Foam wall structures and methods for making them are described. The wall structures include a frame, a foam panel overlying a front surface of the frame, and a polyurethane foam layer disposed in a cavity of the wall structure. The polyurethane foam layer has a density, as determined by ASTM D1622-14, of at least 44 kg/m.sup.3 and exhibits ASTM E84-16 Class A flame spread and smoke development characteristics. The polyurethane foam layer is the cured reaction product of a polyurethane foam-forming composition that includes a polyisocyanate, an aromatic polyester polyol having a functionality of greater than 2.5 and an OH number of at least 300 mg KOH/g, which is present in an amount of at least 50% by weight, based on the total weight of the polyurethane foam-forming composition less the weight of the polyisocyanate, a catalyst, and a blowing agent composition. The blowing agent composition includes water and a hydrofluoroolefin.

Isocyanate-reactive compositions that include a hydrofluoroolefin blowing agent, polyurethane foam-forming compositions, as well as spray-applied polyurethane foams formed therefrom that can provide structural support to wall structures and can also exhibit ASTM E84-16 Class A flame spread and smoke development characteristics at a foam thickness of 4 inches.

A stay-in-place concrete formwork system allows stucco to be applied directly to the formwork, avoiding the need to provide a further surface treatment of the wall prior to applying stucco. Apertures are provided on an exterior facing wall of the formwork panel to receive and embed stucco therein. The panel may also be formed with outward stucco-engaging projections. Other features include using rigid insulation to brace the stucco and keep concrete from the apertures, a sealing joint element, extendible panels for use in curved formwork, rainscreen features and an alligator connector panel for adjustable lengths of formwork faces.

A stay-in-place concrete formwork system allows stucco to be applied directly to the formwork, avoiding the need to provide a further surface treatment of the wall prior to applying stucco. Apertures are provided on an exterior facing wall of the formwork panel to receive and embed stucco therein. The panel may also be formed with outward stucco-engaging projections. Other features include using rigid insulation to brace the stucco and keep concrete from the apertures, a sealing joint element, extendible panels for use in curved formwork, rainscreen features and an alligator connector panel for adjustable lengths of formwork faces.

The invention comprises a product. The product comprises a foam insulating panel, the panel having a first primary surface and an opposite second primary surface, wherein the foam insulating panel defines at least one recessed channel in the first primary surface, the at least one recessed channel being sized and shaped to provide a mold for a structural reinforcing member. The product also comprises a concrete panel formed on the first primary surface and filling the at least one recessed channel so as to provide a structural reinforcing member for the concrete panel. The product further comprises an elongate anchor member in the foam insulating panel and extending from the first primary surface of the foam insulating panel into the concrete panel. A method of making a composite reinforced insulated concrete structure is also disclosed.

A composite wall, ceiling or floor panel (10), system and method, including a sheet (14) having a first face (18) including at least one first mounting portion (16), and at least one formwork member (20) with at least one second mounting portion (30) arranged to engage with the first mounting portion of the sheet to retain the sheet and said at least one formwork member together. Structural support comes from piers (for a wall) or beams (ceiling or floor) formed in the spacing between adjacent formwork members. The formwork members act as the core of a wall, ceiling or floor panel. An external coating (123) is applied to the formwork members, such as spray shotcrete or render. Channels (28) formed by the formwork members defines integrated ducting for services to be run.

Systems and methods for forming insulated sandwich walls are provided. Outer and inner support members are located between inner and outer strongbacks. Structural material for an outer wall, such as concrete, is deposited between the outer strongback and outer support member. Structural material for an inner wall is deposited between the inner strongback and inner support member. An insulating material is deposited between the outer and inner support members to form an insulating core.

An insulation system for use with a sandwich wall panel is disclosed. The insulation system reduces the risk of flame spread through the sandwich wall panels. The insulation system provides a balance between good insulating properties and reduced flammability, without detrimentally increasing the cost of the sandwich wall panel.

Systems and methods for forming insulated sandwich walls are provided. Outer and inner support members are located between inner and outer strongbacks. Structural material for an outer wall, such as concrete, is deposited between the outer strongback and outer support member. Structural material for an inner wall is deposited between the inner strongback and inner support member. An insulating material is deposited between the outer and inner support members to form an insulating core.

A sprayed-in-place framed wall is disclosed, comprised of a cementitious face and backing layers and a polyurethane foam insulation layer that bonds the cementitious layers to a separate wall frame. Stationary walls are constructed by spraying the materials against one-sided, vertical wall forms positioned around an erected, exterior wall frame. The cementitious materials are restrained by stays. The wall forms may have indentations to enable the resulting wall face to have protrusions such as moulding, bands, quoins and cornices, which may be a different color that the surrounding flat wall face.