Abstract: Modular building methods and systems using precision machined modular panels. Standard modular panels can be used for constructing walls, floor, and roof, with transitions from wall-to-roof and wall-to-floor provided by special transition panels. All panels are pre-slotted to include a channel configured to receive flange(s) of a C-channel member. The present method progresses by assembly of a frame formed from C-channel frame members connected with overlap connections, followed by insertion of foam panels into flange(s) of the C-channel frame members, followed by insertion of another C-channel frame member into a slot on the opposite end of the panels, with such steps repeated, to form the building. Such alternating placement of panels and C-channel frame members eliminates the need for a tape measure, any independent frame for the building, and ensures the walls, floor, and roof are plumb.

Abstract: Below grade fluid containment structures, which may include a foam floor and a foam wall extending upward from the floor, the foam wall being formed from foam panels and optionally a plurality of metal splines. A foam buttress is provided as part of or adjacent to the foam wall, for reducing pressure against an exterior face of the foam wall that would otherwise be exerted by the soil, in the absence of the foam buttress, which places a top portion of the soil at an angle of repose, to minimize inward pressure. A concrete footing can be provided below the foam wall, where the splines of the wall are vertically oriented in the foam wall, with a bottom of the splines anchored into the concrete footing. The interior surface of the pool or other structure can be coated with any desired finish coating.

Abstract: The present invention is directed to below grade fluid containment structures, which may include a foam floor and a foam wall extending upward from the floor, the foam wall being formed from foam panels and optionally a plurality of metal splines. A foam buttress is provided as part of or adjacent to the foam wall, for reducing pressure against an exterior face of the foam wall that would otherwise be exerted by the soil, in the absence of the foam buttress, which places a top portion of the soil at an angle of repose, to minimize inward pressure. A concrete footing can be provided below the foam wall, where the splines of the wall are vertically oriented in the foam wall, with a bottom of the splines anchored into the concrete footing. The interior surface of the pool or other structure can be coated with any desired finish coating.

Abstract: Below grade fluid containment structures, which may include a foam floor and a foam wall extending upward from the floor, the foam wall being formed from foam panels. A granular material is provided for reducing hydraulic soil pressure against an exterior face of the foam wall that would otherwise be exerted by the soil, if the soil were allowed to be positioned up against the foam, particularly the foam wall. The well-draining granular material may be gravel, crushed stone, or the like, which provides better drainage as compared to the surrounding soil material. The interior face of the foam is coated with an elastomeric abrasion resistant impact resistant polymeric coating that seals the below grade interior space defined between the floor and the wall in a seamless water-tight configuration.

Abstract: Modular building methods and systems using precision machined modular panels. Standard modular panels are used for constructing walls, floor, and roof, with transitions from wall to roof and wall to floor provided by special transition panels. The standard panels include a channel formed configured to receive a flange of a C-channel member. The present method progresses by installation of a foam panel (or stack or row of such panels), followed by installation of a C-channel member, with the flange of such member engaged in the panels, followed by installation of an adjacent row or stack of panels, before installation of the next, adjacent C-channel member. Such alternating placement of panels and frame members eliminates the need for a tape measure, the need for any independent frame for the building, and ensures the walls, floor, and roof are square and plumb, as the precision machined panels ensure these requirements are met.

Abstract: Modular building methods and systems using lightweight modular panels, and specially configured transition panels for transitioning from wall to floor, or from wall to roof. Identically configured standard panels are used for constructing the walls, floor, and roof, with transitions from one structure to the next (e.g., wall to floor, or wall to roof). Each of the variously configured panel types includes channels (e.g., 2 pair of channels) formed through the length of the foam body, where the channels are configured to receive splines (e.g., flanges of an I-beam) therein. In the standard panel, the channels may include pairs of top and bottom channels, with the channels offset towards the respective panel major faces. In the transition panels, the channels may be similarly configured, but positioned differently to make the appropriate transition. The splines are connected to a frame, which acts as a template and transfers loads to a foundation.

