession of the recessed partition may be provided where improved concrete flow through the said horizontal opening is required as for example when larger size aggregate in contained in the concrete, where -~6-2~78 1 vibrators are not ~vailable to ass,ist filling, or when horizontal filling is re~uired to be carried out such as hy pumping concrete through submerged horizon-tal nozzles 331 (,Figure 7) described hereinaEter.
The recess of the partition is preEerable. In an alter-nate embodiment the partitions 60 and 62 are not recessed but level with the top surface 12 of the form module (not shown), as for instance to prevent concrete or other bonding material from flowing horizontally between adjacent vertical openings. This ma~
tO be ad~antageous in the creating of vertical separations,control joints, air vents, or vert~cal u~ility canals in the con-, structed wall form. In some embodiments the partition may option-ally be recessed to a negligible horizontal opening as in the case where a fluid bonding material is desired to be used in place o~ regular concrete.
The partition may be made of materials such as plastic, Fiberglas* wire, carbon rod, and metal plate or combinations thereof as substitute materials for concrete. These optional materials may increase the flexibility or the desired strength of the partition as required. The partition serves to position the exterior and interior wall plates.- This enables poured con-crete to surround and hold these plates in the wall accurately.
The partition further makes possible a firm, consistant and proper concrete imbedment of these plates thus increasing the wall integrity and uniformity. A major purpose of the partition is therefore to serve an analagous purpose to tie connector members used in known concrete forming methods.
Concre-te is chosen as the preferred material of con-struction of the partition mainly because the complete form module can be made more efficiently and economically with existing concrete block machinery. As is to be appreciatea by persons skilled in '`,, *~rade Mark -27-~L~5~Z~
1 the art the enti,re ~dule may be made -~rom other materials including fox example ar,y bonded insulation mate~ial such as hollow plastic beads mi,xed wi-th silica sa,nd and cement co~ered with a protecti~e surface coating suc~ as epoxy, Fiberglas* or carbon fiber blends, thoroughly mixed with bonding material.
In a resultant wall made of the completed form module assembly and poured concrete (which has hardened) the form module itself then functions as a protective and possibly decorative facing connected and anchored to the inside of the form via the submerged recessed partition anchored to the interior wall plate.

The recessed partition allows the optional placement of horizontal reinforcing rod 311 (E~igures 6 and 7) into the said horizontal opening durin~ assembly o~ the form modules to be installed as desired. ~hen a wall form or portion of a wall has been as~
sembled from self aligning insulated form modules 10 by stacking such modules in halfway overlapping rows, concrete may then be poured into the vertical openings 30, 32 and 34 to fill the entire inner vertical and horizontal openings and thus surrounding the hori~ontal reinforcing rod.
Form modules built into a wall form serve as a form for the setting concrete where the load or the weight of the wall form and concrete is temporarily carried by the exterior and interior wall plates. When the concrete has hardened the weight or load bearing function of the interior and exterior wall plates may cease and or become negliyible. The hardened concrete carries the bearing weight completely or may be optionally shared with the exterior and interior wall plates should the top surfaces of the interior and/or exterior wall plate be of substantial width, as shown Eor example, at 155 in Figure 11. It is preferable that the temporary wall form weight is carried by the interior and exterior wall plates partly assisted by an insulation sec-tion *Trade Mark -2~-.. . .

~5~;Z7~3 1 and a cover plate. When the concrete hardens~ pre~erably, itthen is mai:nly respons~ble for carry~n~ the bearing weight of the wall. Optionally, be-fore concEete has been poured and while it is setting the wall form weight could be carried by the exterior wall plate and the insulation section 40 (Figures 1, 3, 4A and 5) and/or the insulation cover plate 21 (Figures 2 and 4A~. The weight or load of the stacked and setting wall form can as well be optionally carried by the interior wall plate and the insulation section 40, and/or the said insulation cover plate 21.
It can be appreciated that the terms interior wall plate and exterior wall plate are only definitions. Although it is typically preferably that the exterior wall plate is on the outside of the building, and the interior wall plate is facing the inside of the building (along with the insulation section and cover plate~, they may be optionally interchanged, exchangin~ their usual facing positions in the wall. In this case the interior wall plate, insulation section and insulation cover plate faces the exterior of the building while the exterior wall plate faces the interior of the building.
Preferably exterior top surface 24 is formed incorporating exterior indented portions 57 (Figure 1) and interior top surface 55 is formed with a top surface central recession 58 or vice versa. This allows a space or gap to be formed between exterior top surface indented portions 57 and complementary bottom surface 14 as well as between interior wall portion central recession 58 and complementary bottom surface 14 into which concrete may flow.
This also allows a space between exterior wall portions wherein in one embodiment as described hereinafter, anchor mechanisms may protrude between modules into a central recession for 3 attaching further wall coverings or for suspending objects hung from the formed wall. Also, particularly on insulated form ~t~27~
1 modules, the exterior and inter,i,or end surfaces are preferably marginally recessed to allow poured concrete to become partially locdged between their opposing end sur~aces as laid in the wall.
The exterior top surface 24 and exterior end surface 25 may have optional top notches 80 and end notches 82 (Figure 2) respectively, at regular intervals ('only partially shown).
As well notches may be opt~onally included on the exterior end surface 31 along with or in place of the end notches 82 (not shown).
The interior wall plate may have optional interior end notches 84 (Figure 2) at regular intervals on the interior end surface 52. As well notches may be optionally'included on the interior end surEace 54 as well as or in place of the interior end notches 84 (.not shown). The interior top surface 55 may optionally have air relief notches and preferably incorporates the interior top surface recessed portion 58 whereby concrete flows next to the insulation section covering the interior top surface recession 58. These notches may be more often used in non freeze areas of the world or for interior wall-pillar applications.
The top and end notches where used, cause air to escape out of the entire inside vertical and horizontal openings as well, acting similar to air relief valves, These notchés when used allow in most cases quick filling of the wall form and good penetration about the said exterior top and end surfaces 24, 25 and 31, and about the interior top and end surfc~ces 55 to 58, 52 and 54, respectively. These notches can be usec'l as "check ports"
where a needle may be inserted to ascertain whether the wall form has been properly filled. Instead of a straiqht horizontal edge 344 and vertical edge 345 (Figure 151 these notches provide a further benefit of lessening the requirement for vibrating of the form to eliminate air pockets as is determined by the size ~5~8 1 of the notches. Where notch~s are used the preferred size of the notches is 1/16 inch diameter in the pre~erred dLmensioned embodiment although the size o~ each notch ~a~ Yary, For interior load bearing purposes or in exteEIor no freeze applications, installation of the notches causes the form module to be more expensive to manufacture, and is sometimes preferable to have plain horizontal and vertical, interior and exterior surfaces as shown in Figure 15 of an ~nsulated form module. Preferably narrow top and end surfaces of the exterior wall plate are provided with indented portions 57 and/or central recessions 58 and proximate the exterior wall surfaces to acilitate air escape between modules during filling of the inner vertical and hori~ontal openings without locking in o~ air pockets as shown for example at 101 (Figures 7 and 8) where air escape is faster than in modules having the more expensive notches. Plain, narrow exterior top and end surfaces of the form module with accompanying indented portions 57 and/or central recession 58 are preferred as they are typically less costly to make tkan top and end edges which incorporate notches. With or without the notch openings on the interior top and end sur~aces air may be allowea optionally to escape into in-terior vertical grooves 56 (Figure 4) when provided and/or into the said insulation section as descrlbed hereinafter.
The minimal overall bearing and typically 98~6 bonded total contact surface area of the interior and exterior wall plate top surfaces on the preferred embodiment for which di-mensions have been provided is approximately 1/2 or less square inch. This is the temporary bearing portion of the wall. The hardened concrete's overall bearing and bonded surface for the dimensioned embodiment is approximately 94 1/2 square inches or 98% of the bearing area of each module.

