Abstract: A building panel structure is disclosed, in which composite building panels are used to form a structure. A composite building panel is disclosed which 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: Disclosed is a decorative panel having a composite structure bonded by an elastomeric cementitious coating. The cementitious coating bonds together a foam core and glass fiber mesh to form a highly durable and lightweight decorative panel. The panel can further include a finish coat of a substantially maintenance free pigmented coating. The panel may be attachment to the exterior surface of barriers and bridges. The lightweight construction of the panel adds little weight to the structure it adorns while matching or exceeding the wear characteristics of the attached structure.

Abstract: A composite for constructing concrete floors is completely factory assembled and comprises a body of expanded plastic having at least two parallel channels, open on the upper surface of the panel, extending the length of the article, adapted to be filled with concrete. A steel reinforcement bar fabric is installed into each channel, which may comprise at least two parallel steel bars connected by cross bars. At least some cross bars extend beyond a lowest reinforcement fabric bar to provide spikes long enough to pass through the plastic bottom and protrude therefrom.

Abstract: A system of making self-aligning concrete block structures. Structure is made of interlinking blocks that have insulative foam that is affixed during the molding process. The interior surface of the blocks is specifically designed to avoid the use of interior framing by providing wooden strips such that drywall can be directly affixed. The concrete block system include top blocks, inside and outside corner blocks, and the necessary forms for their construction.

Abstract: An insulated concrete form system for constructing the exterior walls and gable ends of a structure is disclosed using expanded polystyrene forms that interconnect and are bonded to each other and to the structure's slab or foundation with concrete. Internal, substantially columnar voids are provided in each of the panel forms and both the interior and the exterior surfaces of the walls and gable ends may be finished with a variety of finish materials using furring strips that are incorporated into the interior and exterior surfaces of the forms.

Abstract: A corner bracket for modular foam forms for poured concrete walls includes an outer, horizontal strap with generally vertical strips attached thereto or molded therewith for encapsulation in the outside and optionally the inside foam panels of such a form.

Abstract: A knocked-down insulating concrete form including two spaced apart lightweight panels maintained in position by a tie assembly. The tie assembly including a pair of vertically elongated anchors which are each attached to one of the two panels, and a tie engaging the anchors to maintain the panels in spaced apart relation. The tie engaging the anchors via a slideable locking mechanism for selectively preventing slideable movement between the tie and the anchors.

Abstract: A shear panel for constructing underlayments for floors and roofs of buildings includes a first rectangular layer of fire-resistant material, such as cementitious board, bonded to a second rectangular layer of thin high-strength material, such as galvanized steel. The length of the second layer is longer than the length of the first layer. The additional length of the second layer forms a tab extending from one end of the panel. During construction, a first panel is attached to a set of beams (floor joists or roof rafters) with the tab spanning between adjacent beams. A second panel is positioned on the beams with at least a portion of the second panel overlapping the tab of the first panel. The overlapping portion of the second panel is fastened to the tab of the first panel to form a continuous shear diaphragm for the floor or roof.

Abstract: Variable length polypropylene ties are used to form an insulated concrete wall by holding sheet materials in a fixed distance part so concrete can be cast between the two sheet materials.

Abstract: Prefabricated, lightweight, modular, concrete structures, such as columns and a variety of end caps, have a strong, chip resistant surface exhibiting ornamental designs that include projections and impressions. The high strength of the surface layer is due to reinforcement of the concrete with alkali resistant short length (0.125-0.25 inch) glass fibers that allow replication of fine surface details in the column surface. The surface layer is supported by a second glass fiber reinforced concrete layer that incorporates long length (0.5-1.5 inch) alkali resistant glass fibers. In combination, the first and second layers are about 0.25 to 0.5 inches thick, and the lightweight column is readily handled by forklift trucks or economically transported on flat bed trucks without surface chipping or breakage. The modular concrete structures include concrete columns, end caps and arches, as well as other geometrically decorative assemblies.

