Abstract: This invention is an additively manufactured wall panel using computer aided design (CAD) and computer aided manufacturing (CAM) to design and manufacture multi-colored and multi-layered wall panels. This results in a variety of highly attractive, multi-colored wall panel faces ranging from brick, colored grout lines and multi-colored stones to multi-colored geometric designs. The design and manufacturing process greatly reduces the amount of precast cementitious materials by efficiently using higher quality materials. This reduces cost and weight while simultaneously producing a much more comprehensive, multi-functional wall panel complete with an interior frame, exterior insulation and an air, vapor and moisture barriers.

Abstract: A sprayed-in-place framed wall is disclosed, comprised of a cementitious face and backing layers and a polyurethane foam insulation layer that bonds the cementitious layers to a separate wall frame. Stationary walls are constructed by spraying the materials against one-sided, vertical wall forms positioned around an erected, exterior wall frame. The cementitious materials are restrained by stays. The wall forms may have indentations to enable the resulting wall face to have protrusions such as moulding, bands, quoins and cornices, which may be a different color that the surrounding flat wall face.

Abstract: A sprayed-in-place framed wall is disclosed, comprised of a cementitious face and backing layers and a polyurethane foam insulation layer that bonds the cementitious layers to a separate wall frame. Stationary walls are constructed by spraying the materials against one-sided, vertical wall forms positioned around an erected, exterior wall frame. The cementitious materials are restrained by stays. The wall forms may have indentations to enable the resulting wall face to have protrusions such as moulding, bands, quoins and cornices, which may be a different color that the surrounding flat wall face.

Abstract: This invention is an additively manufactured wall panel using computer aided design (CAD) and computer aided manufacturing (CAM) to design and manufacture multi-colored and multi-layered wall panels. This results in a variety of highly attractive, multi-colored wall panel faces ranging from brick, colored grout lines and multi-colored stones to multi-colored geometric designs. The design and manufacturing process greatly reduces the amount of precast cementitious materials by efficiently using higher quality materials. This reduces cost and weight while simultaneously producing a much more comprehensive, multi-functional wall panel complete with an interior frame, exterior insulation and an air, vapor and moisture barriers.

Abstract: This invention is an additively manufactured wall panel using computer aided design (CAD) and computer aided manufacturing (CAM) to design and manufacture multi-colored and multi-layered wall panels. This results in a variety of highly attractive, multi-colored wall panel faces ranging from brick, colored grout lines and multi-colored stones to multi-colored geometric designs. The design and manufacturing process greatly reduces the amount of precast cementitious materials by efficiently using higher quality materials. This reduces cost and weight while simultaneously producing a much more comprehensive, multi-functional wall panel complete with an interior frame, exterior insulation and an air, vapor and moisture barriers.

Abstract: This invention is an additively manufactured wall panel using computer aided design (CAD) and computer aided manufacturing (CAM) to design and manufacture multi-colored and multi-layered wall panels. This results in a variety of highly attractive, multi-colored wall panel faces ranging from brick, colored grout lines and multi-colored stones to multi-colored geometric designs. The design and manufacturing process greatly reduces the amount of precast cementitious materials by efficiently using higher quality materials. This reduces cost and weight while simultaneously producing a much more comprehensive, multi-functional wall panel complete with an interior frame, exterior insulation and an air, vapor and moisture barriers.

Abstract: Frame supported panels with an increased load carrying capacity derived from inducing newly discovered conditions on panels made from weaker, lighter and thinner materials. The fixed/continuous/dropped condition can increase a panel's load capacity many times based on the panel's interaction with frame members. This enables foam panels, for example, to be used in structural applications. It also enables polyurethane foam with any cladding to provide a comprehensive, structural building panel that provides a finished exterior, continuous and cavity insulation, an air, moisture and vapor barrier and increased uplift resistance while eliminating condensation and thermal expansion/contraction.

Abstract: Frame supported panels with an increased load carrying capacity derived from inducing newly discovered conditions on panels made from weaker, lighter and thinner materials. The fixed/continuous/dropped condition can increase a panel's load capacity many times based on the panel's interaction with frame members. This enables foam panels, for example, to be used in structural applications. It also enables polyurethane foam with any cladding to provide a comprehensive, structural building panel that provides a finished exterior, continuous and cavity insulation, an air, moisture and vapor barrier and increased uplift resistance while eliminating condensation and thermal expansion/contraction.

Abstract: Frame supported panels with an increased load carrying capacity derived from inducing newly discovered conditions on panels made from weaker, lighter and thinner materials. The fixed/continuous/dropped condition can increase a panel's load capacity many times based on the panel's interaction with frame members. This enables foam panels, for example, to be used in structural applications. It also enables polyurethane foam with any cladding to provide a comprehensive, structural building panel that provides a finished exterior, continuous and cavity insulation, an air, moisture and vapor barrier and increased uplift resistance while eliminating condensation and thermal expansion/contraction.