Abstract: Modular building methods and systems using lightweight modular panels, and specially configured transition panels for transitioning from wall to floor, or from wall to roof. Identically configured standard panels are used for constructing the walls, floor, and roof, with transitions from one structure to the next (e.g., wall to floor, or wall to roof). Each of the variously configured panel types includes channels (e.g., 2 pair of channels) formed through the length of the foam body, where the channels are configured to receive splines (e.g., flanges of an I-beam) therein. In the standard panel, the channels may include pairs of top and bottom channels, with the channels offset towards the respective panel major faces. In the transition panels, the channels may be similarly configured, but positioned differently to make the appropriate transition. The splines are connected to a frame, which acts as a template and transfers loads to a foundation.

Abstract: Agricultural barns, warehouses, and methods for construction including a floor, walls that include foam wall panels, a wainscot of impact resistant panels at a lower portion of the wall, and a ceiling formed from foam roof panels integrated into the roof truss assembly. Once the floor, walls, and ceiling are assembled, walls and ceiling can be coated over with an abrasion resistant, impact resistant polymeric coating (e.g., akin to a truck-bed liner), tying these structures together in a seamless shell that provides sufficient elasticity to accommodate typical expansion/contraction due to daily and seasonal heating/cooling, humidity changes, etc. The sealed interior envelope allows the interior surfaces to easily be pressure washed daily, or whenever else needed. Such construction is particularly well suited to an agricultural barn or warehouse, where cattle or forklifts may run into the lower portion of the walls, and pressure washing may be a daily need.

Abstract: Agricultural barns, warehouses, and methods for construction including a floor, walls that include foam wall panels, a wainscot of impact resistant panels at a lower portion of the wall, and a ceiling formed from foam roof panels integrated into the roof truss assembly. Once the floor, walls, and ceiling are assembled, walls and ceiling can be coated over with an abrasion resistant, impact resistant polymeric coating (e.g., akin to a truck-bed liner), tying these structures together in a seamless shell that provides sufficient elasticity to accommodate typical expansion/contraction due to daily and seasonal heating/cooling, humidity changes, etc. The sealed interior envelope allows the interior surfaces to easily be pressure washed daily, or whenever else needed. Such construction is particularly well suited to an agricultural barn or warehouse, where cattle or forklifts may run into the lower portion of the walls, and pressure washing may be a daily need.

Abstract: The present invention is directed to below grade fluid containment structures, which may include a foam floor and a foam wall extending upward from the floor, the foam wall being formed from foam panels. A granular material is provided for reducing hydraulic soil pressure against an exterior face of the foam wall that would otherwise be exerted by the soil, if the soil were allowed to be positioned up against the foam, particularly the foam wall. The well-draining granular material may be gravel, crushed stone, or the like, which provides better drainage as compared to the surrounding soil material. The interior face of the foam is coated with an elastomeric abrasion resistant impact resistant polymeric coating that seals the below grade interior space defined between the floor and the wall in a seamless water-tight configuration.

Abstract: Modular building methods and systems using lightweight modular panels, and specially configured transition panels for transitioning from wall to floor, or from wall to roof. Identically configured standard panels are used for constructing the walls, floor, and roof, with transitions from one structure to the next (e.g., wall to floor, or wall to roof). Each of the variously configured panel types includes channels (e.g., 2 pair of channels) formed through the length of the foam body, where the channels are configured to receive splines (e.g., flanges of an I-beam) therein. In the standard panel, the channels may include pairs of top and bottom channels, with the channels offset towards the respective panel major faces. In the transition panels, the channels may be similarly configured, but positioned differently to make the appropriate transition. The splines are connected to a frame, which acts as a template and transfers loads to a foundation.

Abstract: Modular building methods and systems using lightweight foam modular panels. Each panel includes one or more channels formed through the length of the foam body, where the channels are configured to receive splines therein. The channels may include pairs of top and pairs of bottom channels, each channel being offset from the center of the foam body, so that the channels are oriented towards the respective panel faces. Splines may also be positioned along the top and bottom of the panel (such splines forming a web center portion of an I-beam). In combination with the splines in the top and bottom channels, these web center portion splines form horizontally extending I-beams at the top and bottom of each panel, so that stacked panels include a horizontally extending I-beam there between. Side-by-side panels include vertical posts there between, such that the system forms a post and beam construction system.

