Abstract: This invention relates to doors having internal blocking components that reduce or eliminate telegraphing of the outer surface of the door facings. In particular, the invention relates to steel-edge steel doors that have internal solid wood blocks that have one or more integral cantilever beams formed into the blocks to interact with the adjoined oppositely arranged door facings in order to eliminate visually apparent door telegraphing. The blocks are modified to contain notches formed therein to form the cantilever beams.

Abstract: An insulation cap for wall framing members comprising a base section; a first side wall extending outwardly from said base section; a second side wall laterally spaced from said first side wall and extending outwardly from said base section complementary to said first side wall; a generally U-shaped channel defined by said base section, said first side wall and said second side wall define for receiving a framing member so that at least a portion of an exterior surface of said framing member is encased by said base section, said first side wall and said second side wall; whereby a thermal break is provided between an exterior and interior sheathing around framing members and creates an airtight arrangement with insulation material for improved R values.

Abstract: Waterproof engineered floor and wall planks have a veneer layer bonded with a plastic composite core, and an underlayer, preferably an underlayer of cork.

Abstract: A thermal break wood and rigid insulation stud is comprised of two non-dimensional lumber sections with a thermal break section of rigid foam insulation therebetween. A non-metallic truss arrangement of mechanical fasteners holds the lumber and insulation sections secured together greatly improving the strength of the thermal break wood and rigid insulation stud. The studs in a wall are 24? on center. The studs are used for headers and sills and also may be used for top and bottom plates. The corners have an exterior all wood stud, an interior all wood stud and an interior all wood stud adjacent to the interior wood stud completing the interior corner for nailing gypsum board thereto. This corner has a thermal break space between the exterior and interior wood studs for insulation placement. The corners may also have two 3×6 thermal studs oriented 90 degrees from each other and an interior all wood stud for completing the interior corner for nailing gypsum board thereto.

Abstract: A thermal break wall system comprised of 3×6 thermal studs each comprised of two non-dimensional lumber sections with a thermal break section of rigid foam insulation therebetween. The studs are 24? on center. The studs are used for headers and sills and also may be used for top and bottom plates. The corners have an exterior all wood stud, an interior all wood stud and an interior all wood stud adjacent to the interior wood stud completing the interior corner for nailing gypsum board thereto. This corner has a thermal break space between the exterior and interior wood studs for insulation placement. The corners may also have two 3×6 thermal studs oriented 90 degrees from each other and an interior all wood stud for completing the interior corner for nailing gypsum board thereto. This corner arrangement also has a thermal break through its construction.

Abstract: A method of manufacturing a hollow core door is disclosed, as well as a corresponding hollow core door. The method includes the steps of providing a solid flat door skin, moisturizing the flat skin, applying a conditioning resin thereto, pre-heating the flat door skin, and thereafter pressing the flat door skin between a pair of heated platens in a press in order to reform the flat skin into a molded skin including a plurality of panels defined therein. The press continuously closes in order to reform the flat skin into the molded skin, with the rate of press closure being a function of the determined hardness of the flat skin to be reformed. The resulting door skins have an improved bond strength, and are efficiently manufactured.

Abstract: A flooring material having a textile pad substructure with a density of greater than 10 pounds per cubic foot is provided. The textile pad has reinforcement and binding fibers. The binding fibers are thermoplastic and are used to bind the reinforcement fibers together. The pad is created by heating and compressing a fibrous textile batt so that it has a density of greater than 13 pounds per cubic foot.

Abstract: A reinforced water-resistant board includes a cover board with a reinforced water-resistant membrane applied to a surface of the cover board. The reinforced water-resistant membrane includes a primer layer, a reinforced membrane, a traffic coat, and a sealing layer. The primer layer is applied over the surface of the cover board. The reinforced membrane includes fleece soaked in a liquid resin and is applied over the primer layer. The traffic coat is boned to the reinforced member. The sealing layer is applied over the traffic coat.

