A method of manufacturing includes providing a continuous flat cover to an assembly line, where the assembly line includes a conveying means. The method also includes applying a flowable reaction material continuously to the flat cover, where the reaction mixture is configured to expand within the flat cover. The method also includes welding the continuous flat cover around the reaction mixture to form an initial profile element. The method also includes cutting the initial profile element, continuously along the assembly line, to form one or more profile elements. Each of the one or more profile elements is a portion of the initial profile element, and each of the one or more profile elements includes a geometry for conforming with a construction component.

A sheet for providing an air gap is provided. The sheet includes a body defining a first surface. The sheet also includes cusps. The cusps extend from the first surface of the body, and one or more channels are formed between the cusps. The sheet includes fire-resistant material. This fire-resistant material may be fiberglass, talc, calcium carbonate, powdered metal, or another material(s). The one or more channels may be configured to permit liquid water, air, and/or other fluids to flow through.

A sheet for providing an air gap is provided. The sheet includes a body defining a first surface. The sheet also includes cusps. The cusps extend from the first surface of the body, and one or more channels are formed between the cusps. The sheet includes fire-resistant material. This fire-resistant material may be fiberglass, talc, calcium carbonate, powdered metal, or another material(s). The one or more channels may be configured to permit liquid water, air, and/or other fluids to flow through.

A drywall system is provided including a first drywall panel and a second drywall panel connected to the first drywall panel via a main hinge. A first drywall flap connected to the first drywall panel via a first hinge, and a second drywall flap connected to the second drywall panel via a second hinge. The first drywall panel, the second drywall panel, the first drywall flap and the second drywall flap can hinge to assume at least one corner configuration in which the first and second flaps lie on a first plane, the first drywall panel lies on a second plane and the second drywall panel lies on a third plane, such that the first plane, the second plane and the third plane are mutually orthogonal. A coating can be provided on an external surface of the framing drywall liner for strengthening the groove which, in embodiments can be polyester strip that extends over portions of the first and second gypsum-containing segments on either side of the of the groove.

The present invention discloses a self-supporting prefabricated construction system that does not require a structure and has an arch-shaped configuration of different dimensions, intended for building living spaces and various types of uses. The present invention is based on modular structural elements that have the following configuration: undulating modules for the configuration of various types of roofs, that can be used in different kinds of spaces, wherein said modules are joined in an overlapping manner to generate rigidity and stability to the structure, making up completely sealed and waterproof spaces through various joining mechanisms. These curved undulating roof modules are of two kinds: curved ridge modules, whose size will depend on the dimensions of the intended arch, and curved wall modules. The system can have modules for different types of facades and interior dividing walls, which have a straight shape with obtuse folds.

Electromagnetically shielded and self-supporting panels form a shielded enclosure. The use of prefabricated, shielded and self-supporting panels to construct an enclosure reduces the time and cost of constructing such an enclosure.

A manufacturing process, and related products, for fabricating translucent articles in the form of tiles. The manufacturing process includes holding together a stack of corrugated cardboard pieces and saturating the cardboard pieces with an impregnating agent. Additional steps may include machining the cardboard pieces to define a block of a desired shape, slicing the block into tile components, and/or coating one or more tile components with a coating material to produce the article. Articles include translucent tiles made of corrugated cardboard pieces saturated with an impregnating agent. The tiles may be arranged to define a surface, such as a floor, a wall, a roof, a lighting installation, an architectural construction element, an architectural aesthetic element, or a solar panel.

A stiff wall panel assembly includes a wall panel including a single, continuous, and unitary layer including a central portion having a plurality of central portion ribs spaced therealong, a first wall track engaged with the central portion and having a plurality of first ribs spaced therealong, and a second wall track engaged with the central portion and having a plurality of second ribs spaced therealong. Studs are engaged with the central portion, the first wall track, and the second wall track. Such studs have a plurality of third ribs each engaged with the central portion ribs, the first ribs, and the second ribs. The first ribs and the second ribs each are linearly interlocked as well as linearly and slidably interfitted within the third ribs of the studs. The first ribs and the second ribs each are parallel to the third ribs of the studs.

A stiff wall panel assembly includes a wall panel including a single, continuous, and unitary layer including a central portion having a plurality of central portion ribs spaced therealong, a first wall track engaged with the central portion and having a plurality of first ribs spaced therealong, and a second wall track engaged with the central portion and having a plurality of second ribs spaced therealong. Studs are engaged with the central portion, the first wall track, and the second wall track. Such studs have a plurality of third ribs each engaged with the central portion ribs, the first ribs, and the second ribs. The first ribs and the second ribs each are linearly interlocked as well as linearly and slidably interfitted within the third ribs of the studs. The first ribs and the second ribs each are parallel to the third ribs of the studs.

Embodiments of the invention included structural decking systems with at least a four-layered seam and methods for manufacturing and assembling structural decking systems with at least four-layered seams. The decking panels may be provided with an edge having an exposed “male lip” with two layers, and an opposite edge having a “female lip” with two layers. Individual panels may be coupled together by placing the female lip of a first panel over the male lip of an adjacent panel, thus creating an unjoined seam. In order to couple the panels together, the panels may be secured through various couplings configurations. The couplings may be formed by deforming, cutting, and/or welding the seam. Not only do the couplings help prevent vertical separation between adjacent panels, the couplings minimize lateral shifting along the seam, and ensure a desired level of shear strength in the seam and across the structural decking system.