US20090301030A1

US20090301030A1 - Wall construction system

Info

Publication number: US20090301030A1
Application number: US12/136,685
Authority: US
Inventors: Tamio Nojima; Susan L. Guinn
Original assignee: Individual
Current assignee: Individual
Priority date: 2008-06-10
Filing date: 2008-06-10
Publication date: 2009-12-10

Abstract

A construction system utilizes a plurality of pre-manufactured units to form a concrete wall. Structurally, each pre-manufactured unit includes a wallboard mounted to an insulation board. Specifically, each wallboard has a first surface and an opposite second surface parallel thereto. For each wallboard, the insulation board is mounted to the second surface of the wallboard and extends to a face substantially parallel to the surfaces. In addition to the pre-manufactured units, the system comprises a temporary backing frame constructed from commercially-available aluminum forms which establish a wall. Also, the system includes a plurality of ties for supporting the units at a desired distance from the backing frame to establish a cavity for receiving concrete to form the concrete wall. After the concrete wall is formed, the backing frame is removed and the pre-manufactured units remain bonded to the wall.

Description

FIELD OF THE INVENTION

The present invention pertains generally to concrete wall constructions. More particularly, the present invention pertains to systems and methods for forming concrete walls with pre-manufactured units. The present invention is particularly, but not exclusively, useful as a wall forming system and method that results in concrete walls bonded to insulation board and finished with wallboards.

BACKGROUND OF THE INVENTION

Typically, interior and exterior concrete walls are constructed using temporary removable form members. These form members are often wooden, synthetic resin or metal. Generally, each wooden form member comprises plywood boards and bridges for interconnecting with adjacent boards. In order to assemble a concrete formwork, the reinforcing bridges of adjacent form members are usually fastened to each other with nails. When assembled, the formwork defines a cavity where the concrete wall will be formed. After the concrete wall is formed, the wooden formwork is removed from the concrete wall.
During construction of a wall, the concrete is poured into the cavity and sets. While setting, moisture from the concrete mix is absorbed by the wooden form member. Due to high water absorptivity of the wooden form member, the concrete loses an ideal water-cement ratio in its surface portion adjacent the wooden form member. As a result, the finished concrete's outer surface is roughened. Occasionally, the rough appearance of the concrete's outer surface leads to the conclusion that the concrete has defectively hardened. Therefore, to avoid this result, the wooden form member may be painted beforehand to reduce its water absorptivity. However, painted form members are high-priced and still may suffer from too much water absorptivity.
While synthetic resin form members do not suffer from water absorptivity like wooden forms, they are generally very heavy and difficult to work with. Further, they often fail to provide sufficient strength and are high-priced.
Also, metal form members suffer from working difficulties associated with great weight. In order to avoid such problems, metal forms are frequently made as thinly as possible. As a result, although the metal itself is relatively strong, the metal formwork has limited strength. Further, metal is prone to corrosion, oxidation and deformation as a result of use.
Regardless of the type of formwork used, the current practice is to assemble the formwork to create a cavity to receive poured concrete. After the concrete sets as a wall, the entire formwork is removed to leave the concrete wall.
In light of the above, it is an object of the present invention to provide a permanently positioned concrete wall forming system. More specifically, it is an object of the invention to provide a system that utilizes pre-manufactured units for forming concrete walls. Another object of the present invention is to provide a pre-manufactured unit comprising insulation board material mounted to a finished wall wallboard. Still another object of the present invention is to provide a concrete wall forming system that eliminates absorption of water from the concrete while the concrete sets. Another object of the present invention is to provide a system that utilizes pre-manufactured units in conjunction with commercially-available aluminum forms to form concrete walls. Yet another object of the present invention is to provide a concrete wall forming system and method that is easy to implement, is simple to use, and is comparatively cost effective.