Abstract: A composite construction element (2) particularly useful for manufacturing building floors, comprises: a) an elongated body (3) made of expanded plastic material, provided with at least one longitudinal channel (4) open on the upper side for receiving a concrete casting (5); b) a reinforcement metal structure (11) of the casting (5), housed in the longitudinal channel (4), associated to the elongated body (3) and having opposite free ends (12) protruding from longitudinally opposite parts of the elongated body (3) for a portion of predetermined length. Advantageously, the composite construction element (2) possesses optimum load bearing characteristics, lightness and flexibility of use.

Abstract: A method for manufacturing frame-type composite panels to a desired length comprises forming an elongate core-frame composite in which frame members have been received in slots on a slab of core material. The composite is cut to the desired length and the frame is finished by application of end members. The method described herein allows composite frame panels to be formed without restriction on the length typically due to the length of the mold in which the core is formed. A drum for use in a system for creating composite panels is disclosed having protruding rings concentric to the drum. A slab of core material is passed between two such drums which form slots in the slab for receiving frame members when they contact the slabs.

Abstract: A shear panel for constructing underlayments for floors and roofs of buildings includes a first rectangular layer of fire-resistant material, such as cementitious board, bonded to a second rectangular layer of thin high-strength material, such as galvanized steel. The length of the second layer is longer than the length of the first layer. The additional length of the second layer forms a tab extending from one end of the panel. During construction, a first panel is attached to a set of beams (floor joists or roof rafters) with the tab spanning between adjacent beams. A second panel is positioned on the beams with at least a portion of the second panel overlapping the tab of the first panel. The overlapping portion of the second panel is fastened to the tab of the first panel to form a continuous shear diaphragm for the floor or roof.

Abstract: CO2-sequestering formed building materials are provided. The building materials of the invention include a composition comprising a carbonate/bicarbonate component. Additional aspects of the invention include methods of making and using the CO2-sequestering formed building material.

Abstract: A method of assembling molded forms of expanded closed cell polystyrene to receive poured concrete for foundations and walls for buildings, including a laid course of forms molded of expanded polystyrene having vertical spaces in the forms and a plastic or metal strip With claws attached to the plastic or metal strip, and the strip is placed in a groove channel in the form and the strip extending into a groove in next abutting form of expanded polystyrene, and the strip width extending into a groove in the next laid course of expanded polystyrene forms and reinforcing bars placed vertically in vertical spaces in the forms of expanded polystyrene, and the reinforcing bars placed vertically in the vertical spaces and held in position by an aperture guide wire having a bias cut on leg end of the aperture guide wire and spanner wires extending across from side to side of the forms of expanded polystyrene, and the spanner wires having bias cut leg ends to stab into the top edges of the forms of expanded polystyren

Abstract: A concrete wall forming system including a plurality of mold units for forming a wall of concrete. The mold units include a bond beam form extending into the body lengthwise, defined by a first wall, a second wall, a bond beam form bottom, a first end and a second end where the first wall and second wall extend a depth defined by a portion of the distance from the top surface to the bottom surface and where the bond beam form does not touch the first side or the second side. First and second ledges extend lengthwise along the body from the first and second sides respectively to the first and second walls respectively of the bond beam form. The bond beam form bottom extends from the first wall to the second wall. At least two column forms extend from the bond beam form bottom to a bottom surface.

Abstract: Taught herein is inter alia a concrete wall modulus comprising a concrete-steel wall having one or more steel mesh plates; at least two form panels being physically connected to the concrete-steel wall; a plurality of steel plates; and a plurality of jointing pieces; wherein the form panels are made in part of polystyrene foam; at least two form panels are arranged in parallel to one another; and at least two the form panels are interconnected by a plurality of the jointing pieces by means of the steel plates.

