Abstract: A wall panel may have a rigid layer, a first insulation layer made from a two-part rigid urethane pour foam, and a second insulation layer made from a phase change material. The first insulation layer may be chemically bonded to the rigid layer and may also be bonded to the phase change layer. The first insulation layer may be positioned between the second insulation layer and the rigid layer. The rigid layer may be a finished surface or a veneer layer may be applied to the rigid layer.

Abstract: A structural insulation sheathing (SIS) comprises: a first upper facial member, a second lower facial member and an insulation member in intimate, planar contact with both the first upper member and second lower members. The first and second facial members are made from the same reinforcing fiber material less than about 3/16 inch thick. The insulation member comprises a foam layer, said structural insulation sheathing having at least 10×, preferably 15 to 20 times greater strength than its individual components.

Abstract: A concrete building block for masonry block walls is formed with first, second and third spaced parallel rectangular face shells, where the second face shell is intermediate the first and third face shells. First and second vertical end cross webs connect the first and second face shells and first and second spaced intermediate vertical cross webs connect the second and third face shells. Insulating inserts include end protrusions extending outwardly at the top edge thereof to fit into notches of the cross webs and include cutouts to accommodate mortar crumbs. The inserts further include longitudinal notches along the entire bottom edges and longitudinal notches along the entire top edges wherein said longitudinal notches along a bottom edge are dimensioned to mate with longitudinal notches along a top edge of neighboring ones of the insulating inserts creating an overlap that serves to (i) insulate against temperature transfer and (ii) provide a sound barrier.

Abstract: A steel wall stud has a rear wall, two parallel side walls, each side wall having a front end wall that projects away from interior cavity formed by the rear and side walls.

Abstract: A wall panel may have a rigid layer, a first insulation layer made from a two-part rigid urethane pour foam, and a second insulation layer made from a phase change material. The first insulation layer may be chemically bonded to the rigid layer and may also be bonded to the phase change layer. The first insulation layer may be positioned between the second insulation layer and the rigid layer. The rigid layer may be a finished surface or a veneer layer may be applied to the rigid layer.

Abstract: A structural panel is manufactured from at least two generally parallel and spaced-apart thin-shell cementitious skins that are joined by a truss matrix. The elements creating the truss matrix, being the truss, the face mesh, and the insulating core, are selected to meet the structural loads to be placed thereon. The thickness of each cementitious skin is selected to meet the structural loads to be placed thereon.

Abstract: A precast concrete wall structure and method for forming a wall structure are disclosed. A frame is positioned within a casting bed. The frame comprises first and second spaced apart metal tracks which are interconnected by a plurality of metal studs. The casting bed has a plurality of surfaces defining a generally rectangular interior area. A forming member is placed above the frame, the forming member comprising a layer of insulating material defining a plurality of integrally-formed rectangular protrusions extending in a parallel and spaced-apart relationship to one another to define a plurality of rectangular-shaped channels therebetween. Uncured concrete is placed within the casting bed and allowed to cure.

Abstract: A prefabricated insulated building panel features a sheet of rigid thermally insulating material, an inner structural layer connected to one face of the insulating material, and an outer layer of cured composite cementitious material connected to an opposite second face of the rigid insulating material with a thickness allowing the cured composite cementitious layer to be supported at the insulating material by bonding action therewith. The panel also features channels at the interface between the composite cementitious outer layer and the insulating material formed by grooves in the second face of the insulating material extending to a periphery of the panel. These channels afford pressure equalization and moisture drainage capabilities to the panel. Additionally, the inner structural layer comprises a layer of cured composite cementitious material bonded to the insulating material, which has a thickened edge portion along the periphery of the panel compared to strengthen the panel.

Abstract: A method of and system for producing Class-A fire-protected oriented strand board (OSB) sheets. Each Class-A fire-protected OSB sheet has: a core medium layer made of wood pump, binder and/or adhesive materials; a pair of OSB layers bonded to the core medium layer; a clean fire inhibiting chemical (CFIC) coating on the surface of each OSB layer, made from CFIC liquid applied to the surface by dipping the OSB sheet into the CFIC liquid in a dipping tank, allowing shallow surface absorption into the OSB layers and ends of the core medium layer at atmospheric pressure; and a moisture, fire and UV protection coating spray coated over the CFIC coating to provide protection against moisture, fire and UV radiation from Sunlight, which is quickly dried by passing through a drying tunnel on the production line.