SUMMARY OF THE INVENTION

In accordance with the present invention, a construction system is provided for forming concrete walls. Structurally, the construction system includes a plurality of pre-manufactured units. These pre-manufactured units are used to erect a boundary for one side of the concrete wall, while a removable backing frame erected from commercially-available aluminum forms bounds the opposite side of the concrete wall. After the concrete sets into the concrete wall, the backing frame is removed and the pre-manufactured units remain bonded to the concrete wall.
For the system, each unit defines an axis and comprises a wallboard and an insulation board. Further, each wallboard includes an exterior surface and a parallel opposite surface. Also, the insulation board is mounted to the opposite surface of the wallboard and extends to a face that is parallel to the surfaces.
As noted, the system further includes a temporary backing frame that has a wall distanced from the face of the insulation board. Also, flat ties are provided for supporting the units at a desired distance from the backing frame. As a result, a formwork defining a cavity between the units and the backing frame is established for receiving concrete. During formation of the concrete wall, the face of the insulation board and the wall of the backing frame bound the concrete.
After formation of the concrete wall, the backing frame is removed. However, the pre-manufactured units are permanently bonded to the concrete wall and form part of the finished wall. Because the pre-manufactured units bound only one side of the concrete wall in the present invention, the need for the aluminum forms of the backing frame during wall construction is reduced by half over current practices.

BRIEF DESCRIPTION OF THE DRAWINGS

The novel features of this invention, as well as the invention itself, both as to its structure and its operation, will be best understood from the accompanying drawings, taken in conjunction with the accompanying description, in which similar reference characters refer to similar parts, and in which:

FIG. 1 is a perspective view of a portion of a wall construction system;

FIG. 2A is perspective view of a portion of a finished wall erected with a wall construction system;

FIG. 2B is a cross sectional view of a finished wall taken along line 2-2 in FIG. 2A, with external studs included;

FIG. 2C is a cross sectional view of a finished wall similar to that of FIG. 2B, with studs provided internally, and with the interconnection between adjacent pre-manufactured units illustrated;

FIG. 3A is a cross sectional view of the interconnection between the wallboard and the insulation board taken along line 3-3 in FIG. 2A;

FIG. 3B is a cross sectional view of an alternative interconnection between the wallboard and the insulation board similar to FIG. 3A;

FIG. 4A is a perspective view showing the interconnection between a flat tie and a brace at the edge of a pre-manufactured unit;

FIG. 4B is a cross sectional view of a wall construction system after formation of a concrete wall as would be seen along line 4-4 in FIG. 4A after the addition of another pre-manufactured unit, and illustrating the concrete wall with a backing frame;

FIG. 5A is a perspective view showing the interconnection between a wallboard and an insulation board;

FIG. 5B is a cross sectional view of a wall construction system after formation of a concrete wall taken along line 5B-5B in FIG. 5A, and illustrating the concrete wall and backing frame;

FIG. 5C is a cross sectional view of a wall construction system after formation of a concrete wall taken along line 5C-5C in FIG. 5A, and illustrating the concrete wall and backing frame;

FIG. 6A is a perspective view of the intermediate plate and clip used to connect the insulation board to the wallboard;

FIG. 6B is a cross sectional view similar to FIGS. 5B and 5C and focusing on the intermediate plate during tightening of the clip;

FIG. 6C is a cross sectional view showing the intermediate plate of FIG. 6B after the clip is locked into position;

FIG. 7A is a perspective view of a bracket used for interconnecting adjacent pre-manufactured units to a tie plate;

FIG. 7B is a cross sectional view of the bracket of FIG. 7A shown interconnecting adjacent pre-manufactured units to a tie plate;

FIG. 8A is a perspective view of a tie sleeve for positioning a tie plate at a non-interface location on a pre-manufactured unit; and