1 A ~urther ad~anta~e of having narrow top and end surfaces of the exterior and interior wall pla-tes is that with concrete bonded to the inner edges of the narrow surfaces a concrete bonded seal is thereby formed at the exterior surface preventing water from flowing into the finished wall and accumulating in crevices to freeze, expand, break and/oP eventually erode the exterior surface and~or exterior or interior wall plate. This preserves the load bearing ability of the wall due to the small fraction of the total load bearing surface of a finished wall the narrow surfaces represent, and further that water or resultant frost cannot lodge between bearing surfaces to cause eventual structural damage.
As the horizontal and vertical interior and exterior chamfers 71, 67, 73, 68, 75, and 69 (Figure 4A) respectively, leading to the top and end surfaces of the interior and exterior wall plates are filled with concrete, th.is widens the : total concrete load ~earing cross-sectional area of the wall and provides a surrounding bond therefore coupling and seating the exterior and interior wall plates by a permanent solid and sealed embedment(see 101, Figures 7 and 8). The top and end surfaces o the interior and exterior wall plates may optionally be coated with a bond sealent; dry cement, or expansion-contraction material which while results in a less ef~ective escape of air from the inner vertical and horizontal opening may provide a superior bond between narrow surface abutments. Usually such coatings would be used in an embodiment with top and end notches as desirable and may optionally be used with straight horizontal and vertical edges.
As seen in Figure 5, the preferred resultant shape of the top and end surfaces coupled with the adjoining exterior 3~ chamfers and exterior opening chamfers is that of an isosceles triangular apex. Similarly, as seen in Figure 5, the preferred 27~3 1 resultant shape of t~e insulated ~orm module top and end surfaces of the interior wall plate coupled with the adjoining interior opening chamfers, is tha~ o~ an ape~ of a right: angle triangle~
Optionally they may both appear as isosceles or right angled triangular apexes especially on the interior wall plate as ex-terior vertical and horizontal chamfers may alt:ernately be used as air vents for trapped moisture. Where a right angle triangular apex is provided on the exterior wall plate an uninterrupted flat exterior face 350 (Figure 16) may be provided on the assembled wall form. The isosceles triangle shape on the interior wall plate is preferred in the non-insulated form module (Figures 21 and 221 to provide a resultant brick and mortar look on the interior wall plate outside surface 511 (Figures 21 and 22~ of the form module in the assembled form wall 700 (Figure 31).
On the bottom surface of preferred form module one exterior raised alignment portion 210 [Figures l, 3 and 11) and two interior raised alignment portions 212 (Figures 3 and ll) are provided which protrude from the bottom surface of the overlying form module thus engaging and aligning with horizontal exterior opening chamfer 67 and horizontal interior openin~ chamfer 71, respectively~ Althouyh this is the preferred method of self ; alignment of the form module lO, the form module may incorporate l, 2, 4 or more raised alignment portions in any combination on either side dependent upon the required need for greater or lesser alignment and/or lateral force resistance. The purpose of the self aligning features of the form module are to spe~ construction provide lateral force resistance in concrete filling, and to form parallel walls. Alignment means are not however always required.

1:~5~7~
1 Where raised alignment portions are not incorporated in the form module~ exter~or br~ces may be proY~ded during con-struction to aid alignment or placement of modules while still holding the wall form in place for concrete placement and final setting. By increasing the number and/or size of raised align-ment portions the lateral stabil~ty of the wall form may be in-creased. This is useful in that t~e wall form then requires less or no brac~ng during construction~ The advantage of fewer raised alignment portions particularly along the horizontal exterior opening chamfer and (as well but less important) along the horizontal interior opening is that a better resultant seal occurs when poured concrete travels into these locations pre-ferably internally sealing the largest possible proportion of the area from exterior moisture penetration.
The raised alignment por-tions may alternately be en-larged or decreased in si~e from a pxeferred 1~4 inch diameter on the dimensioned preferred embodiment, and may be of any shape provided alignment occurs. Enlarged raised alignment portions allow for increased lateral force absorption and cause easier automatic self aligning of module when positioned by hand on the wall form. Sma~ler raised alignment portions allow easier manu-facturing and easier shipping at lower cost. They further allow increased penetration of the concrete filling more completel~
the area directly inside of the exterior and interior top sur-faces 24 and 55 to 58 (Figure 4A) respectively.
The raised alignment portions may form a complete ridge on one and/or both of the interior and exterior wall plate bottom surfaces. This is particularly useful when the form modules are to form a temporary wall and may not have concrete poured into 3~ them being optionally able to be used again.

-3~-~L~5 ~
1 Raised ~lign~ent portions: 211 and 213 (Fi~ure 12) may be alternately employed adjoining the bottom o~ the exterior wall plate surface edge and the bottom surface of the insulation cover plate 21. These may as well ~e ridges and/or smaller raised alignment portions as would be further useful in protecting the upper and lower form module abutting surfaces from weather pene-tration.
The raised alignment portions are made preferably rom "hot melt" a quick setting industrial adhesive but may optionally be made of tar, concrete, plastic, apoxy, Eormed as part of the module or using other easily applied materials.
Optionally embedded in the interior insula-tion sur~ac 11 (Figure 4) are regularly indented minute interior vertical grooves 56 ~Figure 4) which facilitate ea~ier grinding and/or adhesive placement of the interior insulation surface. It is preferable to manufacture the modules without grinding this sur-face ho~lever, grinding of this surface may optionally be carried out to provide a continuous precise depth of product. The bearing shell 200 (Figure 4A) can be manufactured with known mold tech-~ niques to depths accurate to tolerances as low as 1/32 inch andtherefore grinding of the interior insulation surface is required only for bui.lding needs requiring closer tolerances.
Grinding may also be optionally carried out on coverplate insulation surface 219. (Figure 4A) with cover plate vertical grooves 218 (Figure 4A) provided to facilitate grinding and adhesion. These optional vertical grooves or vertical and horizontal chamfer combina-tions may serve as a vertical air and/or moisture ducts particularly in embodiments without the interior top surface central recession 58 in which case the top of the grooves would be level with the entire top surface of the interior wall plate 55. The size of the interior vertical grooves 56 and 7~3 1 the cover plate yertical ~roo~Jes 218 in the preferred dimensioned embodiment is 1/16 inch! These may v~ry in size becoming larger or smaller according to manufacturing or construc-tion needs.
All top and end surf~ces of the said bearing shell 200 and particularly surface 24, 25~ 31, 52, 54 and 55 are preferably ground or otherwise manu~actured to within precise tolerances.
The bearing shell can then be exactly assembled into the wall form en~aging the raised alignment portions 210 and 212 and matching evenly the overlying bottom surfaces. The attached insulation section and cover plate will not affect level stacking or alignment as long as they are level or slightly below the level of the resultant top surfaces of the interior and exterior wall plates~ The bottom surface 14 may -typically be made flat in the manufacturing process as or example in molding. Grinding may be furthRr applied to the top and end surfaces of the insulation cover plate 21 to ensure that these surfaces are level or slightly below the level of the top and end surfaces of the bearing shell 200. Thus the wall form can be assembled from insulated or non-insulated form modules (Figures 1 and 21) respectively, without deviation or imbalance in the basic bearing portion because the adjoining and bearing surfaces are concentrated on the bearingsh~ll 200 ~Figure 4A) portion of the wall form.
It may be noted that the surface areas of the sur-faces of the bearing shell which are preferably ground have been minimized through the incorporation of narrow top and end sur-faces. The insulation cover plate top and end surfaces 217, 215, and 216 (Figure 4A) respectively preferably are wide and flat to ensure that should a fire occur no toxic fumes produced from various possible insulation section materials used would escape into a room adjoining the interior surface of the wall. This is usually necessary for compliance with governmental fire and Z~
1 construction codes.
Because of the triangular apexes and the flush meeting surfaces of the stacked bearing shell portions of the form modules, the narrow top surfaces are least likely to chip or crack under the weight of the filled wall form while wet concrete is harden-ing.
In Figures 2, 3 and 4A-the insulation section 40 is attached to the interior wall plate 50 on the interior insulation surface ll (Figure 4) preferably with adhesive such as contact cement or other usually quick bonding adhesives at the manu-facturing stage. In Figures l to 5 the insulation section 40 is of rectilinear shape. An optional raised insulation alignment portion 42 and complimentary recessed insulation alignment portion 44(as shown in Figure 5) may be used. As best shown in Figure l the insulation section 40 preferably lies parallel to and level with the outside surfaces of the bearing shell 200 and is mounted on the interior insulation surface 11. In the case of the dimensioned preferred embodiment of the insulated form module having the insulation section is preferably lO inches long by 3 inches high by 3 inches depth, The height and length of the insulation section will preferably be of similar length and height dimensions of the form modulels bearing shell 200 The depth of the insulation may vary for example, from l/32 inch where it functions simply as a vapour barrier ko 24 inches or more where it functions as a significant insulative barrier to heat transfer through the wall. Preferably the depth is in the range of between 1 and 12 inches for regular construction needs and may be selected with regard to the particular types of insulation used in the form module. If the optional insulated alignment means are provided, they may be of larger or smaller dimensions and of different alternate raised and recessed shapes ~5~Z7~
1 to suit manufacturing equipment and needs of desired construction.
The insulation section is preferably made of poly-urethene or extruded polystyrene foam but may be as well made with fiber glass, cellulose, vermiculite, plastic bubbles, light expanded clay aggregate, foam beads, mineral wool and other insulative materials used separately or in any mixed combination as building codes and/or construction needs, availability and/or expense of materials may determine. An example of this would be where a rigid fiber glass insulation section is alternately employed being of less insulative value than other materials but being able to be used with an in-terior cover plate which is not made of fire retardent ma-terial.
A water, ultra violet, or freon impermeable layer as for example, made of a dark plastic may be provided to cover the entire surface of the insulation section. When made with a freon impermeable skin, freon gas may be prevented from escaping out of a polyurethene core of the insulation section to establish a greater net insulative value in the insulation section itself than would result had the polyurethene been exposed. The freon gas once escaped reduces the over all ~-value.
A thin water sealent coating may be provided to surround the insulation section's outer skin. This coating may be made of a tar base which prevents water from penetrating ; the horizontal and vertical seams 300 (Figure 7) of the overlying, underlying and end abutting insulation sections attached to the said bearing shells. Where a water impermeable skln may op-tionally not cover the complete surface of the insulation it remains desirable to provide such a skin on the cover plate insulation surface 219 (Figure 4A) and the interior insulation surface 11 (Figures 1, 4 and 5) especially when other insulative materials are used such that moisture protection and additional rigidity may be provided by the skin.