Abstract: A method of manufacturing a hollow core door is disclosed, as well as a corresponding hollow core door. The method includes the steps of providing a solid flat door skin, moisturizing the flat skin, applying a conditioning resin thereto, pre-heating the flat door skin, and thereafter pressing the flat door skin between a pair of heated platens in a press in order to reform the flat skin into a molded skin including a plurality of panels defined therein. The press continuously closes in order to reform the flat skin into the molded skin, with the rate of press closure being a function of the determined hardness of the flat skin to be reformed. The resulting door skins have an improved bond strength, and are efficiently manufactured.

Abstract: The invention comprises a foam insulating panel having an outer surface and a reinforcing member adhered to at least a portion of the outer surface of the foam insulating panel. An insulated concrete form and a method of using the insulated concrete form are also disclosed.

Abstract: A drilling rig with static resistant synthetic inter-connectable structural mat assembly. The assembly has a plurality of static resistant mats, wherein each mat engages another mat without tools or fasteners and each mat has a top layer, a middle layer, a bottom layer, a static charge conduction conduit through the mats, and an optional non-skid coating partially embedded in the mats to support drilling rigs. The mats are made from 100 percent recycled rust proof, non-absorbing post-consumer waste materials.

Abstract: A structural connector is provided that limits transmissions of vibrations between connected structural elements in a building or structure. The structural connector is formed from two opposing sheets with a vibration damping material connecting the two.

Abstract: A method of manufacturing a hollow core door is disclosed, as well as a corresponding hollow core door. The method includes the steps of providing a solid flat door skin, moisturizing the flat skin, applying a conditioning resin thereto, pre-heating the flat door skin, and thereafter pressing the flat door skin between a pair of heated platens in a press in order to reform the flat skin into a molded skin including a plurality of panels defined therein. The press continuously closes in order to reform the flat skin into the molded skin, with the rate of press closure being a function of the determined hardness of the flat skin to be reformed. The resulting door skins have an improved bond strength, and are efficiently manufactured.

Abstract: A composite panel for making a wall of a building includes an outer cladding plate, an inner wall plate, and a supporting structure provided between the outer cladding plate and the inner wall plate and which is partially embedded in a polymer foam.

Abstract: A composite, prefabricated panel for building construction. A panel includes a central core having a first face and a second face. The central core includes structural framing members assembled to define at least one opening. A substantially rigid insulation is disposed in the at least one opening of the structural framing members. A settable cement, which may be, for example, phosphate ceramic, is provided on each of the first face of the central core and the second face of the central core to form a first face of the panel and a second face of the panel. The insulation may define a plurality of passages, each with phosphate ceramic extending through the passage between and being monolithic with the phosphate ceramic on the first face of the central core and the phosphate ceramic on the second face of the central core. A building system with such panels is provided.

Abstract: A composite structural element and a method for making same are provided. The element includes a polymer foam core and at least one fibrous layer adhered to the polymer foam core by epoxy. Nano-particles are suspended in the epoxy prior to curing; preferably they are mixed with the hardener before it is mixed with the resin. The polymer foam core is preferably an exothermic foam such as polyurethane, and heat generated by the exothermic foam cures the epoxy, thereby causing the fibrous layer to adhere to the foam core. The nano-particles may be made from at least one of carbon, a ceramic, tungsten, a carbide, titanium, zircon, aluminum, silver, or boron. When carbon nano-particles are used, the strength of the composite is greatly increased, and the curing time of the heat-curable epoxy is significantly reduced. Ceramic nano-particles can be used to increase penetration resistance and provide increased ballistic protection.

Abstract: A composite building construction system comprising a frame, an expanded wallboard, and a concrete layer. The wallboard comprises an outer portion and inset portion wherein the wallboard is attached to the frame with the outer portion covering an exterior side of the frame and the inset portion is disposed within the frame. The wallboard thus provides exterior and interior insulation for the system. The concrete layer is sprayed on to the outer portion of said wallboard, forming a strong durable composite construction system. One or more rebar supports may be attached to the frame at the exterior side by key bolts and are spaced apart from the wallboard. A wire grid may be attached to the key bolts whereby the grid and the rebar supports provide a support structure for the concrete layer. The frame comprises steel and the wallboard comprises insulative expanded polystyrene.

