A method of manufacturing building panels includes assembling a frame of a building panel. The frame defines at least one cavity and at least one injection aperture in fluid communication with the at least one cavity. The method also includes positioning the frame on one of a base and a shelf of a multi-panel consolidation device having a plurality of shelves, with the shelves being in an expanded configuration, and at least substantially enclosing the at least one cavity. The method also includes forcing the shelves of the multi-panel consolidation device into a collapsed configuration, and injecting an expandable polymer through the at least one injection aperture into the at least one cavity. The method further includes forcing the shelves into an expanded configuration after a predetermined period of time selected to permit the expandable polymer to form a foam bonded to the frame.

The insulating barrier of a panel including has a first stratum and a second stratum, each having a plurality of ridges that face each other, and run athwart of each other. Clearance between at least some adjacent pairs of the ridges provide a mechanical chase that reaches across at least most of the panel. A cladding overlaying at least one side of the insulating barrier is denser than the barrier. The mechanical chase is in the form of a groove through which a utility feed can be routed when the panel is to be mounted in a building.

A composite wall, ceiling or floor panel (10), system and method, including a sheet (14) having a first face (18) including at least one first mounting portion (16), and at least one formwork member (20) with at least one second mounting portion (30) arranged to engage with the first mounting portion of the sheet to retain the sheet and said at least one formwork member together. Structural support comes from piers (for a wall) or beams (ceiling or floor) formed in the spacing between adjacent formwork members. The formwork members act as the core of a wall, ceiling or floor panel. An external coating (123) is applied to the formwork members, such as spray shotcrete or render. Channels (28) formed by the formwork members defines integrated ducting for services to be run.

A composite wall, ceiling or floor panel (10), system and method, including a sheet (14) having a first face (18) including at least one first mounting portion (16), and at least one formwork member (20) with at least one second mounting portion (30) arranged to engage with the first mounting portion of the sheet to retain the sheet and said at least one formwork member together. Structural support comes from piers (for a wall) or beams (ceiling or floor) formed in the spacing between adjacent formwork members. The formwork members act as the core of a wall, ceiling or floor panel. An external coating (123) is applied to the formwork members, such as spray shotcrete or render. Channels (28) formed by the formwork members defines integrated ducting for services to be run.

A building system comprising a plurality of tubes, a plurality of connection nodes comprising tubular sections for connection to the tubes, wherein the tubes are arranged to connect between the connection nodes to form a frame for a building, wherein at least one continuous cavity is formed through at least a portion of the nodes and tubes when the nodes and tubes are connected, the building system further comprising fluid tight seals between the tubes and connection nodes to enable fluid to flow through the at least one continuous cavity.

A building system comprising a plurality of tubes, a plurality of connection nodes comprising tubular sections for connection to the tubes, wherein the tubes are arranged to connect between the connection nodes to form a frame for a building, wherein at least one continuous cavity is formed through at least a portion of the nodes and tubes when the nodes and tubes are connected, the building system further comprising fluid tight seals between the tubes and connection nodes to enable fluid to flow through the at least one continuous cavity.

A plurality of rainscreen elements or features that are applied to the front or outer face of a structural panel or the weather resistant barrier layer on the structural panel. When an exterior cladding or sheathing product is installed over the structural panel, the rainscreen elements or features provide built-in water flow gaps or channels to facilitate and increase water drainage off the face of the structural panel, thereby minimizing water storage in the space between the structural panel and the outer cladding/sheathing. The rainscreen features are incorporated into the structural panel in-line or during the manufacturing process, and do not require any further work during assembly or construction on-site.

A reinforced water-resistant board includes a cover board with a reinforced water-resistant membrane applied to a surface of the cover board. The reinforced water-resistant membrane includes a primer layer, a reinforced membrane, a traffic coat, and a sealing layer. The primer layer is applied over the surface of the cover board. The reinforced membrane includes fleece soaked in a liquid resin and is applied over the primer layer. The traffic coat is boned to the reinforced member. The sealing layer is applied over the traffic coat.

The instant system is a panel made of several layers that is a highly decorative, fire resistant, water resistant, sound proof, R valued insulated, light weight, and energy efficient panel. Such layers include: glass fiber reinforced concrete, glass fiber reinforced concrete with alkaline resistant fibers, alkaline resistant hurricane tested scrim mesh, a solar powered radiant tubing, a fire resistant foam that contains a steel reinforcement, and an epoxy adhesive.

A complete decreased mistake-proof high-reliability waterproofing system is revealed that integrates the waterproofing membrane, drain panel, and abrasion-protected filter fabric, using a factory-controlled process; furthermore, the system incorporates intrinsic devices for installation verification and leak-detection, and the potential for in situ mapping of the functional topography of the waterproofing installation over time.