A panel structure includes panel members that may be connected together using friction stir welding, Each of the panel members includes a first plate, a second plate substantially in parallel to said first plate, and at least one webbing member connecting the first plate and the second plate. The first plate of the first panel member includes a flange positioned in abutment with a flange located on the first plate of the second panel member. The flange of the first panel member includes a projection and the flange of the second panel member includes a groove. The panel members are connected so that the projection is engaged with the groove to thereby resist relative lateral movement that would separate the panel members.

Two-dimensional module panels with custom metal frame members having cutouts to accommodate building services. These module panels are open for visual inspection and can be used in various construction applications such as floors and walls. The cutouts in the metal frame members allow for the routing of building services such as plumbing, wiring, fire sprinkler, HVAC, whether rigid or flexible. The modular construction process involves the placement of module panels at a build site and the joining of building services between adjacent panels. Additionally, the system may incorporate a building information modeling (BIM) system that generates electronic models of buildings with two-dimensional modules and corresponding framing components.

A modular panel is provided and includes a sill plate, a top plate, a plurality of vertical studs, and having at least one skin applied to a major face of the modular panel that presents a first edge having a waveform profile configured to connect to an opposing edge of an adjacent modular panel. At least one of the vertical studs is an end stud having a connector element configured to be secured to a complementing connector of the adjacent modular panel. Two or more of the modular panels may be connected together to form part of a shelter.

Composite building panels and a method for manufacturing a composite building panel are disclosed. A preferred embodiment of a composite building panel comprises a cold rolled steel frame and at least one reinforcing stud. The stud of the preferred embodiment is located within the space defined by the frame and coupled to the frame at the stud's base. The exemplary stud comprises two flanges extending from the base. The flanges of the preferred stud each have a lip at an end distal to the base bent toward each other. Experiments show that the lips on the flanges of the reinforcing studs significantly increase the structural strength of a composite building panel. An alternate preferred embodiment of another composite building panel comprises two boards and at least one reinforcing stud. The exemplary boards face opposite directions, are coupled to each other, and form a space between the two boards.

An insulated concrete form panel system, and method of making same, is provided, the system and method comprising first and second opposed panels forming a cavity therebetween and an internal connector frame serving as a mold for receiving expandable polymer material to form the first and second panels, such that the irreleasably pre-assembled connector frame extends between, and is integral to, first and second panels. The present system provides first and second panel pairs may be mechanically connected to panel pairs positioned adjacent thereto (e.g. above, below, or side-by-side), increasing integrity of the structure.

A single plenum structural panel comprising a top sheet and a bottom sheet. The top sheet and the bottom sheet being parallel to one another. A plurality of spacing structural elements fixedly attach the top sheet to the bottom sheet, such that a yield strength of an assembled single plenum structural panel is greater than a sum of individual yield strengths of the top sheet and the bottom sheet. A plenum is defined by a spacing between the top sheet and the bottom sheet. The plurality of spacing structural elements are formed such that a first plurality of spaced apart unobstructed pathways are created in the plenum for air to move in a first direction from at least one edge of the single plenum structural panel to at least one of an opposite and an adjacent edge of the single plenum structural panel.

The present invention relates to a modular structural panel intended to form part of an inner or outer wall of a building, the structural panel including two faade panels parallel to each other. Both faade panels are connected by at least one first strut extending along a first direction of the structural panel and by a set of second struts extending along a second direction, perpendicular to the first direction, the second struts protruding from an edge of the structural panel by a distance D and the at least one first strut extending in a recessed manner from the opposed edge of the structural panel by a distance D at least equal to the distance D, in order to allow the protruding parts of the adjacent panel in the building to be nested within the intermediary space between this first strut and the close edge of the structural panel.

A door or wall element includes a frame having four hollow profiles; two side panels at opposed sides of the frame and attached to the frame; at least two of the profiles, positioned at opposed sides of the frame, include a groove at the sides of the profiles defining the outer circumferential surface; and each of the side panels at opposed edges has an upstanding rim fitting into the slot of the frame. The element includes a connection piece between two adjacent profiles of the frame wherein the profiles are mitred and the connection piece includes a body having a cross section matching the inner space of a first profile and inserted therein. The body has a mitred end surface from which at least one toothed part protrudes in a direction perpendicular to the longitudinal direction of the body and fits in the inner space of an adjacent second profile.

Methods of manufacturing pre-fabricated insulated wall structures are described in this specification. The methods include (a) attaching a foam panel to a front frame surface of a substantially horizontally positioned frame; (b) placing the frame having the foam panel attached thereto on a track conveyor configured to convey the frame having the foam panel attached thereto in a substantially upright position; (c) conveying the frame having the foam panel attached thereto on the track conveyer in a substantially upright position to a spray foam application station; and (d) spray applying a spray foam composition into a cavity of the frame to form a substantially upright positioned wall structure having a foam layer deposited in the cavity in which the foam layer adheres to the foam panel. Also disclosed are track conveyors suitable for use in such methods.

A method of making a metal frame that will be used to make metal panels that will be used to fabricate modular metal buildings. Currently, the metal frames are manufactured through forming processes, however, the steps adopted end up generating greater difficulty in the conformation of the metal sheet, and, consequently, increase in the manufacturing time; as well as, they cannot achieve a higher degree of quality, which reduces the added value of the metal frame and can lead to greater difficulty of assembly, lower productivity and higher labor cost. The ideal method, comprises of modular plates (1) that are formed by galvanized sheet frames (2), which are manufactured by the method with 22 forming steps through a roll forming machine (7) with profiling rolls (9) with specific frames (10), and each step has a roll (9) and a set of support rollers (12) for each forming step.