Abstract: Described herein is a custom built-to-size, polyurethane-polyurea coated door for walk-in coolers and freezers, which will withstand collision, and wear-and-tear in an industrial or commercial setting.

Abstract: A structural isothermal construction SIP panel comprising a board made of insulating material with two cement-based boards attached to said board made of insulating material per each one of its faces. The insulating board has in each of its sides a “C” type galvanized metal profile, that is embedded in the insulating board and the cement-based boards are attached to the insulating board and are placed overlapped opposite to each other with respect to their longitudinal axis, the overlapped bonding of the cement-based boards with the insulating board creates a protruding area which has a width equal to the width of the galvanized metal profile the bonding between two panels is made using screws. Two manufacturing methods and a bonding method are also provided.

Abstract: A self supporting panel system used to fabricate ceilings, floors, walls, or roofs. The panel system is assembled from a plurality of panels, each having a core that is sandwiched between opposing plate members. In a preferred embodiment, the core of each panel includes a unifying material to enhance the load bearing capacity of the panel.

Abstract: Disclosed is an eco-friendly incombustible biocomposite including: a) a polymer matrix comprising a natural fiber; and b) a ceramic sheet laminated integrally with the polymer matrix. The biocomposite is eco-friendly since the natural fiber is used as a reinforcement material and is incombustible since it is laminated integrally with the ceramic sheet. Further, it has superior storage modulus, dimensional stability and flexural properties and lightweightness, and is processable into various structures. Thus, it is very useful for automotive or building indoor/outdoor materials.

Abstract: A method of manufacturing a hollow core door is disclosed, as well as a corresponding hollow core door. The method includes the steps of providing a solid flat door skin, moisturizing the flat skin, applying a conditioning resin thereto, pre-heating the flat door skin, and thereafter pressing the flat door skin between a pair of heated platens in a press in order to reform the flat skin into a molded skin including a plurality of panels defined therein. The press continuously closes in order to reform the flat skin into the molded skin, with the rate of press closure being a function of the determined hardness of the flat skin to be reformed. The resulting door skins have an improved bond strength, and are efficiently manufactured.

Abstract: A thermally reflective panel assembly for use in a structure, the roof panel assembly comprising an exterior panel having opposing outer and inner surfaces separated by exterior panel edge surfaces; an interior panel having opposing outer and inner surfaces separated by interior panel edge surfaces that are aligned with the exterior panel edge surfaces; an intermediate section fixed to the inner surfaces of the exterior panel and the interior panel to define compartments between the exterior and interior panels; and at least one layer of metallic material fixed to at least one surface of the compartments.

Abstract: A method comprises a) attaching a first skin to a first surface of an open cell foam to form a precursor for a door, window or panel; and b) attaching a second skin to the precursor in a separate step from step a). A precursor for a door, window, or panel, comprises a skin attached to one face of an open cell foam, but not to an opposing face of the open cell foam.

Abstract: A composite building construction system comprising a frame, an expanded wallboard, and a concrete layer. The wallboard comprises an outer portion and inset portion wherein the wallboard is attached to the frame with the outer portion covering an exterior side of the frame and the inset portion is disposed within the frame. The wallboard thus provides exterior and interior insulation for the system. The concrete layer is sprayed on to the outer portion of said wallboard, forming a strong durable composite construction system. One or more rebar supports may be attached to the frame at the exterior side by key bolts and are spaced apart from the wallboard. A wire grid may be attached to the key bolts whereby the grid and the rebar supports provide a support structure for the concrete layer. The frame comprises steel and the wallboard comprises insulative expanded polystyrene.