2~
1 An insulation cover plate 21 (Figures 2 and 4A) is adhered to the insulation section serving as a protective cover plate preventing damage or decay by weather, fire, or abrasion in handling. In Figure 4A the cover plate consists of the outer cover plate surface 20, cover plate insulatiQn surface 219, (optionally with cover plate vertical grooves 218), cover plate top surface 217, first cover plate end 215, second cover plate end 216, horizontal cover plate chamfer 221, first vertical cover plate chamfer 222, and second vertical cover plate chamfer 223. The top end, and cover plate insula~ion surfaces are preferably parallel with the outer sur~aces of the form module and planar. The outer cover plate surface may be flat, but is preferably texturized, and may be pitted, patterned etc. as in the case of th previously described exterior wall surface 22 (Figure 1). The texturized outer cover plate surface is further demonstrated at 130 (Figure 6). The cover plate insulation surface may have various o~her surface arrangements as would best couple with the insulation section for various adhesion methods.
The preferred material of construction for the in-sulation cover plate 21 is concrete. Alternative materials suit-able for the bearin~ section 200 as previously described and in combination with metal plates, plaster, wood, marble, rock chip, gypsum, may also be used, preferably to provide a favourable appearance.
The preferred height and length of the cover plate is the same as for the insulation section, however the depth may vary, for example, from l/lOOth of an inch as where a metal skin or foil comprises the cover to a 3 inch concrete cover plate piece as may be required for gymnasium or warehouse surfaces.
An advan-tage of the form module of the present in-vention is the ability to easily provide and intermix various 7~3 1 bearing shells, insulation sections, and insulation cover plates to suite construction engineering and architectu.ral needs thus simplifying the on-site construction once the form modules are manufactured. The result is Eewer on-side complications and lower overhead and labour costs. The skilled or semi-skilled labour requirements on site are greatly reduced because the modules are preplanned and machine built in plant. The sel~

, aligning features and uniformity of the modules greatly reduce construction time, A pre-formed anchor member 35 may be laid into the first cover plate insulation surface opening 94 (Figure 4B) to extend over and pass below the top surface of the insulation section 40 and the interior top surface central portion 58 and to enter into the vertical opening 30 vertically alongside the interior opening surface 19 (Figures 1, 2, 3, 4A and 5). Pre-ferably the anchor member is 1/8 inch diameter wire however the invention i5 not so limited. Alternate anchor means include wire mesh, screen, bars, rods, and metal clip9 of variable thickness conn~cted to the insulation cover plate and ~0 passing through the insulation section to either at least protrude into the vertical opening or -to overlay the interior vertical opening surface (see 96 on Figures 4A and 12). A
preEerred material for the anchor member 95 is steel with an anti-corrosion coating such as galvanizing, epoxy zinc~ or plastic. The anchor member may alternately be made of plastic, copper, other metals, carbon, epoxyblends and other rigid materials.
As adhesives are suitable for bonding the insulation cover plate and insulation section to the bearing shell, the anchor member serves as a mechanical coupling means to join the insulation section and insulation cover plate to the bearing --~10--shell particularly when concrete poured into the wall form, sur-rounds the anchor member and haraens permanently securing the anchor member as a fixed mechanical coupling means. Constructionr fire and earthquake codes may require such mechanical coupling means for face plates, The sald ~nsulation section and insula-tion cover plate perferably serve no load bear;ng purpose. They may optionally do so, however, the anchor member preferably provides only a means for connection and is not required for load bearing purpose~ in the finlshed wall. The insulation section and/or insulation cover plate may optionally serve as a load bearlng facility when foam insulation and/or other insul-ative member and~r sand, stone or clay are poured into the verti-cal openings 30, 32 and 34 instead of the usual load bearing concrete. This may be done when the bearin~ ability of the form moduIe is of lesser importance and where more insulation may be required. Such an arrangement may be use~ul for a temporary shelter. Foam rubber, silicone, epoxy blends, mortar, and other alternate bonding materials may be used for providing permanent or temporary bonding, for providing control joints, and for filling the vertical cavities particularly where smaller vertical openings are provided. Polyurethene may as well be used as an alternate bonding material.
Once concrete is poured into the vertical openings 30, 32, and 34, it automatically covers and forms around the anchor member 95 as shown at 101 (Figure 8). The preEerred anchor member appears as a clip in Figure 5 and may be optionally used as a means of joining the insulation section and cover plate to the bearing shell 200 of the form module without requiring adhesive to be applied to the interior and cover plate insulation surfaces 11 (Figure 4) and 219 (Figure 4A) respectively. The anchor member may also merely assist in holding the insulation 7~
1 section and coyer plate tQ the bea~i~n~ shell. Because the anchor member is recessed below the top surface of the insulation section as seen at 95 (~igure 5~ the overlying insulation seals flush at the horizontal surface. As well, the abutting ends o~ the in-sulation section meet flush (Figure 8) and thus seal along all the insulation section's exterior top, e~d and bottom surfaces 306 (Figures 6 and 7 partly shown). Once built into the completed wall form the insulation behaves as if it were a single piece whereby moisture cannot penetrate through the combined sealed insulation ~ body, and whereby thermal transfer may be reduced. As the anchor member is preferably of small cross-sectional area it represen-ts but a small thermal bridge.
A prefèrred cover plate surface and exterior wall sur-face when complied in a wall may appear as a textured brick and mortar wall as seen at 701 ~Figure 31)~ The combination of the horizontal, vertical and exterior chamfers 72, 70 and 74 ~Figures 1 and 4A) and the horizontal and vertical cover plate chamfers 221, 222 and 223 (Figure 4A) respectively may combine to form the outline of a conventional brick and mortar wall as there is a resultant shadow provided in the various chamfer voids 331 (Figure 5) and 700 (Figure 31). In the preferred dimensionea embodi-ment the chamfer void 331 is 3/8 inch in height or wid-th as is similar to a preferred brick or block spacing in conventional brick and block mortared walls. These chamEer voids may be made smaller or larger for different desirable wall appearances. Many other chamfer variations may he provided including multiple sur-faced chamfers and curved chamfers.
It may be desirable for the exterior wall surface to be texturized while the cover plate surface remains flat (or vice-versa). A flat surface may allow quicker installation of gypsum board.

