Abstract: A modular building system allows for quickly and easily erecting prefabricated wall panels on a building foundation at a construction site. The system allows for manufacturing and installing, at a high level, complete budding components, using steps that are highly repeatable and scalable, resulting in construction that is quick and efficient, and easily performed at many types and locations of construction sites. A system in accordance with the invention comprises a wad panel, a floor panel and a roof panel. The wad panel comprises a horizontal member supported along a bottom horizontal edge, and a plurality of vertical studs integral to the horizontal member and extending vertically downward from the horizontal member. A floor panel comprises a rail disposed rigidly fixed to the foundation and defining an enclosure to receive the plurality of vertical studs of the wall panel to thereby vertically position the wall panel upon the foundation.

Abstract: The techniques disclosed herein include a blueprint compositing technique that may process blueprint data to generate multiple composable components. The multiple composable components may be processed to produce multiple blueprint component options including a master blueprint. A master blueprint and at least one other blueprint component option may be selected. A composited blueprint may be produced based on the selections of the master blueprint and the at least one other blueprint component option.

Abstract: Below grade fluid containment structures, which may include a foam floor and a foam wall extending upward from the floor, the foam wall being formed from foam panels and optionally a plurality of metal splines. A foam buttress is provided as part of or adjacent to the foam wall, for reducing pressure against an exterior face of the foam wall that would otherwise be exerted by the soil, in the absence of the foam buttress, which places a top portion of the soil at an angle of repose, to minimize inward pressure. A concrete footing can be provided below the foam wall, where the splines of the wall are vertically oriented in the foam wall, with a bottom of the splines anchored into the concrete footing. The interior surface of the pool or other structure can be coated with any desired finish coating.

Abstract: A racked fence gate assembly comprises an upright having a longitudinal opening and a lateral opening. The assembly also includes an insert received within the longitudinal opening and coupled to the upright. The insert also includes a support portion extending from a rear wall. The assembly further includes a rail having trimmable areas at proximal and distal ends that is at least partially received within a cavity of the insert at a racking angle, the rail including a channel configured to at least partly receive the support portion therein.

Abstract: Below grade fluid containment structures, which may include a foam floor and a foam wall extending upward from the floor, the foam wall being formed from foam panels. A granular material is provided for reducing hydraulic soil pressure against an exterior face of the foam wall that would otherwise be exerted by the soil, if the soil were allowed to be positioned up against the foam, particularly the foam wall. The well-draining granular material may be gravel, crushed stone, or the like, which provides better drainage as compared to the surrounding soil material. The interior face of the foam is coated with an elastomeric abrasion resistant impact resistant polymeric coating that seals the below grade interior space defined between the floor and the wall in a seamless water-tight configuration.

Abstract: A method of manufacturing a hybrid insulating panel includes providing a mold of a frame, dispensing a first foam material in a liquid phase in the mold, and placing a beam in the mold. The method includes curing the first foam material to form an integrated frame, in which the integrated frame includes the beam at least partially surrounded by the first foam. Further, the method includes dispensing a second foam material into a panel cavity to form a panel body. The panel cavity is at least partially defined by a side of the integrated frame. The method includes curing the second foam material to form a panel body, wherein the panel body is secured to the integrated frame.

Abstract: An insulation system is configured for mounting to corrugated walls such as the walls of a shipping container. A first end has a first coupling surface and a second end opposite the first end has a second complementary coupling surface. Mating alignment portions are on a top surface of the panel and on a bottom surface of the panel. The second face includes a corrugated surface with a protruding first surface parallel to the first face, a recessed second surface spaced apart from and parallel to the first surface, and third and fourth surfaces extending between the first surface and the second surface, the third and fourth surfaces being orthogonal to the first and second surfaces.

Abstract: A method for forming a structural wall section by sandwiching a corrugated metal panel between correspondingly corrugated EPS inner and outer panels. Also disclosed is a structural wall formed from a corrugated metal wall sandwiched between inner and outer EPS panels with a corrugated side on each of the EPS panels engaged with the corrugated metal panel.

Abstract: A building comprising a structural frame of the building, at least one window or door supported by and substantially aligned to the frame, and an external wall formed by at least one insulated sandwich panel, the panel(s) in the external wall being supported by the frame and being offset externally from the frame, wherein the frame is exposed in at least part of the interior of the finished building and wherein at least part of the internal wiring of the building traverses the interior of the building on and/or in the frame.

