A foam filled structural plank made from a plurality of structural beams assembled together to form a structure capable of supporting the weight of a building thereon, wherein the plurality of structural beams define an enclosure therebetween and an outer perimeter therearound; and a structural building foam such as having expanded polystyrene foam having a density from 1.5 to 3.0 PFC filling the enclosure.

A set of structurally insulated panels and method of building construction, the set of panels having an indexing system that allows for any one panel to be easily attached to any other panel via indexing pins placed in pre-arranged openings. The indexing system enables essentially any number of panels to be assembled in essentially any reasonable manner to construct a building structure.

Modified and connected foam wall structures and methods for making them are described. The wall structures include a frame, a foam panel attached to the frame, a foam layer disposed in a cavity defined by the frame, and a structural adhesive. The structural adhesive may be disposed in at least one of: (A) an aperture located within the foam layer, and (B) an aperture located between the foam layer and a frame member. In some cases, a cured structural adhesive is located between connecting members of adjacent foam wall structures.

The present invention provides an anchor assembly for attaching a first structure to a second structure. The anchor assembly has a body having a first face and a second face. The first face is transverse to the second face and has an elongate slot. The second face has a through hole. The body is fabricated from a material that fails at a temperature in excess of 1,000° F. A fastening member is positioned in the elongate slot for connecting the first face to the first structure and for sliding engagement with the elongate slot in response to relative movement of the first structure and the second structure.

The present disclosure concerns an exterior wall panel comprising a wall framework defining inner and outer wall surfaces and having peripheral edges. The exterior wall panel further comprises a vapor barrier membrane superposed to the inner wall surface and covering at least one peripheral edge and being secured thereto, a weather barrier membrane superposed to the outer wall surface and covering at least one peripheral edge and being secured thereto. The present disclosure also concerns an external wall panel assembly comprising a plurality of such external wall panels and a method for forming such an exterior wall panel assembly.

Wall structures and methods of manufacturing wall structures are described. The wall structures include a frame, a foam panel attached to the frame, a brace disposed in a cavity defined by the frame, and a foam layer. The wall structures can impart a high wall racking strength and good thermal performance through the combination of the foam layer, brace, and the foam panels.

Installation and construction methods for installing a wall panel are provided. The wall panel includes a surface member and a long joint member that extends horizontally, is fixed to one plate surface of the surface member, and is joined to a pair of wooden columns. The method includes: disposing the joint member between the pair of wooden columns; joining both longitudinal ends of the joint member to respective side surfaces, facing each other, of the pair of wooden columns; installing the wooden beam between the pair of wooden columns and adjusting erection of the wooden columns; and fixing an edge of the surface member to front surfaces of the pair of wooden columns and the wooden beam.

Foam wall structures and methods for making them are described. The wall structures include a frame, a mesh mechanically fastened to a front surface of the frame, a foam panel at least partially abutting and overlying the mesh, and a foam layer disposed in a cavity defined by the frame, the mesh, and the foam panel. Buildings that include such wall structures are also described.

Described herein is a wall assembly for use in walls of energy efficient residential or commercial buildings which can provide improved thermal resistance, moisture resistance and structural capacity. The wall assembly includes a frame assembly, an outer fiberboard, and a closed cell foam layer. The fiberboard is laminated with a lamination such as a non-perforated, non-woven polyolefin permeable membrane. The closed cell foam layer couples the frame assembly and the outer fiberboard. Also described herein is a method of manufacturing the wall assembly.

A system and method for assembling framing assemblies for use as ceiling or floor structures of modular building units using automation are disclosed. The framing assemblies include trusses that are attached at the lateral edges thereof by a joist including at least one layer of dimensional lumber to form a substantially rigid framework. Cover panels are positioned over and attached to an inner surface of the framing assembly.