FIG. 8B is a cross sectional view of the tie sleeve of FIG. 8A shown in engagement with a pre-manufactured unit with a flat tie passing therethrough.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring initially to FIG. 1, a wall construction system is shown and generally designated 10. As shown in FIG. 1, the system 10 includes a plurality of pre-manufactured units 12 comprised of a wallboard 14 mounted to an insulation board 16. For interior use, the wallboard 14 is preferably gypsum board or drywall. For exterior use, the wallboard 14 is preferably oriented strand board (OSB). The insulation board 16 is generally a plastic foam product such as expanded polystyrene. Importantly, such a plastic foam product adheres well to concrete.
As shown, each unit 12 defines an axis 18. Further, the wallboard 14 includes a planar exterior surface 20 that is substantially parallel to the axis 18. Likewise, the wallboard 14 forms a planar opposite surface 22 that is substantially parallel to the exterior surface 20. As shown, the insulation board 16 is mounted to the opposite surface 22 of the wallboard 14 and extends to a face 24 that is substantially parallel to the surfaces 20, 22.
In FIG. 1, the units 12 are used with a temporary backing frame 26, which may be created from commercially-available aluminum forms. Structurally, the backing frame 26 includes a wall 28 that is distanced from the insulation board 16. Together, the units 12 and the backing frame 26 define a formwork 30 having a cavity 32 for receiving poured concrete 34.
Referring now to FIGS. 2A and 2B, a portion of a finished wall 36 formed from a system 10, such as that shown in FIG. 1, is illustrated. In FIGS. 2A and 2B, it may be seen that the backing frame 26 (shown in FIG. 1) has been removed while the units 12 remain bonded to the concrete wall 38. In FIGS. 2A and 2B, the unit 12 a illustrated includes an alternative construction that provides for additional support during the concrete pouring and setting operation. Specifically, the unit 12 a includes a series of cut-outs or grooves 40 that are substantially parallel to the axis 18.
In FIGS. 2A and 2B, the length of the unit 12 a is three feet which corresponds to the length of standard commercially-available backing frames 26 (shown in FIG. 1). For the unit 12 a, the cut-outs 40 are positioned one foot apart, on center. Also, each cut-out 40 has a width of four inches and a depth of two inches and is bounded on three sides by the wallboard 14. During erection of the concrete wall 38, 2×4 studs 42 (shown in FIG. 2B) are positioned in the cut-outs 40 for bracing purposes. After the poured concrete 34 (shown in FIG. 1) sets to form the concrete wall 38, the studs 42 can be removed. At that time, utility features 44 such as electrical conduit, outlet, gas piping, AV cabling, phone wiring and the like may be positioned in the cut-outs 40. Further, the unit 12 a forms conduits 46 substantially perpendicular to the axis 18 for passing through the cut-outs 40. Preferably, conduits 46 are positioned sixteen inches and forty-five inches from the floor, respectively. Alternatively or additionally, cut-outs 40 that are perpendicular to the axis 18 may be provided in the units 12.
Referring to FIG. 2C, another alternative unit 12 b is illustrated. As shown, this unit 12 b includes studs 42 at an internal position between the wallboard 14 and the insulation board 16. Again, the studs 42 are used to provide bracing to withstand the concrete 34 (shown in FIG. 1) pressure during formation of the concrete wall 38. As a result, formworks 30 (shown in FIG. 1) using units 12 b with internal studs 42 require less additional bracing. Also, because the studs 42 are not removed from the units 12 b after formation of the concrete wall 38, various external sidings and interior wall material may be conveniently nailed or screwed into the studs 42 through the wallboard 14. While not shown, the unit 12 b may also include conduits 46 for receiving utility features. Further, while not illustrated in FIGS. 2A-2C, the units 12 preferably include small vertical channels at the boundary 48 between the wallboard 14 and the insulation board 16 in order to avoid condensation problems.
