An ultrastable cementitious material with nano-molecular veneer makes a cementitious material by blending 29 wt % to 40 wt % of a magnesium oxide dry powder containing 80 wt % to 98 wt % of magnesium oxide based on a final total weight of the cementitious material, with 14 wt % to 18 wt % of a magnesium chloride dissolved in water and reacting to form a liquid suspension, mixing from 2 to 10 minutes, adding a phosphorus-containing material, and allowing the liquid suspension to react into an amorphous phase cementitious material, wherein a portion of the amorphous phase cementitious material grows a plurality of crystals. The plurality of crystals are encapsulated by the amorphous phase cementitious material forming a nano-molecular veneer. A process to make the ultrastable cementitious material. A tile backer board incorporating the ultrastable cementitious material and a process for making the tile backer board.

A concrete construction (100) made by 3D concrete printing that contains: two or more layers (102, 106) of cementitious material extruded one above the other, and at least one elongated steel element (104) reinforcing at least one of the layers (102, 106). The elongated steel element (104) has an elastic and plastic elongation at break that exceeds 4%. The high elongation of the elongated steel element gives an increased ductility to the concrete structure (100).

A concrete slab (20) comprises conventional concrete and a combined reinforcement of both post-tension steel strands (22, 26) and fibres (29). The post-tension steel strands (22, 26): —have a diameter ranging from 5 mm to 20 mm, —have a tensile strength higher than 1700 MPa. The fibres (29) are present in a dosage ranging from 10 kg/m.sup.3 to 40 kg/m.sup.3 in case of steel fibres are in a dosage ranging from 1.5 kg/m.sup.3 to 9 kg/m.sup.3 in case of macro-synthetic fibres.

The present disclosure provides skirt panel systems for a post-frame building, comprising: one or more precast skirt panels, each of the precast skirt panels having an outer surface to be oriented away from the interior of the post-frame building, an inner surface to be oriented towards the interior of the post-frame building, a top, a bottom, and two opposing ends, each of the precast skirt panels configured for attachment to at least one post of the post-frame building, and each of the precast skirt panels configured for abutting each other end-to-end to form a skirt wall on the post-frame building; and an attachment apparatus for attaching the one or more precast skirt panels to the at least one post. The present disclosure also provides methods for constructing a post-frame building using such systems.

A method and system for an automated modular construction factory is presented. A plurality of pre-cast construction panels, a quality control zone, a transportation system, a general stockyard, a sequencing system, an assembly zone, an assembly system, a transit system, a finishing zone, and a plurality of finishing stations are provided. The pre-cast construction panels undergo quality control under the quality control zone and are transported and ordered to the general stockyard through the transportation and sequencing systems. The panels are then assembled into a constructed room in the assembly zone through the assembly system. The constructed room is transported by the transit system to the finishing zone where the constructed room is furnished and completed by the plurality of finishing stations.

A method of forming an architectural concrete structure having a desired look (i.e., color) and texture, wherein the method generally includes pouring a base concrete layer using conventional concrete. A surface concrete mixture is prepared and includes a mixture of sand and small aggregates to give the surface concrete mixture the desired color and texture for the architectural concrete structure. The base concrete layer provides strength and durability to the concrete structure, while the surface concrete layer provides the desired look and texture of the concrete surface. The surface concrete mixture preferably includes small aggregates to create a smooth and uniform texture.

An article of manufacture is disclosed comprising a 3D-printed wall panel having an interior side and an exterior side. The exterior side comprises a textured surface formed by 3D printing the wall panel onto a textured form. In certain embodiments, the textured surface mimics at least one of natural stone, brick, and wood siding, and the medium printed onto the textured form is concrete. The interior side has 3D printed structural elements printed thereon designed to mimic conventional wood-stud framing in at least one of dimensions and spacing. A method for fabricating the 3D printed wall panel as described above is also disclosed.

The present invention pertains to an element of an autoclave aerated concrete (AAC) material having a web of a second material different from AAC embedded therein and generally centrally disposed in a depth dimension of the element and between two planar faces and the second material supporting hardware for connecting the element to other structures.

A voided floor panel is provided. The voided floor panel includes a pre-cast dome, strands, reinforcing bars, and a slab. The pre-cast dome includes a flange portion, stem portions, and joint portions. The strands are pre-tensioned. The reinforcing bars are inserted through rebar block-outs of the pre-cast dome. The joint portions, the strands, and the reinforcing bars are cast within the slab. The strands improve a resistance of the slab to flexure. The joint portions improve a vertical shear resistance between the slab and the pre-cast dome. The joint portions may include corrugated dovetails for further improving a horizontal shear resistance between the slab and the pre-cast dome.

A precast concrete panel and method for forming the panel are disclosed. A method of forming the panel to be used as a floor, wall, or roof structure includes positioning one or more forming members within a casting bed having a plurality of upright surfaces defining a generally rectangular interior area, the one or more forming members comprising an insulating material extending along a length dimension of the one or more forming members to define a plurality of rectangular-shaped channels in a parallel and spaced-apart relationship, placing uncured concrete within the casting bed and allowing the concrete to cover the one or more forming members and substantially fill the channels, and allowing the concrete to cure.