A system for fabricating fillable, Stay-In Place footer, wall and roof forms with a quick fastening system that is an insertable or snap together and has a one pour footer to eave and/or ridge capability. The system includes a three-dimensionally produced form, inserts to accept rebar, reinforcement wire, and insulation, and can be filled with various cementitious materials with reinforcing materials and aggregates. Options to mold in electrical and plumbing races, window and door openings and frames, and to provide designs and finished surfaces round out the versatility of this building system.

A system for fabricating fillable, Stay-In Place footer, wall and roof forms with a quick fastening system that is an insertable or snap together and has a one pour footer to eave and/or ridge capability. The system includes a three-dimensionally produced form, inserts to accept rebar, reinforcement wire, and insulation, and can be filled with various cementitious materials with reinforcing materials and aggregates. Options to mold in electrical and plumbing races, window and door openings and frames, and to provide designs and finished surfaces round out the versatility of this building system.

A wind turbine foundation comprising a concrete support slab having a horizontal rebar grid therein, a concrete pedestal integral with the support slab and having vertical post tensioning elements therein and a plurality of concrete ribs on top of and integral with the support slab and integral with the pedestal, the ribs having rebar therein and extend outwardly from the pedestal, the pedestal, slab and ribs are connected to each other to form a monolithic foundation. The foundation design reduces the weight and volume of materials used, reduces cost, and improves heat dissipation conditions during construction by having a small ratio of concrete mass to surface area thus eliminating the risk of thermal cracking due to heat of hydration.

A wind turbine foundation comprising a concrete support slab having a horizontal rebar grid therein, a concrete pedestal integral with the support slab and having vertical post tensioning elements therein and a plurality of concrete ribs on top of and integral with the support slab and integral with the pedestal, the ribs having rebar therein and extend outwardly from the pedestal, the pedestal, slab and ribs are connected to each other to form a monolithic foundation. The foundation design reduces the weight and volume of materials used, reduces cost, and improves heat dissipation conditions during construction by having a small ratio of concrete mass to surface area thus eliminating the risk of thermal cracking due to heat of hydration.

A building system (5) including a panel system (10) and a formwork system (78). The panel system (10) includes a plurality of modular panels (12) arranged to fit with one another in a predetermined grid arrangement (13) to form side walls of a building in a fitted condition. At least the bottom sides (24) of each of the modular panels (12) includes a plurality of apertures (34) that are arranged at predetermined spaced apart locations along the bottom side (24) so as to coincide with the predetermined grid arrangement (13). The formwork system (78) includes a plurality of modular formwork members (80) that are associated with each of the modular panels (12) to provide a supporting slab (72) having slab apertures (76) to allow coupling with the modular panels (12). Modular panels (12), formwork members (80) and associated methods of use are also disclosed.

A building system (5) including a panel system (10) and a formwork system (78). The panel system (10) includes a plurality of modular panels (12) arranged to fit with one another in a predetermined grid arrangement (13) to form side walls of a building in a fitted condition. At least the bottom sides (24) of each of the modular panels (12) includes a plurality of apertures (34) that are arranged at predetermined spaced apart locations along the bottom side (24) so as to coincide with the predetermined grid arrangement (13). The formwork system (78) includes a plurality of modular formwork members (80) that are associated with each of the modular panels (12) to provide a supporting slab (72) having slab apertures (76) to allow coupling with the modular panels (12). Modular panels (12), formwork members (80) and associated methods of use are also disclosed.

A system for retaining a flowable and curable building material to form a portion of a foundation includes side walls disposed in a predetermined configuration having a first side wall and a second side wall, and at least one component having an interior cavity disposed in one of the side walls. A bracket assembly includes an outwardly bounding reinforcement post for each of the side walls, a separator bar having a plurality of apertures sized to receive and retain each of the reinforcement posts at locations corresponding to nominal widths of the at least one component. A barrier is disposed between the outwardly bounding posts. The barrier and the component in the side wall is retained in the foundation after the building material cures. The barrier prevents backfill from filling a volume between the outwardly bounding posts.

A system for retaining a flowable and curable building material to form a portion of a foundation includes side walls disposed in a predetermined configuration having a first side wall and a second side wall, and at least one component having an interior cavity disposed in one of the side walls. A bracket assembly includes an outwardly bounding reinforcement post for each of the side walls, a separator bar having a plurality of apertures sized to receive and retain each of the reinforcement posts at locations corresponding to nominal widths of the at least one component. A barrier is disposed between the outwardly bounding posts. The barrier and the component in the side wall is retained in the foundation after the building material cures. The barrier prevents backfill from filling a volume between the outwardly bounding posts.

In a general aspect, a method is presented for manufacturing support structures for offshore wind turbines. In some implementations, the method includes constructing a plurality of modular sections that assemble to define the support structure. One or more of the plurality of modular sections are configured to anchor to an underwater floor. At least one of the plurality of modular sections is constructed by operations that include forming a wall along a perimeter to bound a volume, filling the volume with a castable material, and hardening the castable material. In some instances, forming the wall includes depositing layers of printable material successively on top of each other. The method also includes joining the plurality of modular sections to assemble the support structure.

In a general aspect, a method is presented for manufacturing support structures for offshore wind turbines. In some implementations, the method includes constructing a plurality of modular sections that assemble to define the support structure. One or more of the plurality of modular sections are configured to anchor to an underwater floor. At least one of the plurality of modular sections is constructed by operations that include forming a wall along a perimeter to bound a volume, filling the volume with a castable material, and hardening the castable material. In some instances, forming the wall includes depositing layers of printable material successively on top of each other. The method also includes joining the plurality of modular sections to assemble the support structure.