Cross-referencing FIG. 2A with FIG. 2C, the interconnection between adjacent units 12 may be understood. In FIG. 2A, the unit 12 a is shown having a planar first end 50 and a planar second end 52. For such a construction, units 12 that are adjacent one another in the formwork 30 (shown in FIG. 1) may be interconnected by an adhesive tape or glue 54 positioned on the ends 50, 52. Alternatively or additionally, as shown in FIG. 2C, the units 12 may include interlocking ends 50, 52. Specifically, the first end 50 of each unit 12 may form a notch 56 between the wallboard 14 and the insulation board 16. Accordingly, a reciprocating protrusion 58 is formed by the insulation board 16 at the second end 52. As can be seen in FIG. 2C, the ends 50, 52 of adjacent units 12 are fitted together to provide mechanical interconnection between the notches 56 and protrusions 58. This design effectively combats watery concrete seepage through the formwork 30 (shown in FIG. 1).
Referring now to FIGS. 3A and 3B, the interconnection between the wallboard 14 and the insulation board 16 in a unit 12 is illustrated. Generally, an adhesive (not shown) may be used at the boundary 48 to bond the wallboard 14 to the insulation board 16. However, the use of adhesive sometimes results in adverse effects to human health due to chemical vapors. In fact, adhesives are prohibited from use in connecting wallboard 14 to insulation board 16 in certain applications. Also, the use of adhesives can result in condensation problems during the concrete setting stage. Therefore, the present units 12 are provided with a mechanical fastening between the wallboard 14 and the insulation board 16.
As shown in FIGS. 3A and 3B, fasteners 60 are provided to interconnect the wallboard 14 and the insulation board 16. In FIG. 3A, the fastener 60 is a bolt that includes a shaft 62 having a proximal end 64 and a distal end 66. Further, the fastener 60 includes a head 68 at the proximal end 64 of the shaft 62. Also, a receiver 70, such as a double-ended female coupling, engages the distal end 66 of the shaft 62. For purposes of mechanical engagement, the receiver 70 includes a cap portion 72.
As shown in FIG. 3A, the fastener 60 is driven through the wallboard 14 and insulation board 16 until the head 68 of the fastener 60 abuts against the exterior surface 20 of the wallboard 14. Further, the receiver 70 is driven into the insulation board 16 through the face 24 to engage with the distal end 66 of the shaft 62. As the receiver 70 is screwed onto the shaft 62, the cap portion 72 of the receiver 70 abuts the face 24 of the insulation board 16 to compress the insulation board 16 against the wallboard 14.
As shown in FIG. 3A, the receiver 70 further provides for threaded attachment to an extension rod 74. Further, the extension rod 74 may be mounted to a plate 76. As shown, after concrete 34 (shown in FIG. 1) is poured and sets into a concrete wall 38, the plate 76 anchors the unit 12 to the wall 38. Also, the plate 76 may include holes for receiving wire that may be connected to rebar in the concrete wall 38. Preferably, the wallboard 14 and insulation board 16 are prepared with holes located for receiving the fastener 60 and receiver 70 in alignment.
In FIG. 3B, an alternate method of fastening the wallboard 14 to the insulation board 16 is shown. In FIG. 3B, the fastener 60 is a screw having a proximal end 64 with a head 68 and a distal end 66 with an aperture 78. As shown, the fastener 60 is screwed into the wallboard 14 and insulation board 16 until the head 68 abuts the wallboard 14. Thereafter, a wire 80 is passed through the aperture 78 and connected to rebar 82. After the concrete 34 is poured and sets into the concrete wall 38, the connection between the rebar 82 and the fastener 60 mounts the wallboard 14 to the insulation board 16.
Referring now to FIGS. 4A and 4B, the interconnection between the units 12 and the backing frame 26 is illustrated. Specifically, FIG. 4A provides a perspective view of a single unit 12 for clarity, while FIG. 4B shows two adjacent units 12 connected to a backing frame 26, after formation of the concrete wall 38.
In order to interconnect the units 12 to the backing frame 26, a flat tie 84 is provided at multiple positions along the interface 86 between adjacent units 12. Generally, commercially-available backing frames 26 include sections that are three feet by eight or nine feet. Further, five to six flat ties 84 are generally used at each interface 86 between adjacent units 12.
