Abstract: A strong, light-weight foamed weight bearing structural member having insulating properties and withstanding atmospheric erosion is formed by introducing a plurality of hollow bodies with shells thereabout into a molten mass of refractory material as a foaming agent and freezing the hollow bodies in place. These shells provide color, strength and texture characteristics to the structural member and may be steered non-uniformly such as near the outer surface to provide toughness, texture, or color, preferably by electrically charging the bodies and establishing an electric field in the molten mass of refractory material.

Abstract: An improved article made of foamed glass or similar materials and method of manufacture is disclosed. Thus, a construction panel may be formed to bear weight, withstand weather and take reasonable impact and abuse, because of a tempered outer skin supported inside by a skeletal network of solid poreless material formed about low density pockets of substantially constant size and frequency.These panels are made by continuous pulling of the panels through a heat controlled mold in contact with the surface skin from a continuously fed molten mass into which is injected from the bottom size and frequency controlled foaming agents or gaseous bubbles which rise in the molten mass to a position where they are frozen in place.