Abstract: A precast composite building system usable for walls, roofs, and floors of buildings, comprising a concrete composite panel element having embedded steel I-beams, wire mesh, embed plates, and steel tension reinforcement bars interconnected vertically, horizontally, and angularly by columnar elements rigidly fixed to the supporting foundation, embedded into the panel elements affixed to a transverse steel beam so as to form a perimeter tie-beam connection structure to which additional floor, roof, and wall elements are attached, forming a unitary, superior, load-bearing structure.

Abstract: A plurality of large wall elements for outer and inner walls and for roofs in buildings is piled up in the form of a stack (10) on a tilting table (1) and said tilting table (1) is rotated 90° with the purpose of gaining access from the top down to the narrow sides of the panels to be produced to fill the intermediate spaces (12) of the panel elements with concrete from the top. After hardening, the panels may be transported in vertical position.

Abstract: A system for constructing insulated concrete structures comprising panels molded from a closed cell foam plastic, with a facing material attached to the outside surface of panels adding substantial strength to panels during material handling and construction, providing a substrate for finish materials and adding UV resistance to panel surfaces. Panels are placed horizontally in an opposing and parallel spaced-apart relationship. Vertical studs are embedded in panels extending the full height of the panels, each stud has a flange and groove connected with a web. Spreaders slide vertically into the grooves of studs in opposing panels creating a form with a cavity between panels. Each spreader has opposing flanges connected by horizontal members, horizontal members having multiple formations, thus when spreaders are stacked the formations compliment each other allowing wall reinforcing to be locked in any preferred location. A chase way is provided in panels to accommodate electrical wiring.

Abstract: An insulated concrete form panel assembly for constructing insulated concrete walls includes a frame comprising a plurality of steel studs and at least two cross members that connect the studs together. A pair of insulating panels are fastened to and span respective inner and outer opposing sides of the frame so as to define concrete receiving cavities between the panels and the studs. A brick ledge may be constructed by separating a laterally extending, generally rectangular elongated mid portion of the outer insulating panel from a remainder of the outer insulating panel. An upper edge of the mid portion is then moved a predetermined distance outward from the remainder of the outer insulating panel such that the mid portion is disposed in a desired position at an angle to the remainder of the outer insulating panel. The mid portion is then secured in the desired position relative to the frame.

Abstract: The present invention relates to building panels used in the construction industry, and more specifically composite building panels comprised of an insulative core, concrete, and carbon fiber which are preformed, cast and transported to a building site for modular construction.

Abstract: Reinforcing bars for concrete structures, are made from a composite of a depolymerizable and repolymerizable thermoplastic resin and longitudinally oriented reinforcing fibers. These reinforcing bars provide excellent tensile reinforcement, and do not exhibit the corrosion problems of conventional steel reinforcing bars. The rebars are readily formed into a great many shapes that are adapted to many specialized reinforcement requirements.

Abstract: A system of building construction comprises prefabricated modules with wall sections having finished paneling on both faces, inner foam panels and spacers made from insulating foam, and a steel-reinforced concrete core. The modules come complete with outer and inner finished panels, as well as inner insulating foam so that no on-site mounting of the panels to the wall module is required. The foam panels and facing panels are attached together with a plurality of coilies or rigid spacers, held together with simple screws to create a complete wall system. Concrete is subsequently poured into the module cores to create a monolithic structure. The Inner-wall and outer wall is already in place and needs only to be decorated as desired. All elements stay in place and no forms or heavy external bracing are needed.

Abstract: A structural panel is formed of an isogrid web. The structural panel has a flat face covering one open side of the isogrid web and four sidewalls forming the edges of the isogrid web, The flat face and the sidewall form, in combination, an open topped box like structure. The isogrid web has a first plurality of ribs oriented vertically thereby providing columnar support for the structural panel and a second plurality of nibs oriented transversely at an angle to the first plurality of ribs thereby providing lateral support for the structural panel. The first plurality of ribs and the second plurality of ribs form, in combination, a pattern of repeating isosceles triangles thereby forming the isogrid web. The first plurality of ribs and the second plurality of ribs meet at a third plurality of nodes forming the vertices of the isosceles triangles.

Abstract: A method of manufacturing a low-moisture penetrating decorative floor surface. The completed floor surface has an appearance of a solid granite slab floor with greater durability. The floor surface has a smooth, flat appearance and can be manufactured in different shapes. The floor surface may be formed over a wood or concrete sub-floor and includes a self-leveling, cementous, low moisture penetrating material to which suitable colorants may be added. The cementous material comprises a topping and silicate-based sealant mixture that is mixed together and poured and leveled over the sub-floor to a desired height. Flakes of contrasting material is then sprinkled over the top surface of the mixture to create a decorative appearance. After drying, the surface is finely ground to a smooth finish. A coat of silicate-based sealant is then applied to the surface that penetrates the porous surface to create a low moisture emitting surface The surface is then ground to a fine surface and rinsed.