Abstract: A concrete form includes a first sidewall and a second sidewall positioned in parallel and spaced relation to each other and a cross tie having opposed first and second ends, where at least the first sidewall is a removable sidewall removably secured to the first end of the cross tie. The second sidewall is removably secured to the second end of the cross tie and may be a removable sidewall or a non-removable sidewall. The concrete form also includes a spacer positioned between the first sidewall and the first end of the cross tie. The spacer may be removable along with the first sidewall. Concrete forming assemblies and methods may incorporate concrete forms as described herein.

Abstract: Insulated buildings are described. The building include: (a) a sloped roof that is a prefabricated insulated roof assembly; (b) a generally horizontally arranged flooring assembly having an end that is arranged over a wall structure and under the sloped roof assembly; (c) a sloped member that is arranged over the end of the flooring assembly that is over the wall structure, and (d) a rigid foam insulation member arranged in the cavity of the roof assembly so as to bridge a lower surface of a rigid foam insulation board in the roof assembly to the sloped member.

Abstract: An insulated interlocking superblock assembly enables the quick and convenient construction and support of structural elements of a building. At least one all-structure is utilized to construct a wall for the building. The wall-structure includes a planar base body, a first lining, a second lining, and a plurality of interlocking features. The planar base body is constructed out of a plurality of blocks. Further, the plurality of blocks is arranged into a grid pattern to form a continuous planar structure. A corresponding feature from the plurality of features engages an arbitrary block to an adjacent block, thereby allowing the planar base body to be rapidly erected. The first lining is attached along a first lengthwise edge of the planar base body. Similarly, the second lining is attached along a second lengthwise edge of the planar base body, thereby allowing the attachment of the ceiling and the floor.

Abstract: A structural insulated building unit is provided for constructing a building. The structural insulated building unit includes an insulating core, first and second cementitious panels, and a connecting portion. The insulating core is defined by multiple sides and opposing first and second faces. The first and second cementitious panels are coupled to the first and second faces of the insulating core. The connecting portion is provided on one of the sides of the insulating core, and aligns the structural insulated building unit with an adjacent structural insulated building unit having a complementary connecting portion when constructing a building.

Abstract: A reinforcing element includes a first and a second reinforcing mat having metal mat rods, which are welded at angles to each other at junction points, which reinforcing mats are held spaced apart from each other at a normal distance by rod-shaped spacers with respect to the first mat plane and the second mat plane of the reinforcing mats. The spacers are metal and are permanently connected to individual mat rods of the first and second reinforcing mat by welding connections, preferably resistance welding connections, wherein at least individual spacers protrude outward at least beyond the first mat plane of the first reinforcing mat in a direction pointing away from the second reinforcing mat by a first protrusion length. Further, a double wall is furnished with the reinforcing element and a method produces the reinforcing element and the double wall.

Abstract: A prefabricated building product structure made of sintered expanded polystyrene includes a composite assembly formed by aggregating steel to the sintered expanded polymeric mass, preferably of high density, and by embedding therein rod-like steel elements, preferably pre-assembled and forming a cage of electrowelded elements. A method of related production includes positioning the rod-like steel elements, preferably pre-assembled forming a cage of electrowelded elements, in the mold for the expansion of the polystyrene, pouring in the mold incoherent granules or pearls obtained from the polymerization of the styrene, with grain size and volume appropriate for the attainment of a high density finished product, expanding and sintering or amassing the incoherent polystyrene through contact with water vapor at a temperature higher than ninety degrees centigrade, and trapping the armor in the monolithic mass thus obtained to attain a solid geometry, according to the mold, of armored sintered expanded polystyrene.

Abstract: A method of installing an insulation system proximate a jamb having steps of: providing a stud member adjacent an opening in a wall; providing and positioning an angle jamb member having a front panel portion and a side panel portion; extending a fastener through the angle jamb and into the stud member; providing a plurality of spaced apart bracket members; positioning and attaching the bracket members in a substantially perpendicular orientation relative to the stud member; and positioning each of a plurality of insulation panels between adjacently positioned and spaced apart bracket members.

Abstract: Disclosed herein is a fiber reinforced cementitious composition comprising a cementitious binder and at least one synthetic inorganic reinforcing fiber type, wherein the synthetic inorganic reinforcing fiber type comprises at least one of a man-made mineral fiber type such as basalt fibers, an aluminosilicate wool fiber type or an alkaline earth silicate wool fiber type.