As shown, the flat tie 84 has a first end 88 at the wallboard 14 and a second end 90 at the backing frame 26. Further, a hole 92 is provided at each end 88, 90 of the tie 84. Because the unit 12 lacks sufficient strength to hold the tie 84 directly, a brace 94 is positioned on the exterior surface 20 of the wallboard 14 of adjacent units 12 along both sides of the interface 86. For purposes of the present invention, the braces 94 may extend for the entire height of the units 12. As shown, each brace 94 is provided with a plurality of holes 96 for interconnection with the first end 88 of the flat tie 84. Specifically, a pin 98 is passed through the hole 92 in the first end 88 of the flat tie 84 and the selected holes 96 in the braces 94. Also a wedge 100 is used between the pin 98 and the unit 12 to hold the pin 98 in place.
In FIG. 4B, it can be seen that the second end 90 of the flat tie 84 is connected to the backing frame 26. Specifically, the backing frame 26 includes a pair of tabs 102 formed with holes 104 for alignment with the hole 92 in the second end 90 of the flat tie 84. As shown, a pin 106 passes through the holes 92, 104 to engage the flat tie 84 to the backing frame 26. As can be seen from FIG. 4B, the flat tie 84 maintains the distance 108 between the unit 12 and the backing frame 26. As a result, the distance 108 may be selected to ensure that the concrete wall 38 has the desired thickness.
As shown in FIG. 4A, the flat tie 84 includes an engineered weakness 110 at its second end 90. Structurally, the engineered weakness 110 may be a pair of notches that reduce the width of the flat tie 84. As a result, after the backing frame 26 is removed from the concrete wall 38, the exposed second end 90 of the flat tie 84 may be easily separated from the rest of the flat tie 84 embedded in the concrete wall 38. Specifically, the second end 90 of the flat tie 84 may be hammered, causing it to break at the engineered weakness 110. As a result, the flat tie 84 is not exposed when the concrete wall 38 is finished.
Referring now to FIGS. 5A-5C, an alternative interconnection between the units 12 and the backing frame 26 is illustrated. Specifically, FIG. 5A provides a perspective view of a single unit 12 for clarity, while FIGS. 5B and 5C show two embodiments for connecting adjacent units 12 to a backing frame 26, after formation of the concrete wall 38.
Cross-referencing FIGS. 5A-5C, flat ties 84 are used to interconnect the units to the backing frame 26. Unlike the flat ties 84 of FIGS. 4A and 4B, the flat ties 84 illustrated in FIGS. 5A-5C do not require the additional use of braces. Specifically, each flat tie 84 in FIGS. 5A-5C includes an end plate 112 at its first end 88 for mounting to adjacent units 12. Preferably, the end plate 112 is about three inches by three inches.
For the flat tie 84 a illustrated in FIGS. 5A and 5B, the end plate 112 a is U-shaped and has a central portion 114 and two legs 116. As shown, the central portion 114 abuts the exterior surface 20 of the wallboard 14 of adjacent units 12. Further, each leg 116 is received within a slot 118 formed in the wallboard 14 of each adjacent unit 12. As a result, the end plate 112 is secured to each unit 12 and distributes stress on each wallboard 14. In order to utilize a plurality of end plates 112 having legs 116, the units 12 may be provided with slots 118 every twelve to sixteen inches along each interface 86.
Alternatively, the flat tie 84 b may have an end plate 112 b as illustrated in FIGS. 5A and 5C. Specifically, the end plate 112 b is planar and includes apertures 120 for receiving fasteners 122 such as nails or screws. As shown in FIGS. 5A and 5C, the end plate 112 b abuts the exterior surface 20 of the wallboard 14 and the fasteners 122 are driven into the insulation board 16. This design is particularly effective for wallboards 14 constructed from OSB because the OSB material holds nails and screws well.
Still cross-referencing FIGS. 5A-5C, the flat ties 84 are secured to the insulation board 16 of the units 12 with intermediate plates 124. As identified in FIG. 5B, the intermediate plates 124 are substantially U-shaped with a central portion 126 and teethed wings 128. As shown, the wings 128 extend through the face 24 into the insulation board 16.
Referring now to FIG. 6A, it can be seen that the central portion 126 of the intermediate plate 124 forms an opening 130 for receiving the flat tie 84 (shown in FIGS. 5A-5C). In this embodiment, it is preferred that the flat tie 84 include graduated indentations (not illustrated) for engagement with the intermediate plate 124. In FIG. 6A, the central portion 126 of the intermediate plate 124 forms a slot 131 parallel to the opening 130. As further shown in FIG. 6A, a clip 132 is also provided to lock the intermediate plate 124 in position. Structurally, the clip 132 includes a substantially planar main portion 134 having a first edge 136 and a second edge 138. At the first edge 136, two curvilinear arms 140 extend from the main portion 134 and curve generally in the direction of arrow 142. Further, the two arms 140 are distanced from one another to define a gap 144 in conjunction with the first edge 136 for receiving the flat tie 84. As shown in FIG. 6A, the clip 132 further includes a tab 146 that extends from the second edge 138 of the main portion 134 in the direction of arrow 148, i.e., opposite the direction of arrow 142.