Abstract: A composite structural element and a method for making same are provided. The element includes a polymer foam core and at least one fibrous layer adhered to the polymer foam core by epoxy. Nano-particles are suspended in the epoxy prior to curing; preferably they are mixed with the hardener before it is mixed with the resin. The polymer foam core is preferably an exothermic foam such as polyurethane, and heat generated by the exothermic foam cures the epoxy, thereby causing the fibrous layer to adhere to the foam core. The nano-particles may be made from at least one of carbon, a ceramic, tungsten, a carbide, titanium, zircon, aluminum, silver, or boron. When carbon nano-particles are used, the strength of the composite is greatly increased, and the curing time of the heat-curable epoxy is significantly reduced. Ceramic nano-particles can be used to increase penetration resistance and provide increased ballistic protection.

Abstract: A multi-layer, thermal insulation quilt (1) comprises two spaced apart, outer layers (2, 3) at least one of which is a reflective thermal insulation layer, between which outer layers there is provided at least one inner layer (4) of thermal insulation, characterised in that the outer layers (2, 3) secured together by a non-metallic, common restraining tag (5) of such length, that the tag (5) determines the maximum separation of the outer layers (2, 3) but effects no compressive loading on the or each thermal insulation layer (4).

Abstract: Construct a wall assembly by: (a) providing a support structure with spaced apart structural members; (b) affixing a thermally insulating layer of polymeric foam boards to the structural members, the foam boards achieving a Class A rating according to ASTM E-84; (c) covering seams between polymeric foam boards with a sealing tape; (d) affixing a plurality of fasteners through the thermally insulating layer to structural members with the fasteners extending beyond the outside surface of the thermally insulating layer; (e) attaching a façade selected from metal panel, metal-composite-metal panels, fiber reinforced cementitious siding veneer and materials having a thickness of at least 1.9 centimeters (0.

Abstract: A noise control flooring system is presented herein for reducing noise transmission in a building structure that contains the system. The system comprises a solid substrate layer, a compressible layer overlying at least a portion of the substrate layer, and an entangled net layer that overlies at least a portion of the compressible layer, wherein the net layer is comprised of multiple polymer filaments and air, together forming a void space. A separation layer overlies at least a portion of the entangled net layer. The separation layer carries a floating solid substrate layer thereupon. This solid substrate layer provides loading for causing the compressible layer to compress into the overlying entangled net layer.

Abstract: The possibility of special lightening, insulating and reinforcing intermediate floor constructions enables fast building of semi-prefibraceted and prefabricated floor with complete insulation, bearing capacity and smaller price. Floor elements and are constructed to that already present steel space trusses can be placed in their channels, so that are hastened the building of intermediate floor constructions and makes them cheaper, too. They are minimum shorting at the ends and at the middle of beams, so the works below can be proceeding and the required working time is shorter. The intermediate floor construction is already insulating, so they are no need for insulating, which makes the construction cheaper and the required working time shorter. The plates are enabling the increase of the height of the floor constructions, by tying two beams in the construction. Usage of distance elements and protects the reinforcement in floor construction, so they are no need for corrosion protection.

Abstract: Disclosed are a fixing structure of insulation panels and a prefabricated refrigerator with the same. The fixing structure of insulation panels includes a recess recessed on one surface of a first insulation panel having an insulation portion inside a casing, and a protrusion formed to be inserted into the recess, on one surface of a second insulation panel having an insulation portion inside a casing, wherein the insulation portions of nonmetal material are exposed to a bottom of the recess and a front end of the protrusion so as to shield a transmission path of heat flowed along a casing contact surface of the insulation panels, thereby improving insulation efficiency.

Abstract: A translucent building block and method of manufacturing the same where the block has at least two oppositely oriented outer surfaces between which extend a plurality of translucent members that are mounted to a retainer which supports the translucent members spaced inwardly of opposite free ends thereof which extend outwardly from the retainer to points adjacent the at least two outer surfaces and wherein a plurality of openings are provided through the retainer to permit passage of cast material during introduction of the material about the translucent members within a mold during a manufacturing process.