Abstract: This invention teaches inter alia a one-piece layered monolithic modulus of composite thermally-insulated concrete walls comprising a foundation; a concrete wall; a plurality of reinforcing steel plates; a pair of wall form panels; a slab; and optionally a plurality of slab-supporting bars; wherein the wall form panels having a plurality of steel plates distributed in uniform spacing and embedded vertically therein are made of polystyrene foam plastic; a plurality of teeth are vertically arranged on the two peripheral edges of the steel plate; a cavity is formed on each tooth; the teeth and the cavities protrude out of the inner surface of said wall form panels; a pair of channel-shaped steels with slots facing upwards are affixed horizontally on the foundation; the bottom surfaces of the wall form panels are affixed respectively into the slots of the channel-shaped steels; a plurality of welded steel fabrics are embedded in the spaces between the wall form panels; at least two wall form panels are interconne

Abstract: An insulated building block having a three-section configuration wherein a first cementitious segment containing the internal core hole of the block is interlocked with second cementitious segment by a serpentine configured insulated insert. The insulation insert is operatively arranged to have multiple lips that mate with various indented ledges on each of the other segments in a location proximate to the surface of the cementitious segments. The insulating insert is also configured with wedge holes that accommodate wedges which press into the installation to maintain continuity of the block. The insulation insert has groves that in combination with the other segments form a trough in fluid communication with weep holes which extend through the insulation insert which allows for condensation and seepage of water to drain from the block.

Abstract: A three-dimensional constructional element 10 is shown having opposing and substantially planar panels 30, 40 mounted on opposing surfaces of a flexible planar member in the form of a flexible mesh material layer 52 therefore making a composite sheet of three layers. Panel 30 includes transverse grooves 12, 14 formed therein and panel 40 includes transverse grooves 16, 18 formed therein. The structure is deformable about each groove 12, 14, 16, 18. In a preferred embodiment the panels 30, 40 are divided into many segments defined by the transverse grooves to allow the constructional element to be deformed so that one of the exterior surfaces of panel 30 is concave while the opposing exterior surface of panel 40 is convex.

Abstract: A composite wall panel for exterior walls of a structure includes a polymeric foam core having a C-stud framing system embedded therein and an exterior and/or interior facing formed of a reinforced concrete bonded to the core surface and mechanically attached to the studs thereby providing increased strength, insulation and resistance to environmental conditions.

Abstract: An improved structural insulated panel and panel joint includes a panel having a core with cementitious facings where the core edge is grooved and along the panel side edges rebated to accommodate a connecting column. A connecting column is “H”-shaped, formed from two “C”-shaped channels sealed together along other webs with legs directed outwardly and for use between two of the panels. Multiple wall structures and details are disclosed.

Abstract: A building component having first and second high density foam panels and improved bridging members for connecting the panels that extend between and may be molded into the panels. The bridging members include a pair of elongated end plates oriented in a top to bottom direction of the panels, a pair of substantially identical web members joining the end plates and being substantially symmetrically disposed above and below a central horizontal axis of the bridging member, and a pair of strip members oriented in the top to bottom direction of the panels intersecting the web members. The web members have a unique configuration that maximizes load bearing capacity with a minimum amount of material. The strip members may abut against and be substantially flush with respective inner surfaces of the foam panels to assist in positioning and forming the panels during molding. Seating areas for positioning horizontally and/or vertically disposed rebar in predetermined positions are also provided.

Abstract: A wall structure and a method for constructing the wall of a building provide protection for inhabitants of the building against ballistic projectiles impacting the wall. The wall structure includes an outer panel and an inner panel. The inner panel is a composite structure that includes a metal sheet having a first face attached to a wallboard panel. Preferably, a sheet of self-healing material is attached to a second face of the metal sheet. A cavity formed between the outer and inner panels is filled with sand or another granular material. A flexible sheet suspended in the cavity provides additional protection. Preferably, a sheet of woven para-aramid fiber such as Kevlar® brand fiber is loosely attached to the flexible sheet to provide further protection.

Abstract: An insulating concrete form can be used to form the walls of a structure when filled with concrete. An outer surface of the insulating concrete form can be formed into one or more patterns. The patterns may simulate popular finishes such as brick, natural stone, and stucco. In some cases, the exterior of the insulating concrete form is coated with a protective, conformal coating, such as a rubberized acrylic coating or an elastomeric paint.