Abstract: A construction system using core blocks having a horizontal front mounting recess in the front surface defining a core detent lip, and face blocks having a horizontal rear mounting recess defining a face detent lip, and connectors for supporting stacked courses of the face blocks suspended on the front surfaces of stacked courses of core blocks, the connectors having a rear hook and a front hook, wherein the face blocks are each supported by their rear surfaces with at least one connector, by engagement of the front hook with the face detent lip and engagement of the rear hook with the core detent lip.

Abstract: Building design data is input into a computer to make a series of wall frames for a building. Operational instructions from the computer are used to fabricate members of the frames, fill the frames with insulating material and apply and external waterproof coating.

Abstract: A structural insulated panel is composed of a structural member in a corrugated form and a cohering, insulating filler material. The structural member has a plurality of front surfaces spaced laterally apart from each other and a plurality of back surfaces spaced laterally apart from each other and spaced apart in depth from the front surfaces. The structural member has a plurality of chord panels which span between corresponding edges of respective pairs of the front surfaces and the back surfaces. Chase channels are formed between adjacent pairs of the cord panels and one of the front surfaces or one of the back surfaces. Each chord panel defines a plurality of apertures. The filler material fills the chase channels, binds to the front surfaces, back surfaces, and chord panels, and extends through the apertures in each of the cord panels to structurally connect the filler material in adjacent chase channels.

Abstract: A panel for a building form made of insulating material such as polystyrene is integrated with a reinforcing member for enabling the panel to resist deformation due to forces applied against its concrete-facing surface. Reinforcement of floor/roof panels is beneficial to reduce the amount of, or eliminate the need for, shoring for supporting the weight of wet concrete or workers. The reinforcement resists against deformation due to cracking, splitting etc. Reinforcement is likewise beneficial for wall forms where the weight of concrete asserts significant pressure against the concrete-facing surface of the form, in order to resist deformation of the wall forms under pressure. The reinforcing member may be made of a plastic material such as polypropylene or high-impact polystyrene. Methods of manufacturing reinforced form panels are disclosed.

Abstract: An insulating panel to be used in a panelized insulation system for insulating and finishing walls, including basement walls has a foam core made of inorganic materials. The system incorporates a capillary break, an integrated water drainage system and an electrical wire chase system within an insulating wall panel. Vertical slots are provided for insertion of metal studs for use in attaching the interior finish panel, such as inorganic fiber cement board with a vinyl laminate finish, onto the insulating panels. Embedding metal studs in the panel core reduces the sound transmission though the panel and eliminates thermal bridging between warm and cold surfaces. Steps on the edges and the top/bottom surfaces of the insulating panel allow more panels to join together with shiplap joints.

Abstract: Flat faced stud members adhered to one face of a rigid, planar core and sheathing adhered to an opposing face of that core create a wall panel. The adhesive used to adhere the sheathing to the core is non-continuous and follows a pattern used to attach the stud members to the core. A top plate and a bottom plate are adhered to the core and adhered to the stud members. A cap connects to at least one of the plates and overlays an end of the sheathing. The cap, plates, core, stud members, and sheathing bound by adhesive create a cohesive assembly which is structurally considered a single unit.

Abstract: A foam wall structure includes a frame, at least one primary support member, and a foam layer. The frame can include: a first member; a second member spaced apart from the first member; and two side members extending between the first and second members. The frame defining a front frame surface and an opposite rear frame surface. The at least one primary support member can be positioned between the two side members and extend between the first and second member. The primary support member defines a front support surface and an opposite rear support surface. The foam layer can be received within at least a portion of the frame and overlies the front surface of the primary support member to form an uninterrupted exposed foam surface. A method of making a foam wall structure is also disclosed.

Abstract: A wall panel configured for quick and easy manufacturing and assembly to create affordable, sustainable buildings. The wall panel has a main wall section having an inside-facing surface and an outside-facing surface opposite the inside-facing surface; a first set of elongated studs embedded in the outside-facing surface of the main wall section, each elongated stud in the first set of elongated studs having a length; a second set of elongated studs embedded in the inside-facing surface of the main wall section, each elongated stud in the second set of the elongated studs having a length; wherein the length of each elongated stud of the first set of elongated studs is greater than a height of the main wall section, and wherein the length of each elongated stud of the second set of elongated studs is equivalent to the height of the main wall section.

Abstract: A composite panel comprises an outer skins and an inner core. The inner core includes a frame, an elastomeric material disposed between at least a portion of the frame and the outer skin, and a foamed polymer filler. Also disclosed is a method of manufacturing the same.