Abstract: A composite material is provided. The composite material includes a plurality of beads in which each bead has a diameter. The composite material also including a plurality of fibers in which each fiber has a length and a width. The composite material further includes a resin binder. In the composite material, the length of each fiber is greater than the width of each fiber, and the width of each fiber is less than the diameter of each bead.

Abstract: An interlocking and insulated construction block includes a first pair of parallel, opposing sides and a second pair of parallel, opposing sides extending normal to the first pair of opposing sides. At least one cavity or recess extends through the construction block and includes a first volume of thermal insulation material. One or both sides of the first pair of opposing sides includes a pair of staggered engaging members or a pair of staggered receiving members configured to engage or lock with a mating pair of engaging members or receiving members of another insulated construction block. A plurality of different embodiments of the interlocking and insulated construction blocks may be provided in a set, and provide for mortar-less construction of walls due to their interlocking nature.

Abstract: The invention comprises a relatively lightweight cementitious-based material panel. The cementitious-based material panel comprises a foam insulating panel having a first surface and a second surface; a first structural layer of cementitious-based material formed on the first surface of the foam insulating panel and affixed thereto; and a second non-structural layer of cementitious-based material formed on the second surface of the foam insulating panel and affixed thereto. The second non-structural layer of cementitious-based material is substantially thinner than the first structural layer of concrete. The second non-structural layer of cementitious-based material is preferably formed from polymer modified concrete, plaster or mortar. A method of making the cementitious-based material panel is also disclosed.

Abstract: A construction panel comprising a rigid insulation layer having an interior surface and an exterior surface, an outer concrete wythe secured to the exterior surface of the insulation layer, an inner concrete wythe secured to the interior surface of the insulation layer, a grid system which ties the outer concrete wythe to the inner concrete wythe and a capillary tube system located within the construction panel wherein liquid is passed through the tubing in order to increase or decrease the temperature of the construction panel.

Abstract: A process of fabricating a static structure including an interior volume that includes the steps of mixing coal combustible residual (CCR) with structural reinforcing materials to form a construction material and utilizing the construction material to fabricate exterior enclosure-forming components of the static structure. The enclosure-forming components are sufficiently reinforced, enhanced and/or thick to provide protection against exterior forces directed against the structure.

Abstract: The invention comprises a product. The product comprises a foam insulating panel, the panel having a first primary surface and an opposite second primary surface, wherein the foam insulating panel defines at least one recessed channel in the first primary surface, the at least one recessed channel being sized and shaped to provide a mold for a structural reinforcing member. The product also comprises a concrete panel formed on the first primary surface and filling the at least one recessed channel so as to provide a structural reinforcing member for the concrete panel. The product further comprises an elongate anchor member in the foam insulating panel and extending from the first primary surface of the foam insulating panel into the concrete panel. A method of making a composite reinforced insulated concrete structure is also disclosed.

Abstract: A composite structural building panel has a first concrete layer and a second concrete layer in spaced apart relationship with one another so as to receive an insulation layer spanning between the first concrete layer and the second concrete layer. A plurality of shear connectors are individually supported to extend through respective bores in the insulation layer between opposing first and second ends of the shear connector which are entirely embedded in the first and second concrete layers respectively. At least some of the shear connectors are oriented at an inclination to a normal axis of the insulating layer.

Abstract: According to one embodiment, an insulated structure includes a frame comprising a plurality of wall studs coupled together and a plurality of foam boards attached to the frame to form a continuous insulative wall. A plurality of fasteners attaches the foam boards to the frame. Each fastener includes an elongate shaft and a cap. The elongate shaft is configured to penetrate through a foam board and into a wall stud to couple the components together. The cap is configured to be positioned atop a foam board to distribute a load relatively evenly to the foam board. A sealing tape is applied across seams between adjacent foam boards and over the fasteners' caps to seal the wall. A sealing caulk is applied to secondary fasteners and penetrations to seal the wall. In some embodiments, the structure has a fastener density of about 1 fastener per 243 in2 of foam board.

Abstract: Approaches herein describe reinforced wood plywood panels comprising multiple layers of wood veneer alternated by wire mesh bonded with glue, epoxy or other approved adhesive via pressure and heat. The number of wire mesh layers number greater than two and separated by wood veneer layers. By creating alternating directions of wire mesh the rigidity and weight barring capabilities of the plywood is greatly enhanced while keeping its weight to a minimum.