Abstract: A molded composite construction panel formed in a vertically oriented continuous molding procedure included a lightweight cellular core of rigid foam material and a relatively thin skin of fiber reinforced concrete encasing the core. The panel further including at least one integrally formed multi-faceted channel being substantially coextensive with at least one edge of the panel. A method of forming a building panel is also disclosed comprising the steps of providing a mold having a mold cavity, disposed vertically, that defines the mold surface for forming the exposed finish surfaces of a molded wall panel, where the mold cavity bottom and side edge walls define the edge walls of the molded wall panel. A foam insert is positioned and secured in the mold cavity. A slurry of concrete, sand, and fiber strands is formed to produce a homogeneous panel mixture. The mold cavity is filled with the panel mixture.

Abstract: An insulating construction form consisting of a pair of spaced apart panels and a plurality of ties is applied to the building of structural walls. The tie members include pairs of resilient retainer arms, which define a series of adjacent receptacles. A reinforcing bar is typically inserted into the receptacles and its displacement therefrom is inhibited by abutment surfaces. Markings are positioned on each panel to guide the attachment of a cladding. In one aspect, the construction form serves for the formation of a corner, wherein a vertical rod is positioned for the attachment of the cladding. In another aspect, the panels includ a plurality of openings made at the time of manufacture.

Abstract: A building panel constructed of a gypsum-cement-catalyst formulation molded in layers and including a rigid stud framework. The layers include surface layers, a fire resistant layer and an insulating layer, as well as reinforcement and building paper. A modified panel is molded in layers with structural strength provided by a grid providing spaced apart wire panels.

Abstract: A vertical reinforced concrete wall for a concrete building including a plurality of insulating panel units horizontally spaced from each other each formed of a polystyrene foam material having a rectangular shape. A pair of channel-shaped vertical side members having side flanges and inturned lips on the side flanges are fitted over the side edges of the insulating panel on site with the lips biting into the insulation panel to secure the side members thereon. The plurality of spaced insulating panel units are mounted between a pair of opposed upper and lower channel-shaped track members which extend horizontally to define the upper and lower ends of the vertical wall. The units are spaced from each other a predetermined distance, such as eight (8) inches, to form space for a vertical concrete column between adjacent insulating panel units.

Abstract: An easily constructed and highly durable structure, and method of making the same. The structure is constructed of lightweight foam panels assembled into walls and a roof, and therefore requires no framework. The entire structure is then sprayed with a cementitious coating. The cementitious coating is applied directly to the foam panels, and dries with sufficient strength and durability to make the structure load-bearing.

Abstract: An expansion or crack joint assembly (32) utilizes a coupler (20) with or without a bottom sheet (34) to join adjacent roadway concrete slabs (86, 90) formed separately initially or continuously cast and later separated by a saw cut, which induces cracking to form a crack joint. The coupler (20) includes a casing (22), an internal component (24,25,62,65), and outer sleeve (26), and end caps (28,30). The casing (22) defines an internal chamber (40) which receives the internal component (24,25,62,65) therein. The sleeve (26) and end caps (28,30) fit over the casing (22). The casing (22) and sleeve (26) transmit loads between the concrete slabs (86,90) while the sleeve (26) and end caps (86,90) operate to reduce stress concentrations. The bottom sheet (34) inhibits water from entering the expansion or crack joint assembly (32) from below, if used, and prevents pumping.

Abstract: The present invention relates to a multiple layer composite material and to a method for producing the same. Said multiple layer composite material has at least one layer of cement-bound concrete and at least one layer of polymer-bound concrete. The transition between adjacent layers of cement-bound concrete and polymer-bound concrete has at least the material strength of the less stable one of the concrete layers adjoining the transition. The layer of polymer-bound concrete allows the diffusion of water vapor, but does not allow liquid water to penetrate. The multiple layer composite material can be produced completely in an aqueous system.

Abstract: A precast concrete bridge system containing one or more sections wherein each section includes a horizontally disposed, load-bearing span that is integrally cast with a pair of vertical side walls. Each wall contains lightweight cores encapsulated in the concrete to create a series of longitudinally extended beams in each wall so that the beams in one wall are coaxially aligned with the beams in an adjacent wall. The cores constitute between 16-35 % of the total section volume.