In FIGS. 6B and 6C, a cross section view of the intermediate plate 124 and clip 132 is provided along line 6-6 in FIG. 6A, showing the intermediate plate 124 and clip 132 in use. Cross-referencing FIGS. 6A and 6B, the flat tie 84 is received within the gap 144 of the clip 132, and the clip 132 is slid along the flat tie 84 until it contacts the intermediate plate 124. Then, as shown in FIG. 6C, the tab 146 of the clip 132 is forced through the slot 131 of the intermediate plate 124. This engagement mechanically fastens the intermediate plate 124 in connection with the insulation board 16. Thereafter, the flat tie 84 may be secured to the backing frame 26.
Referring now to FIGS. 7A and 7B, an alternative interconnection between adjacent units 12 and the backing frame 26 is illustrated. As shown in FIG. 7A, a bracket 150 includes a planar portion 152 that extends along an axis 154 from a first end 156 to a second end 158. At each end 156, 158, the bracket 150 is provided with apertures 160. Further, the bracket 150 forms a slot 162 which extends substantially perpendicular to the axis 154. As shown, the bracket 150 includes an upright portion 164 with a length perpendicular to the axis 154, and a width perpendicular to the axis 154. Structurally, the upright portion 164 defines a channel 166 that is aligned with the slot 162. Further, the upright portion 164 includes an opening 168 parallel to the axis 154 for providing access to the channel 166. Preferably, the bracket 150 has a length of fourteen inches and a width of at least two-and-one-half inches, preferably three inches.
As shown in FIG. 7B, the bracket 150 is positioned on the exterior surfaces 20 of the wallboards 14 of adjacent units 12. Further, the channel 166 and slot 162 (identified in FIG. 7A) are aligned with the interface 86 between the adjacent units 12. As a result, the flat tie 84 can pass through the channel 166 and slot 162 (in the direction of arrow 169 in FIG. 7A), along the interface 86 and into connection with the backing frame 26. As shown, a pin 170 is passed through the opening 168 (shown in FIG. 7A) to hold the flat tie 84 relative to the bracket 150. Cross-referencing FIGS. 7A and 7B, fasteners 172 such as nails or screws are driven through the apertures 160 at the ends 156, 158 of the planar portion 152 of the bracket 150 into studs 42 located within the units 12.
Referring now to FIGS. 8A and 8B, a flat tie sleeve 174 is illustrated. In practice, the flat tie sleeve 174 is intended to provide an additional location for a flat tie 84 (in addition to along the interface 86 between adjacent units 12. Structurally, the sleeve 174 includes a planar base portion 176 and a sleeve portion 178 that defines a pathway 180 through the sleeve 174. As shown in FIG. 8B, the sleeve portion 178 is forced through the wallboard 14 and into the insulation board 16 of a unit 12. Further, the base portion 176 abuts the wallboard 14. As a result, the sleeve 174 provides the pathway 180 through the wallboard 14 and a flat tie 84 may be passed through the unit 12 at any desired location. In other words, placement of flat ties 84 is not limited to interfaces 86 between adjacent units 12. This ability is particularly beneficial when the widths of the wallboards 14 do not correspond to the widths of the backing frame 26, or around corners.
While the particular Wall Construction System as herein shown and disclosed in detail is fully capable of obtaining the objects and providing the advantages herein before stated, it is to be understood that it is merely illustrative of the presently preferred embodiments of the invention and that no limitations are intended to the details of construction or design herein shown other than as described in the appended claims. It is noted that, while the dimensions represented in this description are merely illustrative and not limiting, they are intended to provide for ease of use with backing frames constructed from presently commercially-available aluminum forms.