Abstract: The subject matter of the invention is an energy and weight efficient building block that has a prismatic body made from a post-hardening material (1). The invention is characterized in that a flexible static insert structure (2) is placed inside the body. Furthermore, the subject matter of the invention is the manufacturing and application process for the production of the building block. Manufacturing is characterized in that a static insert structure (2) is placed into the form body (16), then the form body (16) is filled up with the stirred post-hardening material (1) or at first the stirred post-hardening material (1) is poured into the form body (16), and the static insert structure (2) is placed therein afterwards, then the building block with the static insert structure (2), embedded in the post-hardening material (1) is let to dry until set in the form body (16) itself or after being taken out thereof.

Abstract: Methods are provided for repairing an existing structure to cover at least a portion of the existing structure with a repair structure. Such methods comprise mounting one or more standoff retainers to the existing structure; coupling one or more standoffs to the standoff retainers such that the standoffs extend away from the existing structure; coupling one or more cladding panels to the standoffs such that the panels are spaced apart from the structure to provide a space therebetween; and introducing a curable material to the space between the panels and the existing structure, the panels acting as at least a portion of a formwork for containing the curable material until the curable material cures to provide a repair structure cladded, at least in part, by the panels. Corresponding apparatus for effecting such methods are also provided.

Abstract: The invention relates to an electrical panel heating device and to a method and a material for the production thereof; the panel heating device is produced by curing a liquid or pasty material, comprising at least one inorganic binding agent, for example cement and/or gypsum, at least one electrically non-conductive additive, for example sand and/or rock flour, and at least one further additive composed of electrically conductive particles, for example carbon fibers and/or trips; after mixing this material in the liquid or pasty state, it is processed to form a product in the form of a panel which is provided with low-impedance contacts for feeding in a current distributed over an panel.

Abstract: A building panel structure is disclosed, in which building panels are used to form a structure. Roof panels and roof panel tiles are used to form the roof of the structure. The roof panel includes a core and a coating covering a portion of the core. In some embodiments the core consists of a frame and at least one insulating structural block. The insulating structural blocks can be encapsulated polystyrene (EPS) foam blocks. In some embodiments the coating includes ceramic material. In some embodiments the coating includes a first layer and a second layer. In some embodiments the coating materials are formed into a roof tile before they are coupled to the roof panel core. The roof panel and the roof tile can be shaped, formed, and colored to look like traditional roof tiles such as shake roof tiles or Spanish roof tiles.

Abstract: A building panel structure is disclosed, in which building panels are used to form a structure. The building panel includes a core and a coating covering a portion of the core. In some embodiments the core consists of a frame and at least one insulating structural block. The insulating structural blocks can be encapsulated polystyrene (EPS) foam blocks. In some embodiments the coating includes ceramic material. In some embodiments the coating includes a scratch layer and a main brown layer. In some embodiments the scratch layer and the main brown layer are interdigitated to increase the strength and durability of the coating and the building panel. In some embodiments the building panel includes a construction board formed separate from the core. The construction board is formed of coating mixtures and applied to the core after the coating mixtures have cured.

Abstract: A method of building insulated concrete walls by using concrete that exerts low hydrostatic pressure and a special stud that supports and secures simple rectangular shaped insulation boards used as stay-in-place forms on one side of the wall. The construction process begins with the vertical positioning of the studs and insulation boards on one side of the wall. Steel reinforcement is placed next to the insulation boards and low hydrostatic pressure producing concrete is cast against the reinforcement, the exposed part of the stud and the insulation board. As the concrete is placed it embeds the exposed part of the stud and when the concrete cures it causes the stud to be bonded to the concrete and sufficiently rigid to secure the insulation board and wallboard or other cladding that may be affixed to the stud.

Abstract: Ceramic floors and methods of making thereof such that the ceramic tiles are quickly and easily removable from the floor substrate and replaceable at a future date. A ceramic tile floor is laid by releasably adhering a sheet to a floor substrate and bonding at least one ceramic tile to the sheet. A plurality of pre-fabricated articles each comprising a sheet and one or more ceramic tiles bonded to the sheet are laid onto the floor substrate with sheet edges abutting, and the sheets are releasably adhered to the floor substrate. The tile edges are set inwardly from the sheet edges so that a tile of one article is spaced from a tile of another article when the articles are laid. A non-Portland cement grout, preferably urethane grout, is provided between adjacent tiles.