1 The wall surface itsel~ may be made fla-t w;th a combination of flat exterior or flat outer cover plate surfaces where no ex terior or cover plate cham~ers are used. Sucll flat walls may be used in foundation walls, wh~cK may optionally be covered with water proofing or parging as in 355 (Figure 16) as described here-inafter.
The bearing shell preferably including attached said rasied alignment portions 210 and 212 may be used to ~orm walls without insulation sections, insulation cover plates or anchor members as shown in the non-insulated form module of Figure 21.

In both the insulated form module (Figures 1 and 2) and non insulated form module (Figure 21) the resultant formed wall offers the strength of a poured concrete wall and preferably with a pleasing exterior finish. The insulated form module (Figures 1 and 2~ further offers insulation protection along with a durable protective interior surface provided by the insulation cover plate. The following description refers to the Figures 5 to 26 in sequence.

Figure 5 shows a side view of three stacked modules.
Further shown in a decorative protective face plate 133 which is used for adding alternate suraces to the exterior wall face. One example of this is a clay brick plate with a non corrosive wire clip fastened in the vertical core which allows concrete when poured to secure further be bounded with expoxy to the module in the plant.
Figures 6 and 7 shows preferred locations of an optional reinforcing rod whereby horizontal rein-forcing rod 311 is placed into horizontal opening 100 (Figure 5~ as desired preferably during the laying of the modules into the retaining wall form.
Vertical reinforcing rod 312 (Figures 6 and 7) may be placed into ., -~3-1 any vertical openiny 30, 32 and 34 of a completed wall form preferably a~ter the concre-te has been poured, It may op-tionally be placed into the wall prior to the pouri~ng of the concrete at the location shown as 312 or nearer to the optional location 313 for best pouring and filling results~ Otherwise the reinforciny rods may be put anywhere within the internal openings as desirable~
A method of introducing concrete into the wall horizon-tally is with a submerged horizontal nozzle using a concrete-mortar pump at.331 (,Figures 6 and 7). Further shown in Figures 6 and 7 is the completely filled horizontal opening as 102 and the outer edges of the horizontal concrete filling limits 101(Figures 6 to 7 and 8~ Further shown are samples of the textured exterior wall surface 13 and the textured cover pla-te surface 130 (Figures 6 to 7), also shown at 701 (Figure 31).
E'igure 8 depicts at 110 a si.ngle recessed partitioned form module as an alternate embodiment of the form module where as earlier stated there may optionally be only one recessed partition 111. A further alternate anchor member 112 arrangement is used in this case. Form module 110 also represents a half-form module adjoining two double partitioned form modules in tandem, Concrete (or optionally any combination of admixtures and/or additives) is poured at 140 into the adjoined vertical openings 32 and 34 to completely ~ill all the inner openings and indented portions 57 and central recessed portions 58 ~Figures 1 and 2) as in a "direction of travel" shown by arrows 141, 142, 143, 144, 145, 146 and 147. As noted earlier complete filling may optionally be made by the location of notches 80 on the top surface 24 (Figure 8) (.and at other possible notch areas) and/or the insertion of a vibrator shown at 150. It can be noted that concrete may partly fill said notched recessions and optionally leak out of the wall if desirable. The notches provide another method release of ..4~_ ~5~78 . 1 inner air from the cavities~ Further shown are the horizontal and vertical reinforcing rods 311 and 312 (.Figure 8) also shown in~,Figures 6 and 7), Vibration is usually preferred to help fill the exterior and interior opening chamfers 121, 122, 126 and 127 respectively and for example, to aid complete covering of ~he inserted anchor member 95 of the preferred embodiment. Vibrating is also pre-ferable when incorporatlng reinforcing rod into the wall form.
The vibrator 150 aids the concrete to settle into areas more 1~ easily particularly where the concrete contains large size stone chips which may cause blockages and/or resultant air pockets within the wall. Optionally vibrating may not be desirable if the con-crete contains smaller sized aggregate chips allowing for increased fluidity.
Figure 9 aepicts a positioning post or board 170 which fits down the aligned vertical openings 30, 32 or 34 ~Figures 1 and 2) as an alternate meansof alignment of the `insulated form module as for example, where no raised alignment portions are provided on the module~ Figures 9, 10, 11, and 13 further depict an optional flat topped interior wall plate 155 only for purposes of demonstrating that alternately the interior wall plate may singularly (.and/or in cooperation with the exterior wall plate and/or insulation section and/or insulation cover plate~ be used to carry the load of the wall until concrete has set, If used singularly and not in combination with any ot.her areas of the top surface 12 (Figure 5), then the top surface 24 and/or insulation section 40 and/or insulation cover plate will be used as balance points thus carrying negl.igible weight, Figure 10 indicates further al-ternate alignment embodiments with a raised triangular aligner portion 190 and/or alternately located raised triangular aligner portion 192. These ~.~5~ 7~
1 cause alignment with a si,milarly recessed bottom surEace of the overlying fox~ module at 194 and 196 respectively. Another alter-nate aligner embodimen-t is to allow an anchor member to protrude at 195 beyond the bo~tom sur~ace 14 and aliyn with the interior wall plate 155 ~ox other interior wall plate versions not shown) of an underlying module.
Figure 11, 5 and l all show the preferred means of alignment as being exterior and interior raised alignment por-tions 210 and 212 respectively, pro-truding from the bottom sur-face and aligning within the horizontal exterior and interior opening chamfers 67 and 71 ~Figure 12) respectively~
Figure 12 indicates a standard side view oE an insulated form module except for the bottom surface which shows an alternate alignment means being a surface exterior raised al,ignment portion 211 and a cover plate raised alignment portion 213. A further alternate alignment embodiment is to add a pro-truding raised alignment portion to the bottom of the lnsulation section with complimentary recession on the top of the form module (not shown~. This would provide a flat-topped form module which like the preferred embodiment allows easier window, door and wall top plate installation. This is employed in the form module when the preferred raised alignment means is not advan-tageous. The preferred raised alignment portions can be removed from the bottom surface readily as is re~uired at the corners of the wall form.
Figure 13 depicts an alternate insulated form module alignment means where the entire alternate insulation section 240 is raised on the top surface at 242 and has a compli-, mentary recession at 244. This may optionally be reversed.
Various aliynment embodiments have been shown satisfying 1 different needs~ These self alignment means are provided to enable speed in erection o~ the ~orm wall but are not essential.
The absence of al~nment means facilitates the construc-tion of curved walls and surface indentation eEfects~ Straight walls may be made without built ~n alignment means on the modules using existing block laying methods described hereinafter with respect to Figure 17. The load bearing and insulative qualities of the form module are, for the most part, unaffected by the absence or presence of alignment means. T~e preferred embodiments in-corporate self aligning raised alignment portions because most walls are straight and can be put up at lower cost with alignmen-t means.
Figure 14 shows a non-insulated exterior right corner form module 250 and an insulated in-terior right corner form ; module 252 which serve as modules to allow the wall ~orm to turn in either direction. A non-insulated exterior left corner and an insulated interior left corner (not shown~ may be pro-vided to overlie corners 250 and 252 respectively on the next course level 50g6 overlapping. This arrangement allows the exterior surfaces 254 and 256 of the corners to appear similar to a brick corner. It can be appreciated that other corner styles and sizes may be used in other form module designs. The inner vertical openings 30, 32, 34, 260 and 262 all connect and provide a continuous load bearing corner when concrete is added. Re-inforcing rod may be optionally installed .
The insulation sections 40, 270 and 274 all connect giving good insulation results with minimal thermal loss. An optional insulated corner mate form module 279 may be provided where a portion of the insulation cover plate is removed at line 276 and where an extra added insulation portion 277 is placed bet-ween line 276 and line 278. A small insulative over-lay pad 274 2'~

