Abstract: A composite building panel includes an impact resistant adhesively bonded mesh web which, in combination with other panel features, prevents impact penetration by defined projectiles moving at defined energies. Various embodiments include cementitious panels modified with the new web or used in conjunction with the new web to form structural wall and roof panels, some insulated with foam components.

Abstract: A cementitious structural building panel includes two facings made of a mesh reinforced lightweight aggregate core, the facings separated by a plurality of transverse ribs made of the same material and glued to the interior surfaces of the two facings. In use, H-shaped clips are secured to the extending facing edges of each panel so that adjacent panels may be erected and held side-by-side. A flowable material, such as a cementitious fly ash mixture, is poured into the spaces between the ribs and the facings and between the edges of the adjacent panels to form a strong load-bearing multiple panel wall. Once the walls with the panels are erected, the H-shaped clips, which are preferably made of plastic, can be trimmed or shaved off, thereby leaving a smooth or prefinished interior and exterior wall surface which can be readily further finished if desired by the application of paints, stuccos or other facing treatments.

Abstract: A wall panel and joint structure for erecting structurally sound, thermally efficient and inexpensive structures for human habitat. Each wall panel includes a foam core faced on each side with reinforced cementitious facing panels, the foam edges of the composite panel being grooved peripherally inside the cementitious facing panels. At least one metal tongue member is inserted in opposing side edge grooves of abutting wall panels, and fasteners are mounted through the cementitious facing panels, any intervening foam, and into the tongue members to hold adjacent wall panels together. U-shaped channels are provided to finish an upper edge of the wall panel and to secure a bottom edge thereof to a floor structure. Wall mount clips are provided to secure the wall panels to existing subwall structures. Flanges are provided at an upper end of the tongue members to secure roofing members to the wall panels.

Abstract: A wall panel and joint structure for erecting structurally sound, thermally efficient and inexpensive structures for human habitat. Each wall panel includes a foam core faced on each side with reinforced cementitious facing panels, the foam edges of the composite panel being grooved peripherally inside the cementitious facing panels. At least one metal tongue member is inserted in opposing side edge grooves of abutting wall panels, and fasteners are mounted through the cementitious facing panels, any intervening foam, and into the tongue members to hold adjacent wall panels together. U-shaped channels are provided to finish an upper edge of the wall panel and to secure a bottom edge thereof to a floor structure. Wall mount clips are provided to secure the wall panels to existing subwall structures. Flanges are provided at an upper end of the tongue members to secure roofing members to the wall panels.

Abstract: Fiberglass mesh is tentered by conveying the mesh in sliding relation over counter-rotating heated rollers or oscillating heated bars. The mesh is pulled over the rollers or bars and is slit and tightly wound, all in-line.

Abstract: A fiberglass mesh process includes coating fiberglass yarn, conveying the coated yarn to a loom without first beaming the yarn, weaving a mesh fabric of said yarn, conveying the mesh fabric to an in-line fabric treating station from said loom, tentering the fabric, slitting the fabric and rolling the fabric. The tentering step includes conveying the fabric through a nip of heated, counter-rotating rollers or heated bars oscillating across the moving fabric.

Abstract: An improved composite panel includes a foam layer having elongated, inclined grooves running at least adjacent its longitudinal edges, and a cementitious layer formed atop of the foam layer with integral projections extending into the grooves at acute angles with respect to the plane of the cementitious layer. The cementitious material cooperates with the grooves to provide a barrier to moisture ingress between the layers, an improved mechanical lock between layers, and a rigidifying structure strengthening at least the panel edges. Methods of forming the panel are included.

Abstract: Reinforced facings, including reinforcing webs entrained in hydraulic cement via a slurry bath, adhere to a nailable lightweight aggregate cementitious core to form a panel web. The reinforced web is formed on abutting conveyed carrier sheets, and the web is transversely cut, between the sheets, while moving or when stopped, in response to sensing of the sheets. The cut panels, on respective sheets are stacked for curing without damaging the panel edges and in a manner to minimize panel flex. Slurry bath, facing applicators, and cutter and stacking apparatus are included.

Abstract: Reinforced facings, including reinforcing webs entrained in hydraulic cement via a slurry bath, adhere to a nailable lightweight aggregate cementitious core to form a panel web. The reinforced web is formed on abutting conveyed carrier sheets, and the web is transversely cut, between the sheets, while moving or when stopped, in response to sensing of the sheets. The cut panels, on respective sheets are stacked for curing without damaging the panel edges and in a manner to minimize panel flex. Slurry bath, facing applicators, and cutter and stacking apparatus are included.

Abstract: Reinforced facings, including reinforcing webs entrained in hydraulic cement via a slurry bath, adhere to a nailable lightweight aggregate cementitious core to form a panel web. The reinforced web is formed on abutting conveyed carrier sheets, and the web is transversely cut, between the sheets, while moving or when stopped, in response to sensing of the sheets. The cut panels, on respective sheets are stacked for curing without damaging the panel edges and in a manner to minimize panel flex. Slurry bath, facing applicators, and cutter and stacking apparatus are included.

Abstract: Reinforced facings, including reinforcing webs entrained in hydraulic cement via a slurry bath, adhere to a nailable lightweight aggregate cementitious core to form a panel web. The reinforced web is formed on abutting conveyed carrier sheets, and the web is transversely cut, between the sheets, while moving or when stopped, in response to sensing of the sheets. The cut panels, on respective sheets are stacked for curing without damaging the panel edges and in a manner to minimize panel flex. Slurry bath, facing applicators, and cutter and stacking apparatus are included.

Abstract: Reinforced facings, including reinforcing webs entrained in hydraulic cement via a slurry bath, adhere to a nailable lightweight aggregate cementitious core to form a panel web. The reinforced web is formed on abutting conveyed carrier sheets, and the web is transversely cut, between the sheets, while moving or when stopped, in response to sensing of the sheets. The cut panels, on respective sheets are stacked for curing without damaging the panel edges and in a manner to minimize panel flex. Slurry bath, facing applicators, and cutter and stacking apparatus are included.