Claims

1. A wall construction system comprising:

a plurality of pre-manufactured units, with each unit including a wallboard having a first surface and an opposite second surface substantially parallel thereto, wherein each unit further comprises an insulation board mounted to the second surface of the wallboard and extending therefrom to a face substantially parallel to the second surface of the wallboard;

a temporary backing frame distanced from the face of the insulation board to establish a cavity therebetween; and

a plurality of ties for supporting the units at a desired distance from the backing frame for receiving concrete in the cavity to create a concrete wall, wherein the backing frame is removed after formation of the concrete wall, and wherein the pre-manufactured units are permanently bonded to the concrete wall.

2. A system as recited in claim 1 wherein the first surface of each wallboard forms at least one groove for receiving a stud for bracing during formation of the concrete wall, with said groove receiving utility features after the stud is removed.

3. A system as recited in claim 2 wherein each unit defines a conduit extending between grooves for receiving utility features.

4. A system as recited in claim 1 wherein each unit further comprises at least one stud parallel to the surfaces and positioned between the insulation board and the wallboard adjacent the second surface of the wallboard.

5. A system as recited in claim 1 further comprising a means for interconnecting adjacent units.

6. A system as recited in claim 5 wherein the interconnecting means includes a notch formed between the wallboard and the insulation board at a first end of each unit and a reciprocating protrusion formed by the insulation board at a second end of each unit.

7. A system as recited in claim 1 further comprising fasteners for mounting the wallboard to the insulation board.

8. A system as recited in claim 7 wherein each fastener includes a shaft having a proximal end and a distal end, with a head mounted to the proximal end, wherein the shaft passes through the wallboard and the insulation board with the head abutting the first surface of the wallboard, and wherein a receiver engages the distal end of the shaft to hold the wallboard and insulation board therebetween.

9. A system as recited in claim 1 wherein an interface is established between each pair of adjacent pre-manufactured units, wherein each tie is positioned at an interface with a first end at the wallboard of the pre-manufactured unit and a second end at the backing frame.

10. A system as recited in claim 9 wherein each tie includes an engineered weakness at the second end to provide for separation of the second end from the tie after the backing plate has been removed.

11. A system as recited in claim 9 further comprising a brace positioned on the first surface of each wallboard at the interface, with the braces on adjacent pre-manufactured units surrounding the respective tie for connection therewith.

12. A system as recited in claim 9 further comprising a bracket positioned on the first surfaces of adjacent pre-manufactured units and spanning the interface therebetween, with the bracket forming an aperture for positioning the respective tie in the interface.

13. A system as recited in claim 9 wherein each tie includes an end plate at the first end for mounting to adjacent pre-manufactured units.

14. A system as recited in claim 13 wherein the end plate of each tie is U-shaped and has a central portion and two legs, wherein the central portion abuts the first surface of the wallboard of each adjacent pre-manufactured unit, and wherein each leg is received within a slot formed in the wallboard of each adjacent pre-manufactured unit.

15. A system as recited in claim 1 further comprising a plurality of intermediate plates positioned at the face of the insulation board, wherein each intermediate plate includes an opening, with a respective tie passing through the opening, and wherein each intermediate plate includes means for engaging the insulation board.

16. A system as recited in claim 1 further comprising a tie sleeve defining a channel, wherein the tie sleeve is forced through the wallboard and into the insulation board at a desired position relative to the backing frame, and wherein a tie is positioned in the sleeve with a first end at the wallboard of the pre-manufactured unit and a second end at the backing frame.

17. A wall construction which comprises:

a substantially flat wallboard having a first surface and a second surface, wherein the second surface is substantially parallel to the first surface;

an insulation board mounted against the second surface of the wallboard;

a concrete wall formed against the insulation board to position the insulation board between the wall board and the concrete wall, wherein the concrete wall is formed with an external surface substantially parallel to the first surface of the wall board; and

a plurality of ties for holding the wall board against the insulation board and for positioning a backing frame at a distance from the insulation board during formation of the concrete wall, wherein the ties are subsequently used for anchoring the combination of wall board and insulation board against the concrete wall after removal of the backing frame.

18. A method for constructing a concrete wall comprising the steps of:

arranging a plurality of pre-manufactured units, with each unit including a wallboard having a first surface and an opposite second surface substantially parallel thereto, wherein each unit further comprises an insulation board mounted to the second surface of the wallboard and extending to a face substantially parallel to the second surface for bounding concrete during formation of the concrete wall;

erecting a temporary backing frame distanced from the face of the insulation board;

supporting the units at a desired distance from the backing frame to establish a cavity therebetween;

pouring concrete into the cavity and setting the concrete therein to construct the concrete wall; and

removing the backing frame after formation of the concrete wall, wherein the pre-manufactured units are permanently bonded to the concrete wall.

19. A method as recited in claim 18 wherein the arranging step is accomplished by interconnecting adjacent pre-manufactured units.

20. A method as recited in claim 18 wherein the supporting step is accomplished by connecting each pre-manufactured unit to a first end of a respective tie and connecting the backing frame to a second end of the respective tie, and wherein the method further comprises the step of separating each second end from each tie after the backing frame is removed.