1 may be installed on site to prevent thermal bridging if the extra thermal protection to be proyided ~y the corner mate ~orm module 279 is not required~ Air relief notches 280 are optionally included in the corner form module paE~icularly if the regular form modules have this feature. The preferred corner embodiment top edge 282 is shown the same as in a preferred form module embodiment which does not incorporating air relief notches.
The corner insulation opening cavity 264 may be filled with concrete. The form module corners have exterior and interior vertical chamfers at 290, and exterior and interior horizontal chamfers at 292 as well, A corner edge chamfer exists at 294.
Corners may similarly be made to adapt to any complimentary form modules of alternate embodiments herein described, Figure 15 depicts an alternate embodiment o~ the in-sulated form module where the interior wall plate has been ; omitted to create larger vertical openings 330, 332 and 334, The adapted recessed partition 310 i5 adhered and or anchored to -the adjoining insulation section 340 ana further aids the exterior top edge in carrying the load of the wall form until the poured concrete has hardened, The recessed partitions 310 may have a tapered adapted recessed partition base 314 to aid in strengthening these. This embodiment is more use~ul in smaller versions o the insulated form module where the extra vertical opening space is advantageous. The partition anchor member 341 is adapted to fit the recessed partition groove 342. All other aspects of Figure 15 remain substantially the same as other preferred insulated form modules except for the ; ends of the insulation cover plate and the insulation raised and recessed alignment portions 42 and 44, as shown, A preerred alignment means for this embodiment is the same as in Figure lo A straight horizontal and vertical edge 344 and 345 are shown ~o -~8~

5~7~
1 illustrate the form o~ module whlch may be used in non freeze areas or in-ternal load bearing application. The same optional variable compositlons of the ind~vIdual parts, openings, and related construc-tion methods apply to this embodiment as it does embodiment Figure 1.
Figure 16 is an alternate embodiment of the insulated form module where in this case the usual exterior horizontal and vertical chamfers have been eliminated to create a flat exterior surface 350. ~s this has many applications, a parging and/or surface covering 355 is s~own covering the surface.
This may be water proofiny, stucco, plaster, silicone, epoxy blend or any co~ering that is protective and/or decorative. It is preferably stucco when used above ground and may be applied to the flat exterior surface or any interior surEace in any texture, pat-tern, or brick finish as part of the wall. Optionally the covering may as well be equally applied to the non insulated form module Figure 2. An optional total vertical interior opening surface may be used to aid concrete in reaching the abutting edges to form a seal more quickly, 316. Another al-ternate embodiment previously mentioned incorporates a smaller depth insulation section and difEerent types of insulative materials. Figure 16 shows a thin insulation section 360 made, for example, of fiber glass board with a narrow marble chip coated metal plate 362, both joined to the bearing shell with small anchor member 365. The anchor member may optionally be part of the metal plate or embedded with wire screen into the marble chip portion and adhered to these with epcxy. In the module of Figure 16, the horizontal and vertical cover plate chamfers are optional. Further shown are optional raised and recessed in-sulation alignment portions 367. Figure 16 is just one example of a variation of the form module. Figure 16 also shows a -49~

recessed interior wall plate 370 allow~,ng easier concrete filling with less need for ~ihrat~on.
Figure 17 shows a wide exterior ~all plate 400 wide recessed partitions 410, and wide interior wall plate 420 so as to facilitate an optional method of construction by layiny the form modules with mortar appl~ed to the wide top surfaces.
This gives minimum s~rength to the wall without the added expense of filling all the inteEnal vertical openings with concrete.

Another use for this alternative embodiment is in heavier con-struction use and is as well robust to resist damage in handling.

This stronger form module may be filled with concrete comprising higher cement content and/or less fine sand, Further shown in Figure 17 is the optional joininq of the adapted insulation cover plate 430 to the said interior wall plate 420 with a central anchor partition 425 andjor two (or more not shown) spaced anchor partitions 427. Wlth this alternate anchor member embodiment, light expanded clay aggregate, extruded polystyrene foam bubbles, plastic bubbles, vermiculite, polyurethene or any optional in-sulative substance 440 can be added on site into the void ~ remaininy in between cover plate 430 and wall plate 420 and/or the remaining vertical openings 30, 32, and 34. Polyurethene Eoam for example (or other applicable insulative mediums) may be installed in the plant or.on~site, surrounding the anchor partitions 425 and 427. The anchor partitions may optionally be made of cement, steel, carbon epoxy or other rigid materials.
Such anchor partition~s) may be used where the increased ther~
mal bridging which results, for example r with such anchor par-tition being made from concrete is not disadvantayeous as in buildings with lower insulattve requirements. ~ fur~her -alternative to anchor member 95 is anchor members 431 which may ~s~
1 be used in joining the insulation cover plate to the bearing secti~n where extra anchor connection strenyth 's needed~
An alternate alignment embodi-ment as shown in Figure 17 as two evenly spaced raised circular insulation or partition projections 445 (comPlimentary recessions not shown) which allows the constructed insulated form modules to build curved insulated wall forms pivotting and 50% overlapped on these points.
Figure 18 shows an end form mod~le which is normally used at door and window openings in the constructed wall form.
In this case a second recessed partition 62 (Figures 2 and 4Bj is not provided. End plate 450 forms the end of the form module.
Opening surface 451 of end plate 450 has a horizontal end opening chamfer 453 for through interior concrete fillin~. The end form module may optionally have vertical and horizontal cham~ers on exterior surface 455 for a brick an~ mc~-t~r appearance tnot shown). A flat surface may be formed as shown at 455. Shorte;ned insulation section 4S4 is provided as shown as a resul-t of end plate 450 taking up the extra space, Insulation cover plate 21 is similar to those used with preferred embodiment 21 in Figure 4A, however, it is adjacent end plate 450 as well as shortened insulation seation 454. Concrete filling occurs in a similar manner to that discussed previously.
Figure 1~ depicts alternate anchor member embodiments and as well a cut out pattern for a joist receiving form module.
The optional anchor members 470 and 471 shown are alternate means of anchoring where if the joist cut out section 460 is cut out to make a joist receiving form module the anchor members may still be used to anchor the insulation cover plate. The anchor member may alternately be used for increasing the anchor connection strength of the insulation cover platY as attached to the poured bearing shell. Another optional anchor member 475 1 shows the anchor connected to the insulation cover plate 480.
This causes increased anchor join~ny streng-th by embedding the anchor member ~n the concrete to occupy vertIcal openings 30, 32 and 34 as, for example, when heavy objects are to be attached to or imbedded into the outer cover plate sur~ace 20, A pre-ferred anchor member shown as 95 in Figure 18 appears as a clip but it not to be so limited requiring merely to have the anchor member protrude in-to the vertical open~ngs 30, 32 and 34, so as to be anchored by concrete to be poured therein.
1Q Insulation cover plate 480 may be adapted -to have one or more protruding portions 482 which allows the alterna~e anchor member 488 to be located more inside the madule further away from the cover plate outer surface. This is desirable in areas of extreme cold where a frost spot would .
appear on the outer cover plate surface 20 i~ the anchor mem~er is too closely embedded behind this surface whereby the anchor member may transmit frost in extreme cold. A further advantage of this aclaption is that it lends further s~rength to the insulation cover plate 480 although more costly to make.
~ similar result may be produced with the anchor member 489 and a recession in cover plate 480 as shown in Figure 19~
Insulation cover plate protruding portion 482 may be of any suitable shape and size including square shapes, circ.ular shapes and the triangular shape shown as dotted lines at 483.
Joist cut-out sections 460, ~62 and 464 are cut~out of form modules as shown in Figures 1 to 5 to make a joist receiving form module which may be used at the top of each story level or foundation level where joists (with a water proof coYering over the end) are laid into one or more of the joist cut out sections to suit the spacing of jo.ists and to thereby anchor the joists ~15~7~
1 into the wall, The joists are us.ually placed before the next layer of form modules ~re laid. Wall hange~s ~ay opt~onally be used to receive joists; rather than the above described joist form modules. ~ith ioist receiving fo~n ~od~les the e~posed exterior surface 22 is not interrupted by storey levels thus creatiny a more appealing and desirable exterior surface appearance. As the ~olsts sit protruding partway into the bearing section and thus connected to t~e vertical opening there is -then established a firm resultant permanent bond when concrete is poured into the wall form.

Figure 20 shows a completed view of the constructed wall form with the aid of which a general construction method is now described. First shown is a positioniny and/or anchor post 170 (also shown Fiyures 5 and 9) with attached braces 800 anchored to stakes 810 driven into the ground. A corner brace anyle 820 is supported by similar braces 830. When concrete poured into the cavities of the modules comprising the wall has hardened the positioning anchor post 170 may be ea~ily removed out of a covering sheath 840. Positioning anchor post 170 is preferably removed before concrete is poured into the vertical openings (Figure 8) assuming wall alignment is sufficient or an exterior braciny method is used. If desired the positioning anchor posts 170 may also serve to check for proper vertical orientation of the wall. Positioning anchor posts 170 may be spaced 3 to 9 feet along the wall form. Once poured the concrete is optionally vibrated by an immersion vibrator (Fiyure 8~ or by an exterior vibrator (nat shown) applied to the surface of the wall. When concrete has hardened braciny may be removed.

