A lightweight flame-resistant composite panel is provided including a body portion and a side portion folded over the body portion. The side portion includes a channel segment adjacent to the body portion, and an overlapping segment adjacent to the channel segment. One or more panel apertures are located in the body portion and the channel segment for receiving bolts through the side of the panel. An edge reinforcement insert can be inserted underneath the channel segment in a channel defined by the folded side portion along an edge of the body portion. The edge reinforcement insert includes one or more insert apertures for receiving the one or more bolts through the panel, thereby increasing the bolt bearing strength of the panel along its edge. The edge reinforcement insert may comprise an elongated strip, a plurality of separated tabs, or an end cap, or may alternatively be contained within the panel.

A reinforced water-resistant board includes a cover board with a reinforced water-resistant membrane applied to a surface of the cover board. The reinforced water-resistant membrane includes a primer layer, a reinforced membrane, a traffic coat, and a sealing layer. The primer layer is applied over the surface of the cover board. The reinforced membrane includes fleece soaked in a liquid resin and is applied over the primer layer. The traffic coat is bonded to the reinforced member. The sealing layer is applied over the traffic coat.

A reinforced water-resistant board includes a cover board with a reinforced water-resistant membrane applied to a surface of the cover board. The reinforced water-resistant membrane includes a primer layer, a reinforced membrane, a traffic coat, and a sealing layer. The primer layer is applied over the surface of the cover board. The reinforced membrane includes fleece soaked in a liquid resin and is applied over the primer layer. The traffic coat is bonded to the reinforced member. The sealing layer is applied over the traffic coat.

An FRP panel material includes reinforcing fibers oriented in predetermined orientation directions near the surface. In the surface of the panel material, a plurality of either or both of protrusions and depressions having shapes of congruent regular triangular pyramids are provided. The bases of the regular triangular pyramids are arranged on a virtual reference plane along the surface with no gap or overlap so that each vertex of an equilateral triangle constituting each base is shared by six of the bases as vertices thereof. Each of the orientation directions of the reinforcing fibers is parallel to any lateral edge of each regular triangular pyramid as seen in the thickness direction of the panel material.

An FRP panel material includes reinforcing fibers oriented in predetermined orientation directions near the surface. In the surface of the panel material, a plurality of either or both of protrusions and depressions having shapes of congruent regular triangular pyramids are provided. The bases of the regular triangular pyramids are arranged on a virtual reference plane along the surface with no gap or overlap so that each vertex of an equilateral triangle constituting each base is shared by six of the bases as vertices thereof. Each of the orientation directions of the reinforcing fibers is parallel to any lateral edge of each regular triangular pyramid as seen in the thickness direction of the panel material.

A honeycomb-like core member that can be easily manufactured is disclosed, and a structure using such core member is disclosed. The core member has a plurality of flat plate members (a plurality of first flat plates and a plurality of second flat plates), each of which includes a comb teeth portion that has a plurality of notches, which are open in the long side of a rectangular shape of the flat plate member and extend parallel to the short side of the rectangular shape of the flat plate member. The notches are engaged with each other so that the plate members cross each other, and thus, a plurality of hexagonal-cylinder-shaped first cylinder portions and a plurality of triangular-cylinder-shaped second cylinder portions are formed by the plate members.

A sheet for providing an air gap is provided. The sheet includes a body defining a first surface. The sheet also includes cusps. The cusps extend from the first surface of the body, and one or more channels are formed between the cusps. The sheet includes fire-resistant material. This fire-resistant material may be fiberglass, talc, calcium carbonate, powdered metal, or another material(s). The one or more channels may be configured to permit liquid water, air, and/or other fluids to flow through.

A sheet for providing an air gap is provided. The sheet includes a body defining a first surface. The sheet also includes cusps. The cusps extend from the first surface of the body, and one or more channels are formed between the cusps. The sheet includes fire-resistant material. This fire-resistant material may be fiberglass, talc, calcium carbonate, powdered metal, or another material(s). The one or more channels may be configured to permit liquid water, air, and/or other fluids to flow through.

A lightweight plate that contains polycarbonate resin and achieves good strength and formability while providing reduced weight, and a lightweight panel including such a lightweight plate. A lightweight plate includes a resin foam plate having an expansion ratio of 1.2 to 4, and a resin sheet containing fiber and overlaid on a major surface of the resin foam plate. The resin foam plate includes a polycarbonate resin in not less than 50 wt. %. The polycarbonate resin has a viscosity-average molecular weight of 10000 to 100000. The lightweight plate achieves reduced weight by having an expansion ratio of 1.2 to 4, and achieves good strength and formability by including a polycarbonate resin in not less than 50 wt.% and having a polycarbonate resin of a viscosity-average molecular weight of 10000 to 100000.

This invention relates to prefabricated, lightweight, multi-component structural modular building panels and modular building systems. The said panels are framed with edge members that have a unique connecting shape, making them modular. The multi-component panel allows for design flexibility and the mass manufacturing of its components. Connectors serve as a link to assemble the panels together, and to connect them to corners, floors or foundations, roof panels and the roof apex member, and or other conventional construction elements. Connectors and members, all with unique connecting shapes, coupled with the said panels, create a structural wall, roof, similar structure or building system. Assembled panels and members incorporate the primary building structure and the building envelope. The assembled panels, members and other components of the building system, in part or whole, can be flat packed for easy transport and shipping, and can be assembled quickly and easily with semi-skilled labor.