Abstract: A moisture control system for a straw bale core wall having an air pathway from the foundation of the wall to its bond beam permitting air to be pumped into the wall at the foundation level and up through the core of the wall into a plenum space at the top of the wall and out through one or more vents into the atmosphere.

Abstract: A fabricated concrete foundation wall is provided with a plurality of insulation panels and reinforcing ribs to improve strength and reduce the density of the wall panel. The foundation wall panels are easily placed and interconnected together to quickly provide a foundation adapted to support the main walls of a home, for example. The foundation panels in one embodiment generally include a facewall that may have at least one carbon fiber band positioned horizontally therethrough to provide additional stiffness.

Abstract: An insulated concrete form system having a pair of bottom U-shaped channels secured to a concrete slab that serve as a footprint for a concrete wall. Exterior and interior foam sheets are aligned within the bottom U-shaped channels that define the wall. Top U-shaped channels are slipped over a top edge of the foam sheets. A plurality of strongbacks are used to provide structural support for the foam sheets during a concrete pour of the wall. The strongbacks each have a pair of hangers adapted to be secured over the top U-shaped channels to secure the strongbacks to the foam sheets. A top wall spacer is used to join a strongback on one side of the wall cavity to a strongback on a second side of the cavity to resist pressure exerted outward on the foam sheets during a concrete pour to form the wall.

Abstract: An insulated concrete form system having a pair of bottom U-shaped channels secured to a concrete slab that serve as a footprint for a concrete wall. Exterior and interior foam sheets are aligned within the bottom U-shaped channels that define the wall. Top U-shaped channels are slipped over a top edge of the foam sheets. A plurality of strongbacks are used to provide structural support for the foam sheets during a concrete pour of the wall. The strongbacks each have a pair of hangers adapted to be secured over the top U-shaped channels to secure the strongbacks to the foam sheets. A top wall spacer is used to join a strongback on one side of the wall cavity to a strongback on a second side of the cavity to resist pressure exerted outward on the foam sheets during a concrete pour to form the wall.

Abstract: A wall block (10) comprises a substantially rectangular core (11) of substantially rigid insulating material which forms structural load bearing elements in a constructed wall. The block (10) has cladding (12) bonded to its lateral surfaces. The cladding (12) is offset from the lateral surfaces with tie cladding (12) overhanging from the lower lateral edges, the overhanging portion abutting against the core (11) of the blocks (10) on the lower course. The core (11) has a longitudinal void (14) provided in the lower surface along its whole length and al least one vertically extending void (15), extending from the longitudinal void (14) to the upper surface of the core. Furthermore, recesses (21) are formed in the vertical edges of the core (11) and being adapted to receive elongated joint seals (22) to affect scaling of the joints between adjacent blocks (10).

Abstract: The present invention is related to an apparatus and method of constructing walls of framed block assemblies including both exterior and interior partition walls which are assembled through an interlocking structure having dovetail tongues interlocked with dovetail channels. Includes are a plain wall, a wall with mortar for ornamentation, and a wall applied with straight longitudinal blocks.

Abstract: A system, method, and apparatus for forming insulated concrete structures, using a foam panel and lightweight cementious type of material as forms. The assembled forms are then preferably placed into position to form a wall and/or roof type of structure which then has concrete or another cementious type of material filled into at least some of the voids formed in the forms.

Abstract: A moisture control system for a straw bale core wall in which gravity fed moisture from the bales is collected in a sump at the foundation level and drained away, while an airspace is provided above the bale core to collect and direct away moisture of evaporation.

