It is known that panels moulded for structural use can be subject to undesirable levels of shrinkage and this can complicate their end use or a building made from them. It is an object of the invention to go at least some way to addressing this problem. Accordingly there is provided a method of significantly reducing panel shrinkage in the production of a structural building panel. The method involves spraying polyurethane foam onto a rigid open mould such that the foam substantially embeds mesh, which prevents or significantly reduces shrinkage of the polyurethane foam. A skin of polyurea is then sprayed over the polyurethane to enhance structural strength of the panel.

A green or sustainable building infrastructure comprising conjoining modular building segments. The purpose of the invention is to increase the precision, quality, and timing of building projects by allowing modular building segments to be constructed in an off-site controlled environment, transported, and quickly assembled on site. The conjoining modular building segments are prismatic box-like structures conjoined in a variety of configurations, each having at least three walls. The prismatic box-like structures are arranged and attached horizontally to create ceilings and floors, and they are arranged and attached vertically to create walls for the infrastructure. Some of the walls may be removed and the space inside each prismatic box-like structure is available for storage. The prismatic box-like structures may have certain dimensions, comprise specific materials, or be constructed or conjoined in specific ways.

A process for fabricating a unitized structure comprises creating a multilayer structure by applying a flame-retardant resin to a first layer and stacking, on the first layer, an intermediate layer comprising a honeycomb structure. Further, a second layer is stacked on the intermediate layer and the flame-retardant resin is applied to the second layer. The multilayer structure is then heated to a desired temperature and a pressure is applied about the multilayer structure for a predetermined process time. Moreover, the flame-retardant resin is prevented from entering spaces of the honeycomb structure. After elapse of the predetermined process time, the pressure is released, creating the unitized structure.

An integrated joint sealing system that is incorporated into the edges of a sheathing panel, which also may have a factory bonded weather resistive barrier. The edges of each panel are configured as a shiplap joint, or similarly functioning joint, that is present as either an overlap or underlap on each of the four panel edges. The arrangement of the joints are such that one edge will have an overlap and the opposite edge will have an underlap. A flexible gasket material (or materials) is factory applied to one or both sides (underlap and/or overlap) of the shiplap joint. This flexible gasket material, when overlapped with adjacent shiplap panels, provides a weather resistive seal to limit both water and air penetration.

Disclosed is a modular building system including, in some embodiments, one or more wall panels, one or more floor panels, and one or more roof panels. The modular building components of the modular building system including the one or more wall panels, the one or more floor panels, and the one or more roof panels can form housing or storage structures with electrical wiring, plumbing, or both wiring and plumbing. The housing or storage structures can be erected by one or more persons without a need for a plumber, an electrician, or power tools. Also disclosed is a method for erecting one or more housing or storage structure in accordance with the modular building system.

There is currently a demand for buildings that can be formed both quickly and economically. These buildings require the addition of heat insulation to walls or roofs because the materials from which they are otherwise formed have insufficient ability to protect against the cold. This can add undesirable expense and slow down production rates. A method is disclosed of forming a building that addresses this problem. The method comprises arranging a door frame, window frame or edge support frame at a mould and spraying a first spray material onto the outside of the mould so that the spray material sets generally in the shape of the mould and substantially embeds the frame. The first material and the frame is removed from the mould and a second different spray material is sprayed onto the first spray material to provide a skin therefor.

Disclosed is a modular building system including, in some embodiments, one or more wall panels, one or more floor panels, and one or more roof panels. The modular building components of the modular building system including the one or more wall panels, the one or more floor panels, and the one or more roof panels can faun housing or storage structures with electrical wiring, plumbing, or both wiring and plumbing. The housing or storage structures can be erected by one or more persons without a need for a plumber, an electrician, or power tools. Also disclosed is a method for erecting one or more housing or storage structure in accordance with the modular building system.

A hidden siding fastener is provided. The hidden siding fastener includes an upper nail hem hook and an opposing lower pressure point, fold point and lock engagement hook extending therefrom. The nail hem hook is threaded through the back side of a lower piece of siding panel so that the lock engagement hook can nest into a siding lock slot of the same siding panel. Thereby, a separate upper piece of siding panel and specifically its siding lock hook can operatively associate with the lock engagement hook and fold point in a locked engagement, while the pressure point urges a more secure locked engagement between the two pieces of siding panel.

A hidden siding fastener is provided. The hidden siding fastener includes an upper nail hem hook and an opposing lower pressure point, fold point and lock engagement hook extending therefrom. The nail hem hook is threaded through the back side of a lower piece of siding panel so that the lock engagement hook can nest into a siding lock slot of the same siding panel. Thereby, a separate upper piece of siding panel and specifically its siding lock hook can operatively associate with the lock engagement hook and fold point in a locked engagement, while the pressure point urges a more secure locked engagement between the two pieces of siding panel.

An integrated joint sealing system that is incorporated into the edges of a sheathing panel, which also may have a factory bonded weather resistive barrier. The edges of each panel are configured as a shiplap joint, or similarly functioning joint, that is present as either an overlap or underlap on each of the four panel edges. The arrangement of the joints are such that one edge will have an overlap and the opposite edge will have an underlap. A flexible gasket material (or materials) is factory applied to one or both sides (underlap and/or overlap) of the shiplap joint. This flexible gasket material, when overlapped with adjacent shiplap panels, provides a weather resistive seal to limit both water and air penetration.