Abstract: The invention comprises a method of forming a concrete structure. The method comprises placing plastic concrete in a form of a desired shape, encasing the concrete in insulating material having insulating properties equivalent to at least 1 inch of expanded polystyrene and allowing the plastic concrete to at least partially cure inside the insulating material. An insulated concrete form and a method of using the insulated concrete form are also disclosed.

Abstract: The invention comprises a product. The product comprises a composite panel comprising a foam insulating panel having a first primary surface and an opposite second primary surface, and a first layer of a polymeric elastomeric material on the first primary surface such that at least a portion of a first layer of reinforcing material is at least partially embedded in the polymeric elastomeric material. The composite panel also comprises a fastener for attaching the composite panel to a framing structure, wherein the fastener comprises a washer and wherein at least a portion of the first layer of a polymeric elastomeric material and the first layer of reinforcing material are disposed between the washer and the first primary surface. A method of making and using the composite panel is also disclosed.

Abstract: A low cost method for constructing barriers to eliminate a flat or low pitch roof's low spots. Puddles, if allowed to stand there, shorten the roof's life and can do structural damage to the roof deck. Each barrier includes a flexible membrane initially sized and shaped and then positioned to cover at least one low spot and substantially overlap the latter's edges. So positioned, the membrane is heat welded or otherwise joined to form a continuous watertight seal, along its outer periphery, between the membrane and an existing roof deck covering and, when the low spot is next to a parapet, the existing parapet covering as well. Filled with a solidified plastic foam sandwiched between the membrane and the existing covering(s), such barriers, once they have been mechanically fastened to the roof deck and, if necessary, to the parapet, permanently direct storm water away from each of the roof's barrier-covered low spots.

Abstract: The invention comprises a foam insulating panel having an outer surface and a reinforcing member adhered to at least a portion of the outer surface of the foam insulating panel. An insulated concrete form and a method of using the insulated concrete form are also disclosed.

Abstract: An insulated window buck with integrated fastening and anchor elements for a self aligning cut or molded insulated concrete form (ICF) window buck. The insulated window buck with integrated fastening and anchor generally includes an insulated ICF window and door buck made with multiple components with a configuration that allows for the use of various type of materials' on the face and edges of the buck, and have the ability to friction fit to the inside of an ICF wall so as no external bracing or strapping is needed to keep the buck aligned with the ICF wall during concrete placement. Having a firm insulation material component on the internal portion of the buck is an integral part of the invention in that through the use of recesses in the insulation material the fluid concrete can flow into these recesses and make a permanent bond to the buck.

Abstract: A waffle slab interlocking wall, including slab columns, slab beams, and interlocking building blocks. At least one interlocking building block is embedded in a space enclosed by at least one slab column and at least two slab beams or by at least two slab columns and at least one slab beam. The interlocking building block includes an external faceplate and an internal faceplate which are spliced by a connecting piece.

Abstract: A dividing wall panel comprises at least one elongate, fire-resistant hardboard sheet, and an elongate insulating foam slab joined to the at least one hardboard sheet. The insulating foam slab is formed from a molded, continuous foam body compressed either during molding or after molding, or both, to improve its sound insulation properties.

Abstract: The invention comprises a relatively lightweight cementitious-based material panel. The cementitious-based material panel comprises a foam insulating panel having a first surface and a second surface; a first structural layer of cementitious-based material formed on the first surface of the foam insulating panel and affixed thereto; and a second non-structural layer of cementitious-based material formed on the second surface of the foam insulating panel and affixed thereto. The second non-structural layer of cementitious-based material is substantially thinner than the first structural layer of concrete. The second non-structural layer of cementitious-based material is preferably formed from polymer modified concrete, plaster or mortar. A method of making the cementitious-based material panel is also disclosed.

Abstract: The present invention is directed to glass-fiber-reinforced concrete compositions that may be sprayed, methods of preparing and applying such compositions, devices used in preparing and applying such compositions, and composite structural insulated panels that may be fabricated using such compositions, related methods of manufacture, and building systems employing such panels.

