Modular building methods and systems using lightweight modular panels, and specially configured transition panels for transitioning from wall to floor, or from wall to roof. Identically configured standard panels are used for constructing the walls, floor, and roof, with transitions from one structure to the next (e.g., wall to floor, or wall to roof). Each of the variously configured panel types includes channels (e.g., 2 pair of channels) formed through the length of the foam body, where the channels are configured to receive splines (e.g., flanges of an I-beam) therein. In the standard panel, the channels may include pairs of top and bottom channels, with the channels offset towards the respective panel major faces. In the transition panels, the channels may be similarly configured, but positioned differently to make the appropriate transition. The splines are connected to a frame, which acts as a template and transfers loads to a foundation.

A permanent spacing beam for the rapid deployment of roofing trusses on site. Such permanent spacing beams and truss ties as described may utilize a mount end, a retention end, and an elongate portion which spans the distance between the mount end and the retention end. The mount end may have a mount slot and the retention end may have a retention slot. The mount slot and the retention slot may be configured to permanently couple and mount to a first truss timber stud and an adjacent truss timber stud used in residential and commercial roof construction. Such a configuration results in a permanent truss tie being spanned between two roofing trusses thereby creating a more robust and sturdy roof construction.

Load support structures for mounting a load atop a raised rib metal panel roof make use of relatively small, inexpensive, and easy-to-make adapter plugs as interfaces between the raised ribs and one or more component pieces or members of the load support structure, such as an upper diverter or a lower closure member. The adapter plug has an inner surface and an outer surface, the inner surface having an inner profile substantially matching or conforming to some or all of the profile of a particular style of rib profile. The outer surface of the adapter plug has a standardized shape, some or all of which is made to conform to an upper diverter, lower closure, and/or other component member of the load support structure.

A method of and system for producing Class-A fire-protected oriented strand board (OSB) sheets. Each Class-A fire-protected OSB sheet has: a core medium layer made of wood pump, binder and/or adhesive materials; a pair of OSB layers bonded to the core medium layer; a clean fire inhibiting chemical (CFIC) coating on the surface of each OSB layer, made from CFIC liquid applied to the surface by dipping the OSB sheet into the CFIC liquid in a dipping tank, allowing shallow surface absorption into the OSB layers and ends of the core medium layer at atmospheric pressure; and a moisture, fire and UV protection coating spray coated over the CFIC coating to provide protection against moisture, fire and UV radiation from Sunlight, which is quickly dried by passing through a drying tunnel on the production line.

An apparatus is contemplated for creating a structure which simultaneously serves as both a building element and a photovoltaic power source. Components of the invention interface with modules which comprise photovoltaic solar panels. When used collectively, these modules are contemplated as comprising a replacement for a roof or other building component. When the present invention is used, a roof or other building component can be created without the need for a separate underlayment, and without the need for tiles or another outer waterproofing layer. This setup results in power generation, cost savings, and environmental advantages Additionally, embodiments of the invention comprise fixed stop elements which ensure correct placement of modules on a frame assembly. The invention could also include other elements, including water gutters, grab steps which facilitate access, and specially positioned border covers to protect and aesthetically cover wired regions of solar modules.

In a lumber factory, an automated laminated veneer lumber (LVL) process supported by a lumber production line employing a cross-cutting and rip-sawing stage, a dip-coating stage, a spray-coating stage, a print-marking stage, and a stacking, packaging and wrapping stage. At the dip-coating stage, cross-cut and rip-sawed LVL product is automatically transported and submerged through a dipping reservoir containing clean fire inhibiting chemical (CFIC) liquid, and then wet-stacked and set aside to dry. Once dried, the dip-coated LVL products are returned to the production line and sprayed coated with a moisture, fire and UV protective coating at the spray-coating stage, and then passed through a drying tunnel for quick drying of the spray-coating to produce Class-A fire-protected LVL products. The Class-A fire-protected LVL products are stacked, packaged and wrapped at the stacking, packaging and wrapping stage into a package of Class-A fire-protected LVL products, ready for shipping.

A composite structural member for a building structure comprises a first elongate portion having a first end region and a second end region and a second elongate portion having a first end region and a second end region. The second end region of the first elongate portion is connected to the first end region of the second elongate portion so that the composite structural member provided thereby is substantially longer than either of the first and second elongate portions. The first elongate portion may comprise a first member suited for resisting high magnitude forces and the second elongate portion may be a second member, less well suited for resisting high forces but having lower cost per unit length. The composite structural member may be a rafter, especially a rafter of a portal frame.

A permanent spacing beam for the rapid deployment of roofing trusses on site. Such permanent spacing beams and truss ties as described may utilize a mount end, a retention end, and an elongate portion which spans the distance between the mount end and the retention end. The mount end may have a mount slot and the retention end may have a retention slot. The mount slot and the retention slot may be configured to permanently couple and mount to a first truss timber stud and an adjacent truss timber stud used in residential and commercial roof construction. Such a configuration results in a permanent truss tie being spanned between two roofing trusses thereby creating a more robust and sturdy roof construction.

Modular building methods and systems using lightweight modular panels, and specially configured transition panels for transitioning from wall to floor, or from wall to roof. Identically configured standard panels are used for constructing the walls, floor, and roof, with transitions from one structure to the next (e.g., wall to floor, or wall to roof). Each of the variously configured panel types includes channels (e.g., 2 pair of channels) formed through the length of the foam body, where the channels are configured to receive splines (e.g., flanges of an I-beam) therein. In the standard panel, the channels may include pairs of top and bottom channels, with the channels offset towards the respective panel major faces. In the transition panels, the channels may be similarly configured, but positioned differently to make the appropriate transition. The splines are connected to a frame, which acts as a template and transfers loads to a foundation.

The present disclosure provides systems, apparatuses, and methods relating to roof construction. In some embodiments, a roof panel system may include a prefabricated horizontal building frame and a prefabricated roof panel structure. The horizontal building frame component may include a plate having a first aperture. The prefabricated roof panel structure may include two parallel lateral structural members and two parallel transverse structural members, one of the transverse structural members having a second aperture. The system may further include a fastener assembly connecting the horizontal building frame component to the roof panel structure through the first and second apertures.