Abstract: This invention relates to an improved shear wall structural panel assembly that is able to resist gravity loads and lateral forces imposed by wind and earthquake loads. The panel comprises a substantially rectangular frame assembly that is constructed from a plurality of vertical frame members dispensed between and perpendicular to two horizontal frame members. There is a water barrier that is approximately the size of the frame assembly that is fixedly attached to and covering one side of the frame assembly. A reinforcement layer covers and is attached to the water barrier. Four outer frame members are fixedly attached to the perimeter of the frame assembly holding the aforementioned water barrier and reinforcement layer securely in place. A cementitious layer is adjacent to, covering and bonded to said reinforcement layer.

Abstract: The present invention provides a method of constructing a foundation substructure and a building involving pouring concrete between resilient sheets of insulating material, preferably polystyrene, so as to form a complete concrete shell.

Abstract: The invention provides an insulator for use in combination with a structural block having top and bottom surfaces that are connect by side surfaces. The side surfaces and the top and bottom surfaces define a continuous periphery that at least partially forms a mortar joint with adjacent blocks. The periphery has a generally vertical height bounded by the top and bottom surfaces, and a width bounded by the side surfaces. The insulator has a pre-formed portion of insulating material having top, bottom and side surfaces. The top and bottom surfaces define a height greater than the generally vertical height of the periphery of the block. The side surfaces define a width greater than the periphery of the block, so that the insulator extends into and insulates, on at least a portion of all surfaces forming the block periphery, the mortar joint between the block and adjacent blocks.

Abstract: A reinforced insulating element for a wall made of concrete and insulation with one-sided insulation that is preferably prefabricated. It also concerns a wall made with this prefabricated insulating element. The insulating element according to the invention has at least one insulating panel that is equipped with holding elements that are attached to the first flat surface of the insulating panel and are arranged at a distance from each other perpendicularly to the flat surface of the insulating panel; it also has at least one reinforcing mat attached to the holding elements at a distance from the insulating panel, with spacers arranged at those ends of the holding elements facing away from the insulating panel, and/or on that side of the reinforcing mat that is facing away from the insulating panel.

Abstract: An external roofing surface comprised of foam and a cement coating that is Class A fire-resistant under the UL 790 standard, insect resistant, very strong and extremely lightweight is disclosed. The roofing surface is also easily shaped by a number of shaping techniques, which allows for a more aesthetically pleasing appearance and can be used to make a roofing system that interlocks and has channels for underside ventilation. A cement coating is applied to the roofing surface, imparting it with excellent water repellant properties and increasing its strength, durability, and aesthetic appeal. The roofing surface may also optionally be reinforced with various materials to increase the strength and durability. The roofing surface may optionally be coated with a second coating material or a sheathing material to impart a desired strength, durability and/or aesthetic look.

Abstract: Multiple layers of polymer foam form structural concrete into a desired planar shape that retains a foam panel when flat or upright. The polymer foam has a planar shape and an exterior surface with multiple channels into the panel. The channels are generally wider at the bottom and narrower towards the top, preferably a trapezoidal shape. In use, the panel is placed flat within a forming frame, exterior surface upwards. Then concrete is poured upon the exterior surface and into the channels. The trapezoidal shape of the channel prevents removal of the panel from the concrete. The concrete panel can then be used flat or upright as specified for a construction project.

Abstract: A metallic stud for use in the framing of structures, the stud definable in terms of an x, y, z coordinate system, in which the z-axis corresponds to the gravity vector. The metallic stud includes a z-axis elongate generally rectangular integral xz plane web having a width (thickness) in a yz plane. The stud also includes a series of xz plane tabs each having a parallelogram-like geometry and an outer major base. The series of xz plane tabs project within at least one of a positive or negative x-axis direction, in which the tabs interdigitate with void spaces along at least one z-axis edge of the web. The metallic stud also includes a z-axis elongate apex element, within xz plane web, projecting in a y-axis plane and integrally dependent from the web of the stud.

Abstract: A method of constructing a concrete wall. A mold form is placed upon on a surface at a construction site. A support structure is placed into the mold form and concrete is poured around the support structure within the mold form to form a concrete panel. The upward facing surface of the poured panel is altered with one or more of a color, a texture, and a pattern to form a decorative concrete panel while the panel lies on the ground. The decorative concrete panel is then lifted into an upright position by a crane connected to lifting inserts of the panel. The lifting inserts are desirably located at a side or top end of the panel and not in the decorative surface.