Abstract: The invention comprises a relatively lightweight cementitious-based material panel. The cementitious-based material panel comprises a foam insulating panel having a first surface and a second surface; a first structural layer of cementitious-based material formed on the first surface of the foam insulating panel and affixed thereto; and a second non-structural layer of cementitious-based material formed on the second surface of the foam insulating panel and affixed thereto. The second non-structural layer of cementitious-based material is substantially thinner than the first structural layer of concrete. The second non-structural layer of cementitious-based material is preferably formed from polymer modified concrete, plaster or mortar. A method of making the cementitious-based material panel is also disclosed.

Abstract: Disclosed herein are embodiments of foam backing panels for use with lap siding and configured for mounting on a building. Also disclosed are lap siding assemblies and products of lap sidings. One such embodiment of the foam backing panel comprises a rear face configured to contact the building, a flat front face configured for attachment to the lap siding, alignment means for aligning the lap siding relative to the building, means for providing a shadow line, opposing vertical side faces, a top face extending between a top edge of the front face and rear face and a bottom face extending between a bottom edge of the front face and rear face.

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: Provided is a resin panel produced such that the positioning of a reinforcing material can be precisely done, rattling movement is prevented and distortion by molding shrinkage is not caused because the reinforcing materials are maintained in the foam. A resin panel is a hollow double-wall structure including a front wall, a back wall and a peripheral wall joining the front wall and back wall together. The peripheral wall of the resin panel has a welded part on its entire periphery. Within a hollow part is inner packed a foam made of a thermoplastic resin that is formed in advance in the substantially the same shape as the shape of the space within the hollow part. The foam is welded on the inner wall faces of the front wall and back wall of the resin panel. In the foam are formed accommodation parts for accommodating reinforcing materials. The reinforcing materials are lengthwise. The foam intervenes between the ends of both of the reinforcing materials and the peripheral wall.

Abstract: A composite reinforced mull post is disclosed for use in an entryway assembly. The mull post may engage a door on one side and a side light window on the other side. The mull post may comprise a one or two piece outer portion and one or more internal reinforcing members. The outer portion may comprise a plurality of interlocking pieces. The pieces may include a stop portion and a support portion, each with interlocking ribs. A first internal reinforcing member may be formed of engineered material such as a wood laminate, and a second reinforcing member may comprise a channel that extends partially around the first reinforcing member. The reinforcing member may include orthogonal portions conterminously received within a correspondingly shaped central chamber formed by the housing formed by the joined interlocking pieces.

Abstract: A building panel structure is disclosed, where the building panel structure includes composite building panels. A composite building panel 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: The present invention is directed to a method of fabricating a wall structure that comprises a polyurethane backing. In certain embodiments, no additional layer is coated onto or disposed on the polyurethane backing that is formed through the process disclosed herein.

Abstract: A composite building panel that includes a central body, substantially parallelepipedic in shape, containing an expanded polymer matrix, having opposite faces, a top surface, and a bottom surface; at least one embedded framing stud longitudinally extending across the central body between the opposite faces, having a first end embedded in the expanded polymer matrix, a second end extending away from the bottom surface of the central body, and one or more expansion holes in the embedded studs between the first end of the embedded stud and bottom surface through which the polymer matrix expands. A concrete layer can optionally cover a portion of the top surface and/or bottom surface. The building panel can be positioned perpendicular to a structural wall and/or foundation to provide a floor panel. The second end of the framing studs can be embedded in a second central body to provide an insulated concrete form.

Abstract: The invention comprises a method of forming a concrete structure. The method comprises placing plastic concrete in a form of a desired shape, encasing the concrete in insulating material having insulating properties equivalent to at least 1 inch of expanded polystyrene and allowing the plastic concrete to at least partially cure inside the insulating material. An insulated concrete form and a method of using the insulated concrete form are also disclosed.

Abstract: A construction method is disclosed. The method includes providing a bottom support between a plurality of structural members and using the bottom support to support a structural material in a plastic state. The method also includes using the bottom support to support the structural material as it hardens from a plastic state into a hardened state. The structural material remains attached to the bottom support after the structural material hardens. The bottom support is transparent or translucent.

Abstract: A building system comprising: a building panel comprising first and second outer sheet members, an inner sheet member disposed between the first and second outer sheet members, and solid insulating material disposed between the first and second outer sheet members and the inner sheet member; a first track member, the first track member and the building panel being arranged such that the panel is engagable along a first side with the first track member and the first track member is connectable to the first and second outer sheet members; a second track member, the second track member and the building panel being arranged such that the panel is engagable along a second side with the second track member and the second track member is connectable to the first and second outer sheet members and the inner sheet member.