Figure 21 shows a preferred non-insulated embodiment of the form module sim~lar to embodiments of the insulated form module but without an insulation section, insulation cover plate, and anchor,~e~be~s, The non~insulated f,or~ may be advantageous where little i~ns,ulation ~ay be ~e~uired and where the wall is exposed on bcth sides to weat~er. Preferred uses of the non-insulated ~orm module include use in non-insulated walls and founda-tions, bearing and non-bearing interior divider walls, columns and pilasters, non-insulated enclosures,and simple retaining wall applications. The many variations of the embodiments of the insulated form module are equally applicable for use with the non-insulated form module except to the extent the variations may apply to insulation sections which are provided~ as such, non-insulated form modules.
Pre-ferably in the non-insulated form module top sur-face 555 of the interior wall plate is level with the top sur~ace of the exterior wall plate. As may be seen, what corresponds to the interior insulation surface 11 of Figure 4 is the interior outside surface 511 in Figures 21 and 22. Interior outside surface 511 has similar alternative embodiment possibilities as disclosed for the exterior wall surface. In a preferred embodiment this surface appears as a brick and mortar sur-face by the provision of horizontal and vertical interior wall plate outside chamfers 512, 513 and 514, respectively. As well, recessed partitions 60 are preferably parallel and optionally tapered in height as in Figure 15 and optionally tapered in depth as in Figure 5.
The non-insulated form module may be seen to comprise an insulated orm module with the insulation removed. The end raised portion 760 abuts the adjacent form module when placed within a wall and acts as a spacer for the interior and exterior wall plate to allow concrete to communicate to the space proxi-mate the exterior surfaces of these. The indented end portion 761 forms the space proximate which is filled with concrete as 7~3 1 is the case s:i~milar with the raised portion 555 and indented portion 75~. The non-Insulated form module may comprise what has previously been refe~edto as the ~earing shell portion, preferably with attached raised allgnment portions on the bottom thereof. Recessed partition bottoms may be optionally tapered inward to the top surface similar those shown in Figure 15 but joined to the interior wall plate in this case. Increasing their cross-sectional area gives more s-trength to the recessed par~itions being particularly advantageous with partitions of short height.

Figures 22 and 23 show preferred systems for alignment of non-insulated modules similar in many respects to the systems shown in Figure 5. Positioning post 170 has the same purpose as post 170 in Figures 5 and 9. Further shown is an insulation insert which may be installed in plant. The alternate portion raised alignment portion 519 is incorporated when insulation insert 544 is used.
Figures 23 and 24 demonstrate alternate alignment means shown on the exterior and interior wall plates.
Figures 24 and 25 show a raised al~gnment portion 590 and a complementary recessed alignment portion 594 to alternately align the form module. As shown the concrete fills up, seals, and is partially lodged hetween the exterior and interior top edge at 501. Also shown are optional emhedded horizontal and vertical rein~orcing rods 513 and 512 respectively, similar to those shown in Figures S and 7.
Figure 26 shows a recessed alignment channel 520 and a complementary raised alignment portion 522 which provides alignment.

On the end of either the non-insulated or insulated form module there may be provided a tongue and groove ~not 1 shown) which may be needed to add ~urther lateral stability and/or provide additional vert~cal mo~sture penetratian prevention, The insulated or non-insulated form module may have a weather proof coating or sealent applied to the outer surface such as a silicone, epoxy or mortar coating.
Fiyure 31 is a front view of an exterior or interior wall plate surface showing alternate immi~ation brick pattern finishes formed by horizontal and vertical exterior chamfers, 700. A template 720 can be momentarily fitted over the exterior horizontal and vertical chamfers 700 to cover and thus shield the brick faces 730. Mortar may be ~uickly brushed, squeezed, tuck pointed or preferably sprayed in place at 740 as the said fast mortar template 720 exposes only the horizontal and vertical : chamfers 700. The mortar template is held together by vertical template joiners 725 which do not interfere with the mortaring.
The template provides a means for quick and accurate mortarin~
of horizontal and vertical chamfers, which may be carried out to give a mortar appearance. A further advantage is that the exterior mortar can as well give added sealing to the abutting horizontal and vertical top and end surfaces though this is not necessary. The mortar may be o known consistency, colour, or chemical make up (.such as for example expoxymortar).
In areas o frost or freezing the pre:Eerred embodiment o the non insulated and the insulated form modules has top indented portion(s) 57 Figures 1, and/or -the central re-cession 58 Figure 2 where applicable to prevent moisture-frost penetration. In the case of the non-lnsulated form module where both interior and exterior sur~aces or bearing portions may be damaged by frost or freezing then the interior top surface must as well preferably have a top indented portion 759 shown in Figure 21.

~ t7~

1 Concrete weeps (or is vibraked to cause weeping) into the narrow opening seal gaps (surrounding each modules exterior wall plate except for small contact points ~4 and 55) becoming lodged within the gaps thereby causes increased weather resistance and resistance to frost damage. The indented portions 58 in Figure 1, and 758 and 759 in Figure 21 and the recessed end surfaces of the exterior wall plate (and interior wall plate in the case of the non-insulated module which has raised portion 760 and an indented portion 761) forms the resultant narrow opening seal gap. This then allows the cement to become lodged in the seal gap to seal the exterior or exterior and interior surfaces while bonaing one module to another, assuring structural integrity by preventing frost heaving which may have occured in unbonded and unfilled horizontal and vertical abutment crevices.
~ he method of construction of a wall using form modules according to the present invention is now described.
The first row oF form modules is laid level as for example, by using a form to hold these precisely in place until concrete has hardened and subsequent courses are stacked to build any wall shape or siæe. A skilled mason may be used to lay the first row. Optional precision forms may be used to lay the first row. Concrete is introduced into the vertical opening (ater optional bracing is positioned) thus filling all the inner horizontal and vertical openings. The concrete may ~e poured, pumped, injected, or inserted within the modules by any other form of placement. It may be introduced from any angle top or side.
Concrete is the preferred material which is poured into vertical openings to bond the form modules. The invention is not so limi-ted to use of concrete and mortar, insulation material 1 (such as polyurethene ~oam); concrete and mortar and mixtur~s, concrete and mo~tar mixtures with insul~tion materials, and concrete and mortar mixtures with other blended materlal may be used with the form moaule system. E~amples oE the various materials to be incorporated with concrete and mortar are foam chips, hollow plas-tic beads, light expanded clay aggregate, vermiculite haydite, cellulose, wood chips, lightweight ag-gregates, ~iberglas* steel fiber, carbon epoxy rods, rock, sand, gravel, chemical accelerators, plasticisers, setting retardants, water proofing agents and rust proofing agents.
The aim of the insulation type blends of materials is to enhance the resultant insulative or R-value, par-ticularly when the non-ir~sulated form module (Figures 21 to 26) and alternate embodiments are used. Any portion or ratio o mixtures may be used in any of these to create greater or lesser load bearing and/or insulative and/or lightweight needs as required by the builder.
Reinforcing rods whe-ther vertical or horizontal, anchor bolts, and ties are as well optional and may be used as desirable by the builder to be preset in the wall form or after-set in the concrete. When the concrete is hard then the in-sulated or non-insulated wall form becomes part of the com-pleted wall having ser~ed its function as a retaining form and now serving to provide insulation and/or facings to the wall and/or protection to the wall on one or both sides. The implicit ; further value of the orm module system is its variability and adaptability in creating difEerent size walls and shapes quickly and simply in a minimum of steps, thereby simple saving on the expense of various other trades normally required to form a completed wall on a construction site.

