The invention is a system and method for building a polar zonohedron structure from precast cement panels. The building system may include a plurality of panels configured to register with each other. Each panel includes a precast cement base with side walls enclosing a cavity within the precast cement base. The panels include at least one ridge protruding from at least one surface of a side wall of the panel and at least one aperture on at least one surface of a side wall of the panel. Each ridge is preferable configured to interlock with each aperture; in his way, the panels interlock with each other to form the polar zonohedron structure.

A precast concrete panel and method for forming the panel are disclosed. A method of forming the panel to be used as a floor, wall, or roof structure includes positioning one or more forming members within a casting bed having a plurality of upright surfaces defining a generally rectangular interior area, the one or more forming members comprising an insulating material extending along a length dimension of the one or more forming members to define a plurality of rectangular-shaped channels in a parallel and spaced-apart relationship, placing uncured concrete within the casting bed and allowing the concrete to cover the one or more forming members and substantially fill the channels, and allowing the concrete to cure.

A structural insulation panel (SIP) is made of a central insulation material or block core covered with cementitious material. The layers of cementitious material are reinforced with fiber mesh sheets, rebar and corner blocks. The corner blocks are held in thickened cementitious material edges by reinforcement pins that are fixed to the corner blocks. The corner blocks are accessible for lifting the panel and for assembling multiple panels to build a wall.

A precast concrete panel and method for forming the panel are disclosed. A method of forming the panel to be used as a floor, wall, or roof structure includes positioning one or more forming members within a casting bed having a plurality of upright surfaces defining a generally rectangular interior area, the one or more forming members comprising an insulating material extending along a length dimension of the one or more forming members to define a plurality of rectangular-shaped channels in a parallel and spaced-apart relationship, placing uncured concrete within the casting bed and allowing the concrete to cover the one or more forming members and substantially fill the channels, and allowing the concrete to cure.

A building apparatus for a residential or commercial building that includes a prefabricated wall panel and a horizontal beam mounted on a top of the prefabricated wall panel. The prefabricated wall panel includes a first concrete block, a second concrete block, and an insulation panel sandwiched between the two concrete blocks. A plurality of spaced-apart hollow tubes extend between the top side and the bottom side of the prefabricated wall panel and each tube has a flange at its a periphery. The tubes reinforce the first concrete block, and the flanges are supported on the top side of the wall. The horizontal beam is fastened to these flanges. The prefabricated wall panel further includes a U-shape beam that extends from the top side to the bottom side and is positioned at or near the left side or the right side of the prefabricated wall panel. A plurality of slings spaced apart run along a length of the U-shape beam and can provide for assembling two wall panels.

A structural insulation panel (SIP) is made of a central insulation material or block core covered with cementitious material. The layers of cementitious material are reinforced with fiber mesh sheets, rebar and corner blocks. The corner blocks are held in thickened cementitious material edges by reinforcement pins that are fixed to the corner blocks. The corner blocks are accessible for lifting the panel and for assembling multiple panels to build a wall.

Example embodiments of the described technology provide a prefabricated building panel. The prefabricated building panel may comprise an insulative core having first and second opposing faces. The prefabricated building panel may also comprise a cementitious layer encapsulating the insulative core. The cementitious layer may increase one or more performance characteristics of the panel.

A product and a method of manufacture and assembly of a prefabricated wall panel for construction is shown and described. The present invention is directed towards minimizing the labor of multiple additive steps using many layers and materials seen in many building envelopes.

In one example, the method comprises,

A series of prefabricated residential or commercial building panels made of any of varying materials such as hemperete, fiber, cellulose, plant material, bio-aggregate, aggregate, aerated concrete, composite or inorganic materials, of substantially solid body with channel shaped elongated voids substantially located at the vertical sides as well as horizontally across their top.

Said voids in one panel are a connected channel wrapping around 3 or more sides of the panel and exposed to the exterior of said panel. Said panels are placed side by side around the perimeter of a foundation aligning the channel shaped void in one panel with the respective channel shaped void in the panel beside it creating a concrete form, or form for a load bearing material. Said panels are left in place as an integral part of the wall system. Concrete or other load bearing material is placed in said voids substantially vertically between the panels and across their tops creating an air seal and a mechanical bond between panels. The resulting concrete shape inside the wall is a post and beam structure that is substantially equidistant from the interior and exterior of the wall minimizing heat transfer through thermal bridging and minimizing weathering to the concrete. Many of the requirements of a building's wall such as the insulation, the shear strength, the rough openings for windows and doors, the interior and exterior skin, utility chases, drip edges and trim details can be met by this series of prefabricated building blocks. A method of manufacture of the building panels, the product created by that manufacture, a method of panel assembly and integration with other building components, and the finished product created by the manufacture, assembly and integration with other building components are all shown in the present disclosure.

A wall panel includes hollow connector blocks in its lower corners, reinforced with anchor pins embedded in cementitious material of the panel. The connector blocks have holes for connecting adjacent wall panels together and for connecting the wall panels to the floor. Connectors are inserted via exposed apertures in the connector blocks that provide access to their hollow interiors. The apertures can be covered when the panels are fastened in place.

A structural insulation panel (SIP) is made of a central insulation material or block core covered with cementitious material. The layers of cementitious material are reinforced with fiber mesh sheets, rebar and corner blocks. The corner blocks are held in thickened cementitious material edges by reinforcement pins that are fixed to the corner blocks. The corner blocks are accessible for lifting the panel and for assembling multiple panels to build a wall.