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 composite building panel including a central body, substantially parallelepipedic in shape, comprised of an expanded polymer matrix, having opposite faces, a first surface and an opposing second surface; and one or more reinforcing members longitudinally extending across the central body between said opposite faces, having a first side portion embedded in the expanded polymer matrix, and a second side portion extending away from the first surface of the central body and one or more expansion holes located in the reinforcing member between the first side portion of the reinforcing member and the first surface of the central body. The central body includes a polymer matrix that expands through the expansion holes; and a space defined by the first surface of the central body and the second side portion of the reinforcing members is adapted for accommodating utilities through the space.

Abstract: The present invention is directed to a method of fabricating a wall structure that comprises a polyurethane backing. In certain embodiments, no additional layer is coated onto or disposed on the polyurethane backing that is formed through the process disclosed herein.

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 foam wall structure includes a frame, at least one primary support member, and a foam layer. The frame can include: a first member; a second member spaced apart from the first member; and two side members extending between the first and second members. The frame defining a front frame surface and an opposite rear frame surface. The at least one primary support member can be positioned between the two side members and extend between the first and second member. The primary support member defines a front support surface and an opposite rear support surface. The foam layer can be received within at least a portion of the frame and overlies the front surface of the primary support member to form an uninterrupted exposed foam surface. A method of making a foam wall structure is also disclosed.

Abstract: A system for revitalizing an existing structure and a method of using the system are disclosed. The system includes an insulating panel that has a body and reinforcing metal strips. The system also includes at least one fastening strap coupled to the insulating panel, the fastening strap has at least one recess having a hole. The system also has at least one fastening device that passes through the hole in the recess of the fastening strap and secures the at least one fastening strap and the insulating panel to the existing structure. The recesses of the fastening strap are positioned so that the fastening devices engage the body of the insulating panel.

Abstract: A system and method for constructing and using modular building blocks. The blocks may include two walls, a course, end conditions, a reinforcing assembly, and vertical and lateral retaining members. The walls may include lateral supports disposed lengthwise on a top and a bottom surface. Lateral retainer members may be disposed into the lateral supports. The walls may also include channels extending from the top surface to the bottom surface. Vertical retainer members may be disposed into the channels. The course may be disposed between and coupled to the walls and characterized by one or more turns. The reinforcing assembly may be set inside the walls and the course. The reinforcing assembly may include wire mesh portions disposed to form interlocks, where the interlocks provide structural support for the channels. The modular building blocks may be coupled together with structurally complimentary end conditions.

Abstract: A load bearing wall system which is made from a plurality of interlocking panels. Each panel includes a hollow panel body having a first end, a second end, and an interior cavity. A male coupling is positioned at the first end and a female coupling is positioned at the second end. The female coupling is capable of interlocking with the male coupling of another of the plurality of interlocking panels. The male coupling houses a structural stud that extends for the entire vertical height of the hollow panel body. The interior cavity of the hollow panel body is filled with insulation. Interlocking panels intended for straight sections have the female coupling opposed to the male coupling in a linear alignment. Interlocking panels intended for a corner or change in direction have the hollow panel body bent so that the female coupling is angularly offset from the male coupling.

Abstract: A wall system includes a first wall section a structural portion, such as concrete block construction. A second wall section mounts to the first wall section and includes insulating panels connected in an edge to edge relationship to form a continuous insulating layer. A third wall section of conventional finishing materials such as drywall, paneling or exterior finish layer mounts over the second wall section. Each of the insulating panels includes mounting elements at least partially embedded therein that provide for mounting the panels to the first layer and for mounting the third wall section to the second wall section. Each of the panels is lightweight and may be water impervious. The panels have ridges formed therein that define channels for routing wiring and other components. The panels also include complementary edges and complementary alignment features.

Abstract: A composite reinforced mull post is disclosed for use in an entryway assembly. The mull post may engage a door on one side and a side light window on the other side. The mull post may comprise a one or two piece outer portion and one or more internal reinforcing members. The outer portion may comprise a plurality of interlocking pieces. The pieces may include a stop portion and a support portion, each with interlocking ribs. A first internal reinforcing member may be formed of engineered material such as a wood laminate, and a second reinforcing member may comprise a channel that extends partially around the first reinforcing member. The reinforcing member may include orthogonal portions conterminously received within a correspondingly shaped central chamber formed by the housing formed by the joined interlocking pieces.