Abstract: A prefabricated concrete panel for building floors in civil or industrial structures, comprising a concrete body with a reinforcement provided with portions which protrude from one of the larger faces of the body of the panel which constitutes extrados of a floor and are designed to be embedded in the casting of the topping of the floor. At least one first shaped sheet is provided inside the body of the panel, is made of thermally insulating material, is interposed between the two larger faces of the panel body and forms, between the two larger faces of the panel body, a ventilation chamber which is composed of a plurality of mutually connected cells.

Abstract: A system is disclosed for securing insulation panels to the surface of a poured concrete wall by securing caps to the protruding ends of the ties extending through the wall.

Abstract: A prefabricated wall system for free-standing subdivision partitions, highway sound and visual barriers, privacy walls, or walls of a building having a plurality of prefabricated modular panels that are removably interconnected and installed. Each panel is essentially a factory-built sandwich having an expanded plastic foam core between two composite reinforcing wafers. Each wafer is comprised of an inner layer of fiberglass coated with an exterior layer of concrete reinforced with a grid of steel bars. The foam core has a pair of vertical cylindrical voids sized and spaced to mate with foundation columns pre-poured on site. The ends of each panel are reinforced with a steel sling lifting assembly embedded in concrete that includes removable eyebolts at the top edge whereby the panels can be attached to cables at each end for hoisting above the foundation columns and then lowering into place. A vertical groove or trough at each end of the panels receives a connector, such an expansion joint filler.

Abstract: A building board comprises a core of gypsum which has penetrated a glass fiber sheet embedded in one face and a coating of gypsum integral with the core material which has passed through the sheet. An apparatus for making such a board includes; a lower forming surface and an upper forming surface defining a forming zone between them in which the plasterboard is formed. A supply of a first slurry is provided to the lower forming surface. A supply of a second slurry is provided to a glass fiber sheet to coat the upper surface of the sheet with the second slurry. A device is provided for passing the coated sheet into the forming space, whereby the lower surface of the sheet contacts the upper surface of the first slurry. A vibrator roller is provided for vibrating the upper forming surface so that the first slurry passes through the sheet into the second slurry. A method of making the board is also disclosed.

Abstract: The invention relates to a light weight structural element, in particular in the shape of a panel, especially for building construction, containing a support structure. The light weight structural element contains at least two supporting rods, which at their ends are interconnected by cross-bars. Between the supporting rods and the cross-bars may be a core; wherein the surfaces of the supporting rods are interconnected by an adhesive skin made from a material of a thickness between 0.5 and 5 mm. The invention also relates to the construction technique of constructing buildings using the light weight structural elements.

Abstract: A system is disclosed for securing a layer of insulation in place between two spaced apart wall forms while concrete is poured on both sides of the insulation layer.

Abstract: A precast concrete wall panel and system using such panels, with each panel including a rectangular concrete frame having a flat outer side and a recessed inner side. On the perimeter of the panel and along the face of the recessed inner side, concrete ribs are cast for stiffness. The recessed inner side is embedded with an insulation batt. A strip of wood molding is provided on each inner longitudinal edge of the frame. Using this molding, dry wall may be conveniently fastened to the concrete panel to finish the inside wall surface. To form a wall, the panels are placed side by side. Joints between the panels coincide with reinforcement rods extending upwardly from the building foundation. Recesses in the sides of the panels create channels or keys through which the rods extend. Concrete is poured into the keys to secure the panels to each other and to the foundation. The wall panels are complemented with special components such as corner components, window frames and door frames.

Abstract: A die assembly for providing a gypsum ceiling tile having improved acoustic absorption properties includes a punch plate having punches which form perforations through a plasterboard tile and indentors which form indentations in the tile. The punches and indentors are arranged in elongate strips to produce fissure-like perforations and indentations. A stripper plate having apertures corresponding to the punches and indentors and a die plate having apertures corresponding to the punches sandwich the tile, and the punch plate is applied to the tile.

Abstract: 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 the 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: Provided is a composite building material which is more improved in the bonding capability of a cement mortar material itself with a foamed synthetic resin plate layer, furthermore prevents the occurrences of exfoliations and cracks and has higher strength compared with conventional composite materials. Plural concave grooves are formed in parallel on at least one of the surface and backface of a foamed synthetic resin plate layer and a net-like groove lathing material corresponding to the size of each groove is arranged within each groove. A cement mortar material is filled in the groove so as to bury the groove lathing material, a net-like surface lathing material is then stretched over all of one surface and a cement mortar material is further laminated to form a composite building material in which the foamed synthetic resin plate layer and the cement mortar layer are integrated with each other.