Although the disclosure describes and illustrates a preferred embodiment of the invention, it is to be understood *Trade Mark -58-c , . ...

z~
1 that the inyenti,on i.s. not lim~ted to the pa:rticul~r e~odiment disclosed. Many variations: and modifications will now occur to those skilled i,n the art, For a de~init:i,on of the in~ention reference is made to the appended clai~s.

o

Claims (44)

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:

1. A dry stack module for a wall comprising a plurality of dry stacked courses of modules, each module having:
a) a vertically extending cavity therethrough adapted to communicate with cavities of subjacent and superjacent modules;
b) an outer face with a perimeter bordered by perimeter surfaces comprising upper and lower surfaces and end surfaces, the perimeter surfaces being adapted to mate with complementary perimeter surfaces on adjacent, subjacent and superjacent modules to form a space therebetween adjacent the outer face substantially throughout the perimeter of the outer face; and c) communicating means for providing flaw of flowable cementitious binding material from said cavity to the space whereby binding material to be introduced into the cavity may flow from the communicating means through the space to proximate the outer face substantially throughout the entire perimeter of the outer face to provide a seal between modules proximate the outer face, the space having a distance between complementary perimeter surfaces sufficiently small at least proximate the outer face to restrict flow of flowable cementitious binding material therethrough.

2. A dry stack module as claimed in claim 1 wherein each module is adapted for locating abutting engagement with subjacent and superjacent modules.

3. A dry stack module as claimed in claim 2 wherein each module is adapted for locating abutting engagement with adjacent modules.

4. A dry stack module as: claimed in claim 1, 2 or 3 wherein alignment means are provided on each module to align each module with complementary alignment means on subjacent and super-jacent modules.

5. A dry stack form module for a wall comprising a modular concrete retaining form adapted to be filled with flowable con-crete, the concrete retaining form comprising a plurality of dry stacked courses of similar modules, each module comprising an exterior wall portion coupled to an interior wall portion with a vertically extending cavity therebetween adapted to communicate with cavities of subjacent and superjacent modules, each wall portion having an outer face with a perimeter bordered by perimeter surfaces comprising upper and lower sur-faces and end surfaces, the perimeter surfaces of the interior wall portion adapted to mate with complementary perimeter surfaces on subjacent, superjacent and adjacent modules in opposing mating relation thereto with distances therebetween sufficiently small to restrict flow of concrete introduced into said cavity there-between, the perimeter surfaces of the exterior wall portion adapted to mate with complementary perimeter surfaces on sub-jacent, superjacent and adjacent modules to form a space there-between proximate the outer face substantially throughout the perimeter of the outer face, communicating means for providing flow of concrete from said cavity to the space whereby concrete to be introduced into the cavity may flow from the cavity, through the communi-cating means and through the space to proximate the outer face

Claim 5 continued ...

substantially throughout the entire perimeter of the outer face to provide a seal between exterior wall portions proximate the outer face resistant to water penetration, the space having a distance between complementary perimeter surfaces sufficiently small at least proximate the outer face to restrict flow of concrete therebetween.

6. A dry stack form module as claimed in claim 5 wherein alignment means are provided on each module to align the module with respect to subjacent and superjacent modules by mating engagement with complementary alignment means thereon.

7. A dry stack form module as claimed in claim 6 wherein a portion of the upper and lower surfaces of each wall portion is adapted for locating abutting engagement of the module with respect to complementary portions on upper and lower surfaces of subjacent and superjacent modules.

8. A dry stack form module as claimed in claim 7 wherein a portion of the end surface of the interior wall portion is adapted for locating abutting engagement of the module with respect to a complementary portion on an end surface of the interior wall portion of adjacent modules.

9. A dry stack form module as claimed in claim 6 wherein a first of the upper and lower surfaces of the exterior wall portion includes at least one raised portion of small cross-sectional area for abutting engagement with a complementary surface on the exterior wall portion of subjacent or superjacent modules to locate complementary upper and lower surfaces in spaced relation defining said space therebetween.

10. A dry stack form module as claimed in claim 9 wherein one of the upper and lower surfaces of the exterior wall portion comprises an elongate surface extending the length of the module and having a narrow transverse dimension throughout, and one of the end surfaces of the exterior wall portion comprises an elongate surface extending the height of the module and having a narrow transverse dimension throughout.

11. A dry stack form module as claimed in claim 10 wherein said communicating means comprising:
longitudinal channel means in communication with said cavity disposed inwardly of said one of said exterior upper and lower surfaces adjacent thereto to communicate concrete from said cavity to the space along the entire length of the module, and end channel means in communication with said cavity disposed inwardly of said one of said exterior end surfaces adjacent thereto to communicate concrete from said cavity to the space along the entire height of the module.

12. A dry stack form module as claimed in claim 11 wherein a longitudinal inner chamfered surface is provided inwardly of and adjacent to said one of said exterior upper and lower surfaces sloping therefrom inwardly and toward the other of said exterior upper and lower surfaces to provide said longitudinal channel means and an end inner chamfered surface being provided inwardly of and adjacent to said one of said exterior end surfaces sloping therefrom inwardly and toward the other of said ex-terior end surfaces to provide said end channel means.

13. A dry stack form module as claimed in claim 10 wherein a longitudinal outer chamfered surface is provided outwardly of and adjacent to said one of said upper and lower surfaces sloping therefrom outwardly and toward the other of said exterior upper and lower surfaces, and an end outer chamfered surface is provided outwardly of and adjacent to said one of said exterior end surfaces sloping therefrom outwardly and toward the other of said exterior end surfaces.

14. A dry stack form module as claimed in claim 12 wherein said alignment means comprises a raised abuttance on the other of said exterior upper and lower surfaces adapted to abut said longitudinal inner chamfered surface.

15. A dry stack form modules as claimed in claim 13 wherein said alignment means comprises a raised abuttance on the other of said exterior upper and lower surfaces to abut said longitudinal outer chamfered surface.

16. A dry stack form module as claimed in claim 9 wherein said exterior and interior wall portions are coupled by at least one bridging member extending transversely therebetween,

17. A dry stack form module as claimed in claim 16 wherein said one bridging member being displaced from the exterior and interior end surfaces at a first end of the module thereby defining said cavity open to the first end of the module.

18. A dry stack form module as claimed in claim 17 further comprising:
a plurality of said bridging members spaced one from another with one said cavity between adjacent briding members of each module.

19. A dry stack form module as claimed in claim 1 or 5 wherein the cavities of each module vertically align with cavities of subjacent and superjacent modules to provide a plurality of vertically extending passageways through the retaining form.

20. A dry stack form module as claimed in claim 16 wherein said exterior wall portion, bridging member and interior wall portion comprise a unitary body made from materials selected from the group of materials consisting of concrete, clay, plastic, and metal and from a combination of materials selected from the group consisting of cement, silica sand, gravel, plastic beads, and expanded clay aggregate.

21. A dry stack form module as claimed in claim 16 wherein said exterior wall portion and bridging member comprises a material selected from the group consisting of concrete, clay, plastic, and metal and from a combination of materials selected from the group consisting of cement, silica sand, gravel, plastic beads, and expanded clay aggregate and said interior wall portion comprises an insulating material.

22. A dry stack form module as claimed in claim 9 wherein each module further comprises an insulative portion coupled to the remainder of the module with the interior wall portion intermediate the cavity and the insulative portion and having insulative upper and lower surfaces and insulative first and second end surfaces adapted to mate in abutting opposing relation with complementary surfaces on insulative portions of adjacent, subjacent and superjacent modules.

23. A dry stack form module as claimed in claim 22 wherein said alignment means comprises a longitudinally extending key ridge in one of said insulative upper and lower surfaces and a complementary longitudinally extending key-way recession in the other of said insulative upper and lower surfaces.

24. A dry stack form module as claimed in claim 22 wherein said insulated portion being detachably coupled to the remainder of the module by mechanical attachment means a portion of which passes through said cavity whereby after filling of the cavity with flowable concrete, solidification of the concrete about said portion of the mechanical detachment means permanently mechanically couples said insulative portions to the remainder of the module.

25. A dry stack form module as claimed in claim 22 wherein each module further comprises a first facing portion coupled to the remainder of the module with the insulative section inter-mediate said interior wall portion and said facing portion, said first facing portion providing substantially an outer surface of the wall.

26. A dry stack form module as claimed in claim 25 wherein said first facing portion provides a decorative interior surface.

27. A dry stack form module as claimed in claim 25 wherein said first facing portion provides a decorative and protective interior surface.

28. A dry stack Form module as claimed in claim 25 wherein said first facing portion being detachably coupled to the re-mainder of the module by mechanical attachment means, a portion of which passes through said cavity whereby after filling of the cavity with flowable concrete, solidification of the concrete about the portion of said mechanical attachment means permanently mechanically couples the first facing portion to the remainder of the module.