Abstract: Hydraulic cement compositions that include a carbonate compound composition, e.g., a salt-water derived carbonate compound composition containing crystalline and/or amorphous carbonate compounds, are provided. Also provided are methods of making and using the hydraulic cements, as well as settable compositions, such as concretes and mortars, prepared therefrom. The cements and compositions produced therefrom find use in a variety of applications, including use in a variety of building materials and building applications.

Abstract: The invention comprises a product. The product comprises a foam insulating panel, the panel having a first primary surface and an opposite second primary surface, wherein the foam insulating panel defines at least one recessed channel in the first primary surface, the at least one recessed channel being sized and shaped to provide a mold for a structural reinforcing member. The product also comprises a concrete panel formed on the first primary surface and filling the at least one recessed channel so as to provide a structural reinforcing member for the concrete panel. The product further comprises an elongate anchor member in the foam insulating panel and extending from the first primary surface of the foam insulating panel into the concrete panel. A method of making a composite reinforced insulated concrete structure is also disclosed.

Abstract: A load transfer device is provided to connect concrete elements including, but not limited to, sandwich and double wall panel wythes, roof, floor, balcony and canopy members, and pavement. The device may be used to connect and transfer loads between the components of sandwich and double wall panels. The device includes two load transfer members positioned at an angle with respect to one another. Additionally provided are a retention housing for retaining one or more load transfer members at their angled positions and a depth locating means for retaining one or more load transfer members at their proper depth. Also provided are sandwich wall panels and double wall panels employing the load transfer device and methods for manufacturing sandwich wall panels and double wall panels employing the disclosed load transfer device.

Abstract: A building panel structure is disclosed, where the building panel structure includes composite building panels. A composite building panel includes a core and a coating applied over the core. In some embodiments the core consists of a frame and one or more than one insulating structural block. The insulating structural blocks can be encapsulated polystyrene (EPS) foam blocks. In some embodiments the coating includes an inner scratch layer and an outer main brown layer. The inner scratch layer can be formed of at least two layers. The outer main brown layer can include a fiberglass mesh embedded into the outer main brown layer. A method of forming a building panel structure is disclosed which includes forming a core using a frame and one or more than block, applying an inner scratch layer to the core, and applying an outer main brown layer over the inner scratch layer.

Abstract: The present invention relates to various types of connectors used to form concrete columns and beams using a structural insulating core wall as a mold for forming column and beam molds. Some connectors can extend above the structural insulating core, used as support channels within the column and beam molds or are flange extensions of the support channels. Some connectors have grooves within the inner and outer boards so the connectors can twist and lock into the grooves while other slide within the grooves to form column and beam molds. Many connectors have air gaps at the connector flanges for additional fasteners connections. Other connectors are installed horizontally interlocking the vertical support channels and connectors together. Some connectors are full height connectors while other can be short clip or brackets that attach to other connectors.

Abstract: A composite, prefabricated panel for building construction. A panel includes a central core having a first face and a second face. The central core includes structural framing members assembled to define at least one opening. A substantially rigid insulation is disposed in the at least one opening of the structural framing members. A settable cement, which may be, for example, phosphate ceramic, is provided on each of the first face of the central core and the second face of the central core to form a first face of the panel and a second face of the panel. The insulation may define a plurality of passages, each with phosphate ceramic extending through the passage between and being monolithic with the phosphate ceramic on the first face of the central core and the phosphate ceramic on the second face of the central core. A building system with such panels is provided.

Abstract: A structural unit includes a first face shell; a second face shell positioned opposite the first face shell; at least one central web connecting the first face shell to the second face shell; a first partial web forming a gap between an end of the first partial web and a first edge of the second face shell, and defining a first cavity; and a second partial web forming a gap between an end of the second partial web and a second edge of the second face shell, and defining a second cavity.

Abstract: A building panel structure is disclosed, where the building panel structure includes composite building panels. A composite building panel includes a core and a coating applied over the core. In some embodiments the core consists of a frame and one or more than one insulating structural block. The insulating structural blocks can be encapsulated polystyrene (EPS) foam blocks. In some embodiments the coating includes an inner scratch layer and an outer main brown layer. The inner scratch layer can be formed of at least two layers. The outer main brown layer can include a fiberglass mesh embedded into the outer main brown layer. A method of forming a building panel structure is disclosed which includes forming a core using a frame and one or more than block, applying an inner scratch layer to the core, and applying an outer main brown layer over the inner scratch layer.