Abstract: A house, (or other building) built using structural insulated panels (comprising a frame around a slab of polystyrene). Tempered glass covers the panels that are used in the roof and outside walls, and is also used for inside walls and partitions. Windows and skylights are holes in the polystyrene, but are covered by the same glass. Light emitting diodes or starlights are set between the glass covering and the polystyrene. The windows cannot be opened, but fresh air may be introduced by heat recovery ventilators or extra glass outside doors. Structural insulated panels used in forming floors are covered by oriented strand board.

Abstract: A method of manufacturing a hollow core door is disclosed, as well as a corresponding hollow core door. The method includes the steps of providing a solid flat door skin, moisturizing the flat skin, applying a conditioning resin thereto, pre-heating the flat door skin, and thereafter pressing the flat door skin between a pair of heated platens in a press in order to reform the flat skin into a molded skin including a plurality of panels defined therein. The press continuously closes in order to reform the flat skin into the molded skin, with the rate of press closure being a function of the determined hardness of the flat skin to be reformed. The resulting door skins have an improved bond strength, and are efficiently manufactured.

Abstract: A method of manufacturing a hollow core door is disclosed, as well as a corresponding hollow core door. The method includes the steps of providing a solid flat door skin, moisturizing the flat skin, applying a conditioning resin thereto, pre-heating the flat door skin, and thereafter pressing the flat door skin between a pair of heated platens in a press in order to reform the flat skin into a molded skin including a plurality of panels defined therein. The press continuously closes in order to reform the flat skin into the molded skin, with the rate of press closure being a function of the determined hardness of the flat skin to be reformed. The resulting door skins have an improved bond strength, and are efficiently manufactured.

Abstract: A crack inducer controls propagation of cracks in set concrete containing reinforcing bars. The crack inducer has an elongated, rigid core that is relatively narrow in a direction that is parallel to outer surfaces of the concrete. The core has a core width in a first plane that intersects the outer surfaces of the volume, that is at least 20% of the concrete volume width so that a crack in the volume of concrete is induced to propagate from the core and along the first plane. A plurality of spaced cross-plates are connected to the core and a water-stop may be included around part of the core.

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: A prefabricated, faced roofing board composite includes a first board layer made of a polymeric material or a predominantly polymeric material and a fire and weather resistant fiberglass-based facer bonded to a top major surface of the first board layer and forming a top major surface of the composite. The fiberglass-based facer is substantially impervious to the passage of hot gases of combustion, water, and water vapor through the thickness of the fiberglass-based facer. The faced composite can be a cover board, an insulation board; can include cover board and insulation board layers; and can include cover board, insulation board, and baseboard layers. A second fiberglass-based facer that is substantially impervious to the passage of hot gases of combustion through its thickness can form a bottom major surface of the composite.

Abstract: The invention provides a method of constructing a building roof made from Expanded PolyStyrene (EPS) which is coated on the inside and outside with Glass Fiber Reinforced Concrete (GFRC). The building roof is designed in a CAD program. The roof is then constructed of beams, such as I-shaped beams, of foam and GFRC.

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: A low noise roof deck system eliminates the thermal expansion noises associated with metal decking and includes structural features that permit installation of composite roofing shingles directly over the deck without venting. The system includes a composite panel base layer surmounted by a layer of water resistant material, a layer of foam synthetic resin insulation and a layer of mineral board. A second layer of mineral board may be overlaid on the first mineral board layer. The system is easily installed over a system of conventional underlying supports to provide a strong, rigid deck for supporting a waterproof composite shingle roof membrane and forming a quiet weatherproof roof system. The composite base panel has a layer of synthetic resin foam insulation sandwiched between a base layer of wood fibers bonded with an inorganic cement and an upper layer of a resin bonded wood product.

Abstract: A structural sandwich plate member is provided with at least one stud welded to one or both of the outer plates and extending into the core. The stud may be arc stud welded to the outer plate before formation of the core. Alternatively, the stud may be installed after formation of the core by drilling a hole in one outer plate and friction welding the stud to one or both outer plates.