Abstract: A concrete forming system combining the ease of erection and load carrying capabilities of scaffolding with a simplified erection system. Scaffold frames provide the vertical support and walers, supported by and spanning from scaffold frame to scaffold frame, provide the horizontal support. The wet concrete's hydrostatic pressure is placed on the walers, which transfer the load to the scaffold frames that act like trusses. The scaffold frames have at least two legs and are secured at their bottom to perform as a cantilever or, when the hydrostatic pressure is greater, they are secured at their bottoms and tops to perform as a truss fixed at both ends. As such, this forming system does not use form ties which results in an obstacle free form face and facilitates forms that simply hang from the walers.

Abstract: Frame supported panels with an increased load carrying capacity derived from inducing newly discovered conditions on panels made from weaker, lighter and thinner materials. The fixed/continuous/dropped condition can increase a panel's load capacity many times based on the panel's interaction with frame members. This enables foam panels, for example, to be used in structural applications. It also enables polyurethane foam with any cladding to provide a comprehensive, structural building panel that provides a finished exterior, continuous and cavity insulation, an air, moisture and vapor barrier and increased uplift resistance while eliminating condensation and thermal expansion/contraction.

Abstract: The present invention discloses a method and a forming system that reduces the hydrostatic pressure caused by casting freshly mixed concrete or other cementicious material into a vertical form. Reducing the hydrostatic pressure in forms enables relatively weak materials to be used as forms and minimizes the amount of bracing necessary to support the forms—both of which lead to lower construction costs. The method uses the highly thixotropic properties of no-slump or low-slump concrete which enable the concrete to be quickly changed from a semi-solid state to a liquid state and back to a semi-solid state numerous times before it hardens and without affecting the concrete's quality. Since hydrostatic pressure is only present when a liquid state exists, minimizing the amount of liquid concrete in vertical forms will also minimize the hydrostatic pressure present.

Abstract: Frame supported panels with an increased load carrying capacity derived from inducing newly discovered conditions on panels made from weaker, lighter and thinner materials. The fixed/continuous/dropped condition can increase a panel's load capacity many times based on the panel's interaction with frame members. This enables foam panels, for example, to be used in structural applications. It also enables polyurethane foam with any cladding to provide a comprehensive, structural building panel that provides a finished exterior, continuous and cavity insulation, an air, moisture and vapor barrier and increased uplift resistance while eliminating condensation and thermal expansion/contraction.

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: The present invention discloses a method and a forming system that reduces the hydrostatic pressure caused by casting freshly mixed concrete or other cementicious material into vertical forms. Reducing the hydrostatic pressure in forms enables relatively weak materials to be used as form boards and minimizes the amount of bracing necessary to support the form boards—both of which lead to lower construction costs. The method uses the highly thixotropic properties of no-slump or low-slump concrete which enable the concrete to be quickly changed from a semi-solid state to a liquid and back to a semi-solid state numerous times before it hardens and without affecting the concrete's quality. Since hydrostatic pressure is only present when a liquid state exists, minimizing the amount of liquid concrete in vertical forms will also minimize the hydrostatic pressure present.

Abstract: A concrete forming system combining the ease of erection and load carrying capabilities of scaffolding with a simplified erection system. Scaffold frames provide the vertical support and walers, supported by and spanning from scaffold frame to scaffold frame, provide the horizontal support. The wet concrete's hydrostatic pressure is placed on the walers, which transfer the load to the scaffold frames that act like trusses. The scaffold frames have at least two legs and are secured at their bottom to perform as a cantilever or, when the hydrostatic pressure is greater, they are secured at their bottoms and tops to perform as a truss fixed at both ends. As such, this forming system does not use form ties which results in an obstacle free form face and facilitates forms that simply hang from the walers.

Abstract: This invention discloses a method of building concrete walls, columns and other vertical or sloped structures using a vertically oriented vibrating screed and utilization of the thixotropic properties of wet concrete. The vertical screed is a simple, inexpensive and highly flexible apparatus that may be used for a wide variety of applications that involve the applying of cementicious material in the construction of a vertical structure. By using highly thixotropic concrete, the vertical screed is able to place concrete and other cementicious materials in a vertical plane much like concrete is placed with vibrating screeds in the horizontal plane. The vertical screed's applications range from applying a thin cementicious coating to placing concrete in a vertical plane to construct a wall or column. The various configurations of the vertical screed range from a small hand held device to a much larger mechanically controlled apparatus.

Abstract: A plastic stay-in-place concrete forming system used for one or more sides of a multi-sided form and is based upon a form panel comprised of a thin plastic sheet reinforced on its interior side and capable of bonding to the concrete cast inside the form to create a solid composite structure. In one configuration the form panels are connected to internal bracing that connects to a second form side. The internal bracing is comprised of plastic connecting frames, lateral supports or individual connectors that may further reinforce the form panels or may be used solely for connecting purposes. The second side form may be any type of form including the form panel or a stud supporting foam board. The form panel may also be shaped to form two or more sides of an internally braced, multi-sided form. It may also be externally braced on one or more sides of a form.