US20080196355A1

US20080196355A1 - Building system utilizing integrated technology with molded expanded polystryrene cores

Info

Publication number: US20080196355A1
Application number: US12/070,038
Authority: US
Inventors: Dan Williams
Original assignee: Samsung Electronics Co Ltd
Current assignee: Samsung Electronics Co Ltd
Priority date: 2007-02-17
Filing date: 2008-02-14
Publication date: 2008-08-21
Also published as: CN101542052A; WO2008100558A1

Abstract

The disclosure pertains to a method of constructing structures and the resulting structures with SEP technology but with additional building components that create very strong buildings, including the ability to withstand high winds. The disclosure includes the option of constructing vertical concrete columns and horizontal concrete beams within the joined panel walls. This results in combining structural insulated panel technology with insulated concrete form technology. The disclosure also teaches use of compression fasteners that extend through both layers of the panel skin to achieve a mechanical attachment of the panel skins and not relying totally on the adhesive bond found on the typical SIP thus creating a “true” box beam effect of the panel itself. The fasteners have large chambered heads. These fasteners can be used at the junction of abutting panels. The panels are block lap cut and the fastener extends through both block extensions.

Description

RELATED APPLICATIONS

This application claims priority to and the benefit of the provisional application Ser. No. 60/901,738 filed Feb. 17, 2007 entitled “Building System Utilizing Integrated Technology with Molded Expanded Polystyrene Cores.” The text and the drawings of the provisional application Ser. No. 60/901,738 are incorporated by reference herein.

BACKGROUND OF INVENTION

1. Field of Use
The invention pertains to modular constructed building systems that employ green technology and little, if any, wood products.
2. Related Technology
Off site manufacturing of building components such as wood roof trusses are known.

SUMMARY OF DISCLOSURE

The disclosure pertains to a plurality of wall panels fabricated of molded expanded polystyrene (MEPS) with an outer layer or “skin” of cement board, oriented strand board, metal or magnesium oxide. In one example the panels can be 4 feet wide by 8 feet high and 3½ inches to 11½ inches thick. Other dimensions are possible. The vertical ends of the panels may be cut to form block and tongue lap joints with the next adjoining panel. The resulting lap joint allows for increased surface area for bonding the panels together. Adhesives are used to “weld” the MEPS at the panel lap joint to create a “continuous like” structural wall. The panels are secured with compression fasteners that traverse through the thickness of both panels at the block and tongue lap joint and anchor at the outer surface.
The structure can be anchored to a concrete pad. The roof structure can be made of the panel material and attached to the walls with attachment connectors.
The panels may also contain preformed voids creating forms for pouring and shaping internal vertical concrete columns and horizontal concrete beams thereby combining structural insulated panel (SIP) technology with insulated concrete form (ICF) technology.
The horizontal ends of the panels may also be similarly cut and shaped to form block and tongue lap joints.

SUMMARY OF DRAWINGS

The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate preferred embodiments of the invention. These drawings, together with the general description of the invention given above and the detailed description of the preferred embodiments given below, serve to explain the principles of the invention.

FIG. 1 illustrates an example of a SIP panel illustrated to be 4 feet wide and 8 feet long. This is a side view. Also illustrated are the chamfer heads of the compression fasteners mounted vertically every 2 feet. Also illustrated in the tongue component of the lap joint.

FIGS. 2A and 2B illustrate opposing lap joint ends of two SIP panels.

FIG. 2C illustrates the two panels joined together utilizing a compression fastener.

FIG. 2D illustrates a two piece threaded compression fastener.

FIG. 3 illustrates a block lap end cut of a SIP panel with an internal column forming void or annulus.

FIG. 4 illustrates an end view of the SIP panel showing the void for a concrete horizontal beam.

FIG. 5 illustrates an end view of another SIP panel showing an expanded installed top portion into which a concrete horizontal beam can be formed.

FIG. 6 is a detail of the end view of FIG. 5 with vertical and horizontal reinforcing bar and compression fasteners.

FIGS. 7 and 8 illustrate examples of a SIP I-beam attached to a vertical SIP panel with associated structural connectors and compression fasteners.

FIGS. 9A, 9B and 9C illustrate differing perspective views of connectors that can be used to connect I-beam to the SIP panel.

FIG. 10 illustrates the positioning of an angle structural connecting plate on top of a vertical SIP panel and angle roof comprised of an I-Beam.

FIG. 11 illustrates the attachment of a horizontal I beam on the top of a vertically oriented SIP panel.

FIG. 12A, 12B and 12C illustrate 3 views of the angled structural connector plate illustrated in FIG. 10.

FIGS. 13 and FIG. 14 illustrate alternative structural attachment connectors for attaching the vertical SIP panel to an angle I-beam.

