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.

Fire-retardant panels that include: two skins (e.g., sheet metal) and a layer of gypsum or calcium silicate fire-resistant material therebetween; two layers of insulation with fire-resistant material therebetween; a skin (e.g., sheet metal), a layer of gypsum or calcium silicate fire-resistant material, and insulation therebetween; or a combination thereof. Some embodiments include: two contiguous layers of the fire-resistant material, gypsum board, tongue and groove connections; or a frame that extends around the perimeter or has two portions that are attached to the skins or are separated by the fire-resistant material. In some embodiments, the fire-retardant panel is fabricated in a factory before being installed at a jobsite.

Fire-retardant panels that include: a frame with multiple holes in at least two rows that reduce heat conduction through the panel; or a frame that includes two portions separated by a layer of fire-resistant material (e.g., gypsum, calcium silicate, or gypsum board). Some embodiments include layers of skin (e.g., sheet metal) or insulation (e.g., between skin and fire-resistant material). In particular embodiments, the fire-resistant material is (e.g., midway) between: two skins, two layers of insulation, two portions of the frame, or a combination thereof. The portions of the frame can be: sheet metal, attached (e.g., screwed) to the skin(s), or extend around the perimeter. The frame can include: various elongated members, one or two (e.g., parallel) bends, or holes that are: in at least three rows, staggered, elongated, or slots (e.g., parallel to each other or to the skin).

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 system for creating a cementitious building includes a support structure comprising a plurality of support members, and an inflatable rigidizable structural (IRS) form. The IRS form comprises a plurality of geosynthetic cementitious composite mat (GCCM) sections having GCCM configured to absorb water and rigidize in response to hydration, each GCCM section being coupled to another GCCM section of the plurality such that the IRS form is pneumatically inflatable.

This invention is designed to allow one to build a structure quickly. The panels could be comprised of lightweight core material; such as Sing Core, U.S. Pat. No. 7,147,741. Each panel can have a solid wood frame and at least one layer of skin material on both sides of each panel. Skin material can be any flat building material or sheet materials; such as plywood, MDF, veneer, metals, plastics or fiberglass. Solid wood blocking can be placed wherever an anchoring point is needed. Panels can be joined together using tension cables/rods and/or dowels to create walls, floors, or a roof. Each panel in the wall, floor, or roof can have wiring, plumbing, HVAC ducting, or even vacuum ducting installed during manufacturing. Utility lines can be surface mounted to the base panel. This means that there is no need to drill studs to run any utility lines. Utility lines can be fabricated in the factory with outlets, switches, lights, and any other accessories installed where they are needed. This means that the utility lines will only need to be mounted to the wall, floor, or roof upon installation. No electrician will be needed on site for installation. This will solve the issue of having to drill and route utility lines through the wall studs. The walls can have furring strips fastened to the rough wall and the final wall skin can be applied to the other side of the furring strips. This allows fast and simple passage for the necessary utility lines.

The utility lines can also b embedded inside of the structural panels. Athe structural provide the basic structure while providing insulation to the structure. The furring strips can be fastened to at least one side of the structural panels. The final skin can be applied directly to the wall or to the furring strips to hide utility lines, increase shear strength, and appearances.

A method for manufacturing a building element with a wooden frame, the method comprising forming the frame of the element of wooden panels filling the space inside the frame with insulation material, coating the wooden panels which define the outer surfaces of the frame of the building element to be substantially air-tight, filling the space inside the frame with expanded perlite, and applying vacuum in the space inside the building element by a vacuum pump connected to the element. The invention also relates to such a building element with a wooden frame, as well as a building element system consisting of a plurality of such building elements with a wooden frame.

A prefabricated modular reinforced concrete building system includes panel assemblies for foundations, walls, decks, and roofs designed to be built out in a manufacturing facility, shipped to a job site, and filled with concrete. Panel assemblies incorporate a space frame to ensure structural integrity during shipping and during concrete fill. Space frames can include structural columns, rebar mats, spacers, straps, and skin panels. Panel assemblies may be manufactured to contain architectural interior/external finishes, windows/doors, and pre-installed utility distribution systems.

A multiwall sheet (30) comprising a first wall (2); a second wall (4); a plurality of ribs (8) extended between the first and second walls (2, 4); and a plurality of mid-ribs (6), wherein one mid-rib (6) extends between each two adjacent ribs (8), wherein the mid-ribs (6) extend at a mid-rib angle (18) relative to an adjoining rib (8), and wherein the mid-rib angle (18) is not 90 relative to a rib (8) to which it attaches, wherein the mid-ribs (6) attach only to adjacent ribs (8), and wherein the mid-ribs (6) do not attach to either the first or second walls (2, 4).

A door or wall element includes a frame having four elongated profiles. Two side panels are provided at opposed sides of the frame and are attached to the frame. At least two of the profiles positioned at opposed sides of the frame are provided with a groove situated at the sides of the concerned profiles defining the outer circumferential surface of the frame. Each of the side panels are provided at opposed edges with an upstanding rim fitting into the concerned groove of the frame. The profiles are hollow profiles. The door or wall element includes at least one connection piece provided between two adjacent profiles of the frame, and the connection piece includes a guide surface allowing angular movements between the adjacent profiles during an assembly phase of the door or wall element.