Abstract: According to the invention, an architectural thermal barrier component and method of forming same includes an elongate section incorporating a thermal break, for example for use in the manufacture of window, door, skylight frame assemblies and other fenestration related assemblies. The method comprises forming multiple co-extensive elongate elements, one of which includes a channel portion, and aligning the elongate elements with one another by snap-fitting the elements together or sliding the elements together longitudinally. After the initial assembly, the method includes crimping the elements in engagement with one another, filling the channel with a settable liquid of low thermal conductivity, effecting solidification of the settable liquid to form a solidified thermal barrier element, and cutting longitudinally through or debridging any part of the elongate elements that bridges the thermal barrier element.

Abstract: A deck plank cover made from a plastic material, such as a vinyl or HDPE or Wood composite, wherein the deck plank cover is designed to be affixed to the top surface of a preexisting deck plank. The deck plank cover is useful for repairing or protecting mildly deteriorated or deteriorating wooden deck planks of typical wooden decks. The deck plank cover may be affixed directly to the top surface of the existing wooden deck planks, and serves to substantially protect the wooden deck planks from further exposure to the elements. The deck plank cover uses inwardly angled side portions and wood engaging fillets to adhere to the deck planks without the need for screws, nails, or adhesives.

Abstract: The invention is a light weight, strong wall form made of a plurality of support tubes behind a sheet having side attachment means and an upper adjustable engagement with the structure. A plurality of prefabricated wall forms may be connected together in a design and shape desired by the user for use as foundations, concrete forms, or skirting.

Abstract: A sound-proof wall made of FRP in the form of a sound-proof wall panel that includes a core and skin members made of FRP positioned on both sides of the core and whose weight per nit area is within the range of 10-60 kg/m2; and a method of producing the same. This sound-proof wall, though light in weight, has a superior sound insulation property and will never corrode because it is made of FRP. Further, it has a high degree of freedom of engineering design including sound-proof property, design, and shape, capable of producing a desired sound-proof wall with case. Further, since it has a high specific strength, it is possible to attain a drastic weight reduction while retaining the necessary strength, and facilitate working, shorten construction time, and reduce construction cost.

Abstract: A re-bar (reinforcing rod) for concrete comprises an inner rod of a first material, and an over-wrap of a second material. The over-wrap may be structurally or functionally discontinuous relative to the inner rod.

Abstract: An evacuated panel is provided for thermal insulation of a body (3, 4) having non-planar surfaces, the panel having two main faces and comprising a flexible envelope (1), made of one or more barrier sheets, and a filling material formed of at least two boards (2; 2?) of an open cell polymeric foam, the boards lying one over the other, and each board having a thickness between about 2 and 8 mm.

Abstract: A coating system for in-situ coating of a surface formed by a plurality of plasterboard sections comprises a dry powder composition which is dispersible in an aqueous applicator medium and provides a very high quality surface finish to which gloss or matt paint may be applied directly without joint photographing or show-through of fasteners. The coating composition may be applied by a spray coating technique or a roller technique. The dry powder composition comprises calcium carbonate and, by weight, relative to calcium carbonate, from 4% to 11% of a polymeric binder, from 0.60% to 1.5% of a thickening agent and from 0.10% to 0.35% of a surfactant.

Abstract: Conductive roofing materials are formed of a conductive loaded resin-based material. The conductive loaded resin-based material comprises micron conductive powder(s), conductive fiber(s), or a combination of conductive powder and conductive fibers in a base resin host. The percentage by weight of the conductive powder(s), conductive fiber(s), or a combination thereof is between about 20% and 50% of the weight of the conductive loaded resin-based material. The micron conductive powders are formed from non-metals, such as carbon, graphite, that may also be metallic plated, or the like, or from metals such as stainless steel, nickel, copper, silver, that may also be metallic plated, or the like, or from a combination of non-metal, plated, or in combination with, metal powders. The micron conductor fibers preferably are of nickel plated carbon fiber, stainless steel fiber, copper fiber, silver fiber, aluminum fiber, or the like.