Abstract: A building assembly for efficiently and economically constructing walls and roofs for a building assembly that utilizes a prefabricated building panel. The prefabricated panels utilize miter-cuts when joined, form cores, interior and exterior walls, and roofs, when placed together. The walls are pre-formed, offsite according to the required size dimensions and then transported to the job site. The panels are made essentially of a expanded polystyrene panel having cores and channels. Each building panel also includes vertically disposed parallel voids that are approximately 4 in. in diameter, spaced approximately 2 to 4 ft. apart, and receive poured concrete and steel rebar to provide structural rigidity to the entire building assembly. The poured concrete includes rebars that protrude through the entire channel and coring system and are embedded in the slab, and which may be extended above the wall height to bend and overlap the roof for added structural support.

Abstract: A self-supporting construction element (1, 101) of expanded plastics, in particular for manufacturing floor elements and walls of buildings in general comprises: (1) a central body (2), substantially parallelepipedic in shape and having two opposite faces (6, 7); at least one reinforcing section bar (8,9) transversally extending across the central body (2) between the faces (6,7) thereof and embedded in the expanded plastics; a lath (16) for supporting at least one layer (17) of a suitable covering material, associated to a fin (11,12) of the reinforcing section bar (8,9) lying flush with and substantially parallel to at least one of the faces (6,7) of the construction element (1,101).

Abstract: Fiberboards are provided containing at least about 65 wt. % calcium sulfate dihydrate derived from hemihydrate or anhydrous gypsum, and at least about 7 wt. % pulped paper fibers. The boards are capable of being formed into structural members having superior mechanical properties and/or fire resistance, including screw-holding capacities in excess of 650 lbs.

Abstract: A stay-in-place composite form provides a strong and durable concrete structure. The form includes a composite shell having an inner wall surface defining an enclosure into which concrete may be poured and allowed to harden. The composite shell may be made of one or several layers of fabric having a resin matrix impregnated therein. The concrete hardens to form a concrete core within the enclosure and a liner is affixed to the inner wall surface of the composite shell to protect the composite shell from alkalinity in the concrete core. The liner includes at least one sheet of a water-impermeable material to protect the concrete core from water and other corrosive elements. The fabric layers are selected such that the fibers elongate as the concrete is poured into the enclosure due to a weight of the concrete and partially shrink back to compensate for shrinkage of the concrete as the concrete dries to form the concrete core.

Abstract: Reinforcing bars for concrete structures, are made from a composite of a depolymerizable and repolymerizable thermoplastic resin and longitudinally oriented reinforcing fibers. These reinforcing bars provide excellent tensile reinforcement, and do not exhibit the corrosion problems of conventional steel reinforcing bars. The rebars are readily formed into a great many shapes that are adapted to many specialized reinforcement requirements.

Abstract: This invention is intended to provide a high strength porous concrete structure which is preferably applied to a water permeable pavement, a draining pavement, a sound insulating board, a sound-proofing barrier, a sound absorbing block for acoustic, a block for plants, a riverbed block, a water purifying matrix, a gas absorbing matrix, a decorative board for building, a fish reef, a block for fish reef or a block for breeding algae and to provide a method of manufacturing the high strength porous concrete structure.

Abstract: Building element including of two parallel welded wire grid mats (1, 2), of straight web wires (7) which hold the wire grid mats at a predetermined distance apart and are joined at each end to the two wire grid mats, and of an insulating body (8) which is arranged between the wire grid mats and through which the web wires pass, wherein at least one of the wire grid mats is in the form of a grid reinforcement mat which possesses a minimum strength of the weld nodes which complies with the static requirements applicable to the building element, corresponding mechanical strength of the grid mat wires (3, 4) and also corresponding diameters and mutual spacings of the grid mat wires, and wherein the web wires are arranged in predetermined directions relative to the wire grid mats, and the insulating body is held at a predetermined distance from each of the wire grid mats.

Abstract: A reinforcing grid which advantageously includes fibers of both a first type and a second type is provided. The first type of fibers have a strength sufficient to reinforce the hardenable structural material, such as concrete, after hardening. The first type of fibers also have a higher resistance to degradation in the hardenable material than the second type of fibers. As such, the first type of fibers will continue to reinforce the hardened material in the event the fibers of the second type become corroded in the hardened material. Consequently, a less expensive type of fiber can be used as the second type of fiber and can corrode in the hardenable material without concern for the strength of the hardened structural product. According to one embodiment, the first type of fibers comprises carbon fibers and the second type of fibers comprises glass fibers.

Abstract: A precast concrete modular device using thin coffered sections reinforced preferably with carbon and/or glass fiber scrim grids, in between steel reinforced ribs is provided. The thin reinforced sections stiffen the steel reinforced precast frame. The thin sections preferably have a thickness less than about two inches, preferably less than about 1½ inch, and more preferably less than about 1 inch. The resultant modules have an areal weight of less than about 40 lbs. per square foot.

