A sprayed-in-place framed wall is disclosed, comprised of a cementitious face and backing layers and a polyurethane foam insulation layer that bonds the cementitious layers to a separate wall frame. Stationary walls are constructed by spraying the materials against one-sided, vertical wall forms positioned around an erected, exterior wall frame. The cementitious materials are restrained by stays. The wall forms may have indentations to enable the resulting wall face to have protrusions such as moulding, bands, quoins and cornices, which may be a different color that the surrounding flat wall face.

A building construction panel and a building construction panel assembly are presented herein. The panel includes a foam insulation core with first and second oppositely disposed nonlinear longitudinal surfaces, each of the first and second nonlinear longitudinal surfaces include a plurality of pockets defined by a plurality of peaks and a plurality of troughs. A reinforcement mesh panel is disposed along at least a portion of each of the first and second longitudinal surfaces of the foam core. Reinforcing bars are positionable at least partially within the pockets of the surfaces of the foam core, and concrete is layered on top of the surfaces of the foam core and the mesh reinforcement panels to secure the reinforcing bars therein. In some embodiments, the reinforcing bars are positioned between the surface of the foam core and the mesh reinforcing panel.

A stay-in-place concrete formwork system allows stucco to be applied directly to the formwork, avoiding the need to provide a further surface treatment of the wall prior to applying stucco. Apertures are provided on an exterior facing wall of the formwork panel to receive and embed stucco therein. The panel may also be formed with outward stucco-engaging projections. Other features include using rigid insulation to brace the stucco and keep concrete from the apertures, a sealing joint element, extendible panels for use in curved formwork, rainscreen features and an alligator connector panel for adjustable lengths of formwork faces.

An insulated concrete panel comprising an insulation layer having one or more openings extending therethrough, a first concrete layer adjacent to a first surface of the insulation layer, a second concrete layer adjacent to a second surface of the insulation layer, and a wall tie received within one or more of the openings. The wall tie includes a central section received within the one or more openings of the insulation layer, a first concrete engaging at least partially embedded within the first concrete layer, and a second concrete engaging section embedded within the second concrete layer. The second concrete engaging section has a maximum width that is larger than a maximum width of the central section. The central section of the wall tie is configured to transfer shear forces and resist delamination forces between the first and second concrete layers.

Systems and methods for creating insulated sandwich walls with a prefabricated framework are provided. An inner strongback faces an outer strongback. Outer and inner support members are located between the strongbacks. The strongbacks and support members extend vertically from a base. Material for an outer wall, such as concrete, is deposited between the outer strongback and outer support member. Material for an inner wall is deposited between the inner strongback and inner support member. An insulating material is deposited between the outer and inner support members providing longitudinal spacing for the framework.

A barrier forming system is described that includes a plurality of studs, rails and barrier reinforcement members interconnected between top and bottom plates. The interconnected studs, rails, reinforcement members, top plate and bottom plate may be precisely bent or curved in either or both the vertical and horizontal directions. The interconnected studs, rails, barrier reinforcement members, top plate, and bottom plate may be embedded in a filler material to form a curved concrete barrier having a complex geometry.

Foam wall structures and methods for making them are described. The wall structures include a frame, a foam panel overlying a front surface of the frame, and a polyurethane foam layer disposed in a cavity of the wall structure. The polyurethane foam layer has a density, as determined by ASTM D1622-14, of at least 44 kg/m.sup.3(2.75 lb/ft.sup.3) and exhibits ASTM E84-16 Class A flame spread and smoke development characteristics. The polyurethane foam layer is the cured reaction product of a polyurethane foam-forming composition that includes a polyisocyanate, an aromatic polyester polyol having a functionality of greater than 2.5 and an OH number of at least 300 mg KOH/g, which is present in an amount of at least 50% by weight, based on the total weight of the polyurethane foam-forming composition less the weight of the polyisocyanate, a catalyst, and a blowing agent composition. The blowing agent composition includes water and a hydrofluoroolefin.

The invention comprises a product. The product comprises a foam insulating panel, the panel having a first primary surface and an opposite second primary surface, wherein the foam insulating panel defines at least one recessed channel in the first primary surface, the at least one recessed channel being sized and shaped to provide a mold for a structural reinforcing member. The product also comprises a concrete panel formed on the first primary surface and filling the at least one recessed channel so as to provide a structural reinforcing member for the concrete panel. The product further comprises an elongate anchor member in the foam insulating panel and extending from the first primary surface of the foam insulating panel into the concrete panel. A method of making a composite reinforced insulated concrete structure is also disclosed.

A rigid insulating panel comprising an insulating material core with an R-value of at least 2.5 (hr.Math.ft.sup.2.Math. F.)/BTU.Math.in. The insulating material core has opposed first and second surfaces, a pair of spaced-apart longitudinal edges, and a pair of spaced-apart lateral edges extending between the pair of longitudinal edges. At least one of the pair of longitudinal edges and the pair of lateral edges comprises connecting members including a tongue and groove assembly with an inner groove and an outer tongue separated by a substantially S-shaped median wall. The tongue and groove assembly is engageable with the tongue and groove assembly of an adjacent insulating panel to provide a flexible interconnection therebetween. The rigid insulating panel also comprises at least one membrane covering one of the first surface and the second surface. An assembly method for insulating a concrete surface of a building using an assembly of insulating panels is also provided.

An insulation system for use with a sandwich wall panel is disclosed. The insulation system reduces the risk of flame spread through the sandwich wall panels. The insulation system provides a balance between good insulating properties and reduced flammability, without detrimentally increasing the cost of the sandwich wall panel.