Abstract: Modular building methods and systems using lightweight modular panels, and specially configured transition panels for transitioning from wall to floor, or from wall to roof. Identically configured standard panels are used for constructing the walls, floor, and roof, with transitions from one structure to the next (e.g., wall to floor, or wall to roof). Each of the variously configured panel types includes channels (e.g., 2 pair of channels) formed through the length of the foam body, where the channels are configured to receive splines (e.g., flanges of an I-beam) therein. In the standard panel, the channels may include pairs of top and bottom channels, with the channels offset towards the respective panel major faces. In the transition panels, the channels may be similarly configured, but positioned differently to make the appropriate transition. The splines are connected to a frame, which acts as a template and transfers loads to a foundation.

Abstract: Modular building methods and systems using lightweight foam modular panels which are based on fractal geometry. Each panel includes one or more channels formed through the foam body, where the channels are centered between adjacent fractal modules of the overall modular panel. The channels are configured to receive splines (e.g., dimensional lumber) therein. The entire system is based on dimensional lumber sizing. The rectangular panels include a pre-cut slot extending through one face, to the channel, while a score line is formed in the opposite face, aligned with the pre-cut slot of the opposite face. The panels may be easily and quickly cut with a box knife to reduce the number of fractal modules in a given panel, to provide a smaller panel still based on such fractal geometry. Such a cut is made along the score line, where the foam is no more than 2 inches thick.

Abstract: Column and panel concrete fence systems and related methods of construction. Such a method may include placing posts into respective concrete footings, and attaching a 4-arm bracket to each post. The concrete column may be provided in two initially separate portions e.g., each corresponding to a “front” or “back” face of the fence. One of the portions (e.g., corresponding to the front or back of the fence) is attached to a given post, supported on one lateral arm of each bracket. The concrete panel may then be advanced into place, and the other portion of the column is attached to the post, over the first column portion that was already attached to the post. The 2nd portion of the concrete panel is supported on the other lateral arm of the brackets. The panel itself is supported on a middle arm of the bracket, between the lateral column-supporting arms.

Abstract: Modular building methods and systems using lightweight foam modular panels which are based on fractal geometry. Each panel includes one or more channels formed through the foam body, where the channels are centered between adjacent fractal modules of the overall modular panel. The channels are configured to receive splines (e.g., dimensional lumber) therein. The entire system is based on dimensional lumber sizing. The rectangular panels include a pre-cut slot extending through one face, to the channel, while a score line is formed in the opposite face, aligned with the pre-cut slot of the opposite face. The panels may be easily and quickly cut with a box knife to reduce the number of fractal modules in a given panel, to provide a smaller panel still based on such fractal geometry. Such a cut is made along the score line, where the foam is no more than 2 inches thick.

Abstract: Column and panel concrete fence systems and related methods of construction. Such a method may include placing (e.g., pounding or otherwise driving) a plurality of posts into the ground, attaching a bracket to each post. The concrete column may be provided in two initially separate portions e.g., each corresponding to a “front” or “back” face of the fence. One of the portions (e.g., corresponding to the front or back of the fence) is attached to a given post. The concrete panel may then be advanced into place, and the other of the front or back portions of the column may then be attached to the post, over the first column portion that was already attached to the post.

Abstract: Light-weight modular panel systems including a plurality of panels formed of a cementitious material, with a fiber-reinforced shell layer and an adjacent substrate layer. The panels employ a light-weight aggregate that provides the panels with the ability to be cut, sanded, drilled, screwed, and otherwise shaped using common wood working tools. A dual panel thickness wall construction may be formed by using the panels to provide interior and exterior portions of a wall construction. Seams between adjoining panels may be spanned with fiberglass mesh and bonded with polymer modified cementitious adhesive, providing excellent strength in that the joints between adjacent modular panels do not represent a weak point of the wall construction. The resulting wall provides greater strength than the individual panels, and results in a monocoque structure in which interior and exterior panels, and their respective fiber reinforced layers are spaced apart from one another.