Abstract: The application of a reinforcing layer to the visible face of slabs of stone material. For slabs of marble and granite, especially thin slabs, the reinforcing layer is constituted by non-twisted glass threads, preferably in the form of a mat, and by a transparent resin resistant to the action of atmospheric and chemical agents. A reinforced slab is obtained which has a small thickness and in which the resistance to negative flexing is greatly increased, along a front face concomitantly with the resistance to positive flexing along the rear, or invisible, face of the slab when the rear face is also reinforced.

Abstract: The present invention comprises a concrete building system with a method for fabricating composite panels using an improved design plastic connector and assembling them at the construction site to a structure which will be shotcreted on both sides to a concrete building which is highly insulated, is fire and termite proof, hurricane, earthquake and flood resistant and fulfills the requirement for flexible design. The Composite Panels are composed of two concrete layers, enclosing an insulative foam core. The skins are reinforced with wire mesh as structurally required and are connected through the foam core by structural highly insulative plastic connectors using the snap connection on both ends of the connectors so they form a tri-dimentional system and hold the wire mesh in place for the onsite shotcrete application, which includes an application of fiber for shrinkage and cracking.

Abstract: A cladding element is provided with a decorative relief pattern milled into the outer facade of the cladding element, forming a matte having a grid-like interconnective cellular structure. The matte is mechanically fastened to a wall structure as by fasteners extending through a fastening face thereof into the wall and a layer of plaster material is set within the matte's cellular structure. An outer finish coat is applied to complete an outer, wall finish cladding assembly. The interconnective cellular structure is formed of adjacent cells arranged in rows and columns with the cells opening at the outer face of the cladding element. The cells including a first and second set of cells with the first set of cells being tapered to a narrow end adjacent the outer face and a wide end adjacent the fastening face. The second set of cells being tapered to a narrow end adjacent the fastening face and a wide end adjacent the outer face.

Abstract: A construction form for building an insulated concrete reinforced wall includes separable and independently usable lintel block and post block sections, made from injection molding Styrofoam. The lintel block section includes a channel extending horizontally and fully along its top portion. The channel includes multiple knock-out plugs within the bottom wall. The lintel block section also has multiple parallel and vertically spaced apertures with one end opened at a lower end, and extending upward to a closed end terminating at one plug within the bottom wall of the channel. The post block section is stackable with the lintel block section.

Abstract: A building element (1) comprising an outer sheath and an inner core, the sheath being formed of a material having a greater tensile strength than compressive strength and the core having a greater compressive strength than tensile strength; wherein the outer sheath is longitudinally extending and has a first face (7) and a second face (8) which are spaced apart, first (9) and second (21) edges and a first and second end; wherein the first face (7) and the second face (8) are joined at the first (9) and second (21) edges to form the outer sheath as a continuous body, and wherein the first edge (9) and the second edge (21) are so shaped that the first edge (9) of one such building element (1) is adapted to locate in the second edge (21) of another such building element (1).

Abstract: A prefabricated concrete wall form system which can be taken to a construction site, joined to other wall forms to form a wall, and filled with concrete. The wall form has an outer wall and an inner wall, each of which can be made from gypsum wall board, plywood sheathing, OSB sheathing, medium density overlay plywood, cement board, rigid foam board, exterior gypsum sheathing, steel siding, steel or aluminum sheet, or fiberglass panels. The outer and inner panels are braced by a series of horizontal, zigzag wires. Vertical wood strips having horizontal grooves corresponding to the wires are used to hold these wires in place. Electrical boxes, plumbing conduits, electrical conduits, doors, windows, and floor joist pockets are made by including a wood mold inside the wall mold, forming the desired hollow structure within the concrete.

Abstract: A thermal barrier fabricated from pumice, or pumice-like material, and a suitable binder is provided. It may be formed as a self-supporting or load-bearing structural member, or as a thick coating for IR signature reduction. A first embodiment may be used to build a structure, e.g., a room onboard a ship that serves as an effective thermal barrier. Should a fire start in the room, the thermal barrier prevents rapid spreading of the fire and provides crews additional time to fight the fire. A second embodiment, as a thick coating, reduces the IR signature of a radiating body, such as an exhaust stack, by a factor of four. This thick coating helps shield an object from IR surveillance devices or seekers, resulting in much shorter acquisition and tracking times for these IR devices and seekers. In addition to benefits as a thermal barrier, structural members using concepts disclosed for this invention may provide inherent blast and shock resistance.