Abstract: A method for providing standardized modular elements usable to construct a building. The method includes defining a set of allowable functional building block configurations divided into assembly levels, defining allowable configurations and allowable interactions for each allowable functional building block configuration usable in a building configuration. The method also includes producing standardized modular elements based on the allowable configurations and allowable interactions for a desired building configuration. Fabricated standardized modular components are provided (produced, assembled, or fabricated) at an off-site location and employed in a building at an on-site location.

Abstract: An anchoring rail is disclosed. The anchoring rail includes a rail body that has a holding space extending in the longitudinal direction of the rail body, a filler body that is provided in the holding space of the rail body, and at least one fiber-reinforced tear strip that is arranged between the rail body and the filler body for removing the filler body from the holding space. The tear strip has a matrix of modified natural rubber at least partially surrounding the fibers.

Abstract: The invention comprises a method of forming a concrete structure. The method comprises placing plastic concrete in a form of a desired shape, encasing the concrete in insulating material having insulating properties equivalent to at least 1 inch of expanded polystyrene and allowing the plastic concrete to at least partially cure inside the insulating material. An insulated concrete form and a method of using the insulated concrete form are also disclosed.

Abstract: The present disclosure relates to an insulation system for securing cladding to the exterior surface of a building. An insulated panel has a front face and a rear face. Joining elements are defined in horizontal edges of the panel for connecting adjacent panels to each other. A horizontal attachment member, such as a nailing hem, is mounted to the rear face of the panel for attaching the insulated panel to the exterior surface. Receiving members are present on the front face of the panel, and can be located in receiving channels. The receiving member is generally made from a material that is better at retaining fasteners, such as nails, than the material of the insulated panel itself.

Abstract: A composite building panel and method employs a foam core member which has custom excised cutout sections which are specially configured to be bonded to a panel framework made up of light gauge steel framing members. The panel framework is positioned on the inner surface of the base section of the foam core member and surrounds internal sections of the foam core member. Foam pieces which have been excised from the foam core member are positioned within gaps between the framing members and the foam core member. The framing members, foam core member, and foam pieces are bonded together to form an integral panel component. An external seal coating is permanently affixed to the outer surface of the foam core member. Expandable foam can be injected into the gaps between the framing members and the foam core member, in lieu of the foam pieces, to form the bond between the framing members and the foam core member.

Abstract: A composite panel comprises an outer skins and an inner core. The inner core includes a frame, an elastomeric material disposed between at least a portion of the frame and the outer skin, and a foamed polymer filler. Also disclosed is a method of manufacturing the same.

Abstract: The present invention is directed to a method of fabricating a wall structure that comprises a polyurethane backing. In certain embodiments, no additional layer is coated onto or disposed on the polyurethane backing that is formed through the process disclosed herein.

Abstract: A composite reinforced mull post is disclosed for use in an entryway assembly. The mull post may engage a door on one side and a side light window on the other side. The mull post may comprise a one or two piece outer portion and one or more internal reinforcing members. The outer portion may comprise a plurality of interlocking pieces. The pieces may include a stop portion and a support portion, each with interlocking ribs. A first internal reinforcing member may be formed of engineered material such as a wood laminate, and a second reinforcing member may comprise a channel that extends partially around the first reinforcing member. The reinforcing member may include orthogonal portions conterminously received within a correspondingly shaped central chamber formed by the housing formed by the joined interlocking pieces.

Abstract: Wide-body connectors are provided for concrete sandwich walls. Each connector includes a body with longitudinally thickened portions defining flanges and a thinner inner connecting web extending between the flanges. The flanges provide increased bending stiffness for the connector, while the web provides enhanced shear transfer between the concrete layers of the wall. Anchoring surfaces are formed into or overmolded onto the body to anchor the ends of the connector in the concrete layers of the wall and assist in the creation of end moments ofr the transfer of forces between the concrete layers. Preferably, a lip is provided on the connector to limit the penetration of the connector through the insulation layer of the wall. The connectors transfer forces between the concrete layers, without thermal bridging, such that the wall has a substantially composite character.

Abstract: A lightweight beam may have a triangular prism core and a triaxial fabric cover wrapped around the core, with at least one rod proximate an apex of the core. The rod may extend substantially parallel to a centerline of the core. Multiple lightweight beams may be joined to form a larger lightweight structure.

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).