Abstract: An insulated concrete panel having one or more tendons positioned in the insulation layer inside the panel which are put into tension after the concrete panel has been formed.

Abstract: The present invention comprises a stucco wall structure for a building. The wall substrate is arranged for receipt of subsequent layers of surface material. The margin or periphery of said wall to be treated has a screed attached thereto. A sprayed-on coating of urethane is applied onto the wall substrate between the screeds to insure continuous bonding and adherency to the substrate. A first layer of polymer-based base coat and mesh covering is applied to the sprayed-on coating of urethane to provide anchoring and adhesion of a subsequent layer of stucco. An outer layer of stucco applied over the first layer of polymer-based base coat as a final coat thereon.

Abstract: A roofing element comprises a structural box of concrete and an insulating layer extending inside the structural box.

Abstract: A multi-layer wall panel includes a core filler material surrounded by two plastic sheets. Each sheet includes three-dimensional texture formed to resemble masonry or other desired aesthetics. A layer of concrete may be disposed between each sheet and the filler material. The sheet may be removed from the concrete layers to expose the concrete surfaces. Multiple wall panels may be stacked on top of one another and joined side-by-side with posts and connectors to form a wall assembly. A method for manufacturing vertical concrete wall structures is also provided.

Abstract: Device for producing a prefabricated cast concrete element having a plurality of central structural elements each comprising two parralel welded wire lattice mats, straight bridging wires welded at each end to the two wire lattice mats holding the wire lattice mats at a predetermined mutual separation and an insulating member penetrated by the bridging wires arranged with its cover surfaces parallel to the wire lattice mats and at a predetermined distance to the latter and having two concrete shells which each adjoin the insulating member and completely enclose the wire lattice mats of the structural elements, characterized in that a plurality of central structural elements are each arranged with their narrow sides abutting one another with selectable spacing between two shuttering walls and the spaces between the insulating members of the structural elements and the shuttering walls completely filled out with concrete.

Abstract: A 3D construction module comprising at least one vertically upstanding panel with first and second mesh layers oriented generally transversely and longitudinally. The first and second mesh layers have at least one rod member mounted to said panel and are vertically spaced from each other. The rod members form a first horizontally projected retention cell to restrict translation of a bar held in said retention cell between said first and second mesh layers. A third mesh can also be provided to form a second retention cell between said second and third mesh layers. The first and second retention cells restrict translation movement longitudinally and transversely of a vertical reinforcement member held in said first and second retention cells, and restrict rotation of the vertical reinforcement member about both a longitudinal axis and a transverse axis of the said 3D construction module. Horizontal reinforcement meshes are features of the invention.

Abstract: An insulative, lightweight building panel is provided with a lightweight, insulative foam core and which includes one or more carbon fiber or steel reinforcements and an exterior concrete face which are manufactured in a controlled environment and can be easily transported and erected at a building site.

Abstract: A composite mat and sheet structure for installation atop a subfloor to underlie a layer of hardenable, cementicious material such as gypsum concrete or Portland concrete that is poured atop the composite structure to harden in situ.

Abstract: The invention provides a building component comprising first and second high density foam panels each having inner and outer surfaces, top and bottom, and first and second ends, the panels arranged in spaced parallel relationship with their inner surfaces facing each other, and at least two bridging members extending between and through and molded into the panel members. Each bridging member comprises a pair of elongated end plates oriented vertically and abutting against the outer surfaces of the panels; a thin narrow strip member joining the mid-areas of the end plates; a series of first narrow bracing members extending from positions adjacent a mid-point of the narrow strip member to positions spaced a short distance from the ends of the end plates; and a series of second narrow bracing members extending from positions on the first bracing members to positions on the strip member intermediate the plates and the mid-point of the strip member.