29. A dry stack form module as claimed in claim 25 wherein each module further comprises a second facing portion coupled

Claim 29 continued ...

to the remainder of the module with the exterior wall portion intermediate said cavity and said second facing portion, said second facing portion providing substantially an outer surface of the wall.

30. A dry stack form module as claimed in claim 22 wherein each module further comprises a second facing portion coupled to the remainder of the module with the exterior wall portion intermediate said cavity and said second facing portion, said second facing portion providing substantially an outer surface of the wall.

31. A dry stack form module as claimed in claim 29 or 30 wherein said second facing portion provides a decorative and protective exterior surface.

32. A dry stack form module as claimed in claim 25 or 30 wherein said facing portion comprises a material selected from the group of materials consisting of concrete, clay, shale, plastic, metal, ceramic tile, and wood.

33. A dry stack form module as claimed in claim 22 wherein said insulative portion comprises an insulative material selected from the group of insulative materials comprising polyurethane, extruded polystyrene, and fiber glass.

34. A dry stack form module for a wall comprising a modular concrete retaining form adapted to be filled with flowable concrete, the concrete retaining form comprising a plurality of dry stacked courses of similar adjacent modules offset with respect to subjacent and superjacent modules, Claim 34 continued ...

each module comprising a pair of parallel spaced wall portions with a vertically extending cavity therebetween adapted to communicate with cavities of subjacent and superjacent modules, each wall portion having a rectangular outer face with a perimeter bordered by perimeter surfaces comprising upper and lower surfaces and end surfaces, each perimeter surface being elongate and of narrow width, raised portions of small cross-sectional area provided on the upper surfaces and on one end surface for locating abutting engagement with complementary surfaces on adjacent, subjacent and superjacent modules spacing the perimeter surfaces of each module from complementary perimeter surfaces of adjacent, sub-jacent and superjacent modules to define a space therebetween adjacent each outer face substantially throughout the perimeter of each outer face, each space being open to the outer face and to the cavity substantially throughout the perimeter of each outer face, each space having a distance between complementary perimeter surfaces sufficiently small at least proximate each outer face to restrict flow of concrete therebetween substantially throughout the perimeter of each outer face, whereby concrete, introduced into the inner cavity of one module in the retaining form, flows through the cavities of subjacent and superjacent modules and flows through each space to proximate each outer face substantially throughout the entire perimeter of each outer face to provide a seal resistant to water penetration between modules proximate the outer face and the concrete is substantially retained within the retaining

Claim 34 continued ...

form due to the distance between complementary perimeter sur-faces being sufficiently small proximate the outer face re-stricting flow of concrete therebetween.

35. A dry stack form module for the construction of a structural, insulated wall by the steps of dry stacking of courses of similar adjacent modules longitudinally offset with respect to subjacent and superjacent modules and insertion of flowable concrete into cavities vertically extending through the modules, each module comprising:
a) a vertically extending cavity therethrough adapted to communicate with cavities of subjacent and superjacent modules;
b) a pair of spaced parallel wall portions coupled together with the cavity therebetween, each wall portion having upper and lower surfaces and end surfaces adapted to mate with complementary surfaces on adjacent, subjacent and superjacent modules with distances therebetween sufficiently small to restrict flow of concrete inserted into the cavity therebetween;
c) an insulative portion coupled to the module with one of the wall portions intermediate the cavity and the insulative portion and having insulative upper and lower surfaces and insulative end surfaces adapted to mate with complementary surfaces of insulative portions on adjacent, subjacent and super-jacent modules in abutting relation throughout;
d) a first facing portion coupled to the module with the insulative portion intermediate said one wall portion and the first facing portion, said first facing portion providing a first decorative and protective outer surface of the wall; and

Claim 35 continued ...

e) alignment means provided on each module for alignment thereof with respect to subjacent and superjacent modules by mating engagement with complementary alignment means thereon

36. A dry stack form module as claimed in claim 35 further comprising:
f) a second facing portion coupled to the module with the other of the wall portions intermediate the cavity and the second facing portion, said second facing portion providing a second decorative and protective outer surface of the wall.

37. A dry stack form module for a wall comprising a plural-ity of dry stack courses of modules, each module having:
a) a vertically extending cavity therethrough adapted to communicate with cavities of subjacent and superjacent modules;
b) an outer face with a perimeter bordered by perimeter surfaces comprising upper and lower surfaces and two end sur-faces, one of the upper and lower surfaces and anoend surface adjacent thereto being adapted to mate with complementary peri-meter surfaces of adjacent, subjacent and superjacent modules to form a space therebetween adjacent the outer face substan-tially throughout a portion of the perimeter of the outer face bordered by said one of said upper and lower surfaces and said end surface adjacent thereto; and c) communicating means for providing flow of flowable cementitious binding material from the cavity to the space whereby the binding material to be introduced into the cavity may flow from the communicating means through the space to proximate the outer face substantially throughout said portion of the perimeter of the outer face to provide, on solidification

Claim 37 continued ,,, of the binding material, a seal between modules proximate the outer face;
the space having a distance between complementary perimeter surfaces sufficiently small at least proximate the outer face to restrict flow of the flowable cementitious binding material therethrough.

38. A method of construction of a wall from dry stack form modules as claimed in claim 36 said wall comprising a modular concrete retaining form adapted to be filled with cementitious binding material, the concrete retaining form comprising a plurality of vertically stacked, longitudinally extending courses of adjacent similar modules, longitudinally offset with respect to subjacent and superjacent modules, said method comprising the steps of:
1. laying a horizontal first course of modules, 2. dry stacking successive courses of modules on top of said first course to be offset with respect to subjacent modules whereby the cavity of each module communicates ver-tically with a cavity of subjacent modules, and 3. inserting the binding material into the cavities of the modules through cavities of the modules comprising an uppermost course whereby the binding material may fill the cavities and the said spaces between modules.

39. A method of construction of a wall from dry stack form modules as claimed in claim 35 said wall comprising a modular concrete retaining form adapted to be filled with cementitious binding material,

Claim 39 continued .., the concrete retaining form comprising a plurality of vertically stacked, longitudinally extending courses of adjacent similar modules, longitudinally offset with respect to subjacent and superjacent modules, said method comprising the steps of:
1. laying a horizontal first course of modules, 2. dry stacking successive courses of modules on top of said first course to be offset with respect to sub-jacent modules whereby the cavity of each module communicates vertically with a cavity of subjacent modules, and 3. inserting the binding material into the cavities of the modules through cavities of the modules comprising an uppermost course whereby the binding material may fill the cavities.

40. The method of claims 37 and 38 wherein said binding material is pumped into said cavities through a pipe extending vertically downwardly into the cavities and which is gradually withdrawn upwardly as the level of material in said cavities rises.

41. A dry stack form module as claimed in claim 9 wherein one end surface of the exterior wall portion includes at least one raised portion of small cross-sectional area for abutting engagement with a complementary end surface on the exterior wall portion of an adjacent module to locate complementary end sur-furaces in spaced relation defining said space therebetween.

42. A dry stack form module as claimed in claim 16 wherein each bridging member has an upper surface with a recessed portion thereof vertically recessed with respect to the upper surfaces of the wall portion whereby communication is provided via each.

Claim 42 continued ,., recessed portion and each cavity horizontally through the module with the cavities of each module in horizontal communication with cavities of adjacent modules.

43. A method of construction of a wall from dry stack form modules as claimed in claim 42 said wall comprising a modular concrete retaining form adapted to be filled with cementitious binding material, the concrete retaining form comprising a plurality of vertically stacked, longitudinally extending courses of adjacent similar modules, longitudinally offset with respect to subjacent and superjacent modules, said method comprising the steps of:
1. laying a horizontal first course of modules, 2. dry stacking successive courses of modules on top of said first course to be offset with respect to subjacent modules whereby the cavity of each module communicates ver-tically with a cavity of subjacent modules, and 3. inserting the binding material into the cavities of the modules by the horizontal injection of the material therein via the cavities and recessed portions of a module comprising an end module of one course of modules in the retaining form,

44. The method of claim 43 wherein the binding material is horizontally injected through a pipe extending horizontally and longitudinally through the cavities and recessed portions of modules comprising said one course, which pipe is gradually longitudinally withdrawn as the material fills the cavities,