A concrete corner structure with diagonally oriented fiber resin polymer rebar and method that utilizes straight rebar to reinforce the corner structure. The straight rebar intersects with the horizontally disposed rebar in the first and second walls that form the corner structure. The straight rebar is placed at a 45-degree angle with respect to the two walls and tied to the horizontally disposed rebar. This allows for the use of straight rebar to reinforce the corner structure as opposed to a curved rebar.

Various cement-containing compositions are disclosed, including insulating cement, forms, and prefabricated building materials produced from cement-containing compositions with insulating properties. Some of the preferred embodiments include expanded polystyrene and an acrylic component to provide enhanced insulating properties, or have a lower density, lighter weight, and increased insulating R-value in comparison with other cement-containing compositions.

An Advanced Additive Construction device to extrude layers of cementitious material consistently and accurately with an anti-clogging method is disclosed. The device introduces low continuous frequency sonic vibrations with frequency range of 20- to 10000 Hz to slow cement or binding agents from curing the mixture inside the extruder and to get rid of air bubbles trapped in the mixture. Buildup of early cured mixtures inside the extruder tract especially in large volume or long period prints result in accumulation of material inside the extruder tract which causes extruder clogging. A shaker plate coupled with four miniature shakers excite the material mixture inside the extruder orthogonal to the inner casing direction. Furthermore, four more miniature shakers equipped with extension rods excite the material mixture inside the extruder orthogonal to the top mount, thereby preventing any cementitious material sticking within the extruder casing and around the central flight auger. Moreover, increasing the print speed and flow rate of the extruder by 60% which results in cutting the print time to more than 70% when counting the elimination of clogging. Also, it allows the extruder to accommodate a wider range of cementitious mixtures without the need to adjust admixtures and setting times especially for mixtures that have a rapid setting rate. The shaker's vibrating system, FIG. 7, functions within the upper chamber of the extruder casing, the upper chamber has the largest diameter as it operates as a flow control reservoir, which has less pressure compared to the lower chamber of the extruder. The vibrating rods and inner wall system prevent cementitious material from sticking to the extruder inner walls and allows smooth continuous flow of material.

An elongated building element (14) having a pair of longitudinally extending generally parallel co-extensive side walls (15) joined by transverse webs (16). The walls (15) and webs (16) enclose a longitudinally extending space (30) within which there is located a tube (31). The tube (31) is connected to the walls (15) and webs (16) by flanges (33). The tube (31) provides a space (33) with the spaces (30, 33) being intended to be filled with concrete. The building element (14) is intended to be attached to light elements (14) to form a wall.

A building module for use in construction of a building comprising a deck oriented in a horizontal plane and a plurality of hollow structural members extending downwardly from around a periphery of the deck. A method of constructing a building comprising placing a plurality of modules according to a floor plan to form a story of the building, pouring flowable medium that sets to a become a solid structural material into the hollow structural members of the plurality of modules to form structural columns, pouring flowable medium that sets to a become a solid structural material onto the decks of the plurality of modules for form structural slabs, and allowing the structural columns and structural slabs to set to complete the story of the building.

An insulated construction panel having a top end, a bottom end, a first end, a second end, a front side and a rear side, the panel for constructing a single or multi-thickness concrete form, the panel including regularly spaced coplanar passages extending completely through the panel from the top end of the panel toward and through to the bottom end of the panel. For each of the regularly spaced coplanar passages, an angular passage perpendicularly intersecting each coplanar passage at the top end and extending toward and through a portion of a front side surface of the front side and rear side surface of the rear side of the panel, each angular passage extending only partially through the panel from the top end toward the bottom end. For each of the regularly spaced coplanar passages, an angular passage perpendicularly intersecting each coplanar passage at the bottom end and extending toward and through a portion of the front side surface of the front side and the rear side surface of rear side of the panel, each angular passage extending only partially through the panel from the bottom end toward the top end.

Methods and apparatus facilitate the construction of a building using prefabricated building units, each having a horizontal upper exterior surface and a plurality of vertical wall surfaces, wherein at least some of the prefabricated building units have at least one hollow column formwork structure. The prefabricated building units are lowered onto a pre-existing base at a construction site. A first story of the building is created by arranging a plurality of the prefabricated building units adjacent to each other on the base. Structural bearing material is applied to fill the hollow column formwork structures to create structural columns connected to the structural deck. Structural bearing material is applied to the horizontal upper exterior surfaces of the adjacent prefabricated building units to create a single structural deck over the prefabricated building units.

Methods and apparatus facilitate the construction of a building using prefabricated building units, each having a horizontal upper exterior surface and a plurality of vertical wall surfaces, wherein at least some of the prefabricated building units have at least one hollow column formwork structure. The prefabricated building units are lowered onto a pre-existing base at a construction site. A first story of the building is created by arranging a plurality of the prefabricated building units adjacent to each other on the base. Structural bearing material is applied to fill the hollow column formwork structures to create structural columns connected to the structural deck. Structural bearing material is applied to the horizontal upper exterior surfaces of the adjacent prefabricated building units to create a single structural deck over the prefabricated building units.

A water-buoyant structure formed from concrete is disclosed. The structure comprises an outer wall that surrounds a perimeter of the structure and an inner wall separated from the outer wall by a cavity, such that the cavity extends for the perimeter of the structure. Separating the cavity can provide sufficient buoyancy to the structure to allow 5 the structure to float. The combination of outer and inner walls may also provide increased resistance to catastrophic damage in the event of an impact (e.g. the inner wall may remain intact).

A water-buoyant structure formed from concrete is disclosed. The structure comprises an outer wall that surrounds a perimeter of the structure and an inner wall separated from the outer wall by a cavity, such that the cavity extends for the perimeter of the structure. Separating the cavity can provide sufficient buoyancy to the structure to allow 5 the structure to float. The combination of outer and inner walls may also provide increased resistance to catastrophic damage in the event of an impact (e.g. the inner wall may remain intact).