FIG. 15A, 15B and 15C illustrate a front, side and back view respectively of one connector device.

FIGS. 16 and 17 illustrate details of the lap joints joining the adjacent SIP panels for a roof structure.

FIG. 18 illustrates a block and tongue lap joint reinforced by a preformed structural Z shaped member.

FIG. 19 and FIG. 20 illustrate the SIP vertical panel base attached to the floor concrete slab with a structural connector.

FIG. 21 illustrates an isometric view of 3 SIP panels joined together into a wall and containing internal vertical concrete columns and horizontal beams.

FIG. 22 illustrates an isometric view of the vertical edge of two panels forming a block and tongue lap joint and the placement of the compression fasteners.

FIG. 23 illustrates an isometric view of a series of SIP panels joined into a wall and including the structural top and bottom base connectors joining two panels.

FIG. 24 illustrates an isometric view of a block and tongue lap joint reinforced by the 2 shaped structural member illustrated in FIG. 18 and the installation of compression fasteners with a top structural connector plate joining two panels.

FIGS. 25 and 26 illustrate a top view and side view respectively of a SIP panel production line.

FIGS. 27 and 28 illustrate front and side views respectively of a twin SIP laminating press.

It will be appreciated that the foregoing drawings illustrate only one embodiment of the invention and that numerous other variations may be created within the scope of the described invention. Further, the accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate preferred embodiments of the invention. These drawings, together with the general description of the invention given above and the detailed description of the preferred embodiments given below, serve to explain the principles of the invention.

DETAILED DESCRIPTION OF INVENTION

The building structure and method described herein incorporates structural insulated panel technology (hereinafter “SIPs”) and may include a concrete pad or foundation, wall panels that are adhesive bonded and secured together with compression fasteners, optional internal concrete beams and a roofing system attached to the wall system. The structure and the building method come in two versions, one that integrates concrete and one that does not.
Utilization of the concrete column and beam technology achieves a combination of structural insulated panel technology with insulated concrete form technology. Both versions utilize structural insulated panels (hereinafter “SIPs”). In the embodiments disclosed, the concrete columns and beams are installed within the interior of the SIP panels.
The panel is a structural insulated wall or roof panel 11 which has a core made of molded expanded polystyrene (hereinafter “MEPS”) of various thicknesses from 3½″ to 11½″. The outer layers 110 are cement board (CB) or oriented strand board (OSB), metal or Magnesium Oxide (MgO) board which may be pressure adhered with a Type II, Class 2 structural adhesive or similar. One embodiment of a SIP panel is illustrated in FIG. 1. The panel is 4 feet wide and 8 feet high. As discussed the thickness of the panel may be between 3½ inches and 11½ inches. The illustrated panel 1 is a side perspective. Also illustrated are the chamfer heads 3 of the compression fasteners as will be discussed later. The head of the compression fastener can also have square sides. The compression fittings are illustrated as placed every two feet. Other configurations are possible. The tongue 115 of the block and tongue lap joint is also shown protruding from the vertical side of the panel.
The CB and MgO outer materials also have fire retardant properties.
Other components of the structure system, e.g., fiberglass, may be made from an extrusion process. This can allow fabrication of components in custom shapes.
The system utilizes a 3-4″ block projecting tongue fabricated on the vertical edge, and in some cases the top horizontal edge, of each panel and which butt and lap together with the similar edge of a second panel. A series of compression fasteners are placed vertically and horizontally along the butt joint forming the lap juncture. The compression fasteners attach to each panel skin, whether cement board, OSB, metal or MgO of each panel. The compression fastener therefore incorporates both skins of the SIP panels. The compression fasteners are placed horizontally at gables and 2 story walls. This strengthens the bond between the panels.
In one option, concrete may be used in the structure. The panel contains a vertically oriented void that forms the various shapes of the concrete column internal to the panel. A panel is placed on the cement pad of the structure where a vertical concrete column is to be placed. The reinforcing bar (rebar) placed in the column is tied to rebar extending from the concrete pad. Compression fasteners are utilized to stabilize the sides of the form (within the panel wall) when the concrete is poured. The form for the concrete column is a void created in the interior MEPS and extends the length of the SIP panel.
A horizontal beam that sits on top of the vertical column can be created by a second void in the top of the SIP panel or by use of an installed or “detachable” beam form. The rebar of the horizontal beam will be tied to the vertical rebar extending from and attached to the structure's concrete pad. (See information below).
Block projecting tongue lapping is used on all vertical panel joining and at gable ends and when structure side walls have a greater height than the standard SIP wall panels
Block projecting tongue lapping or lap juncture is illustrated in FIGS. 2A through 2C. A two part compression fastener is also illustrated 1, 2, 3. In one embodiment the MPES panel 105 is shown to be between 6 and 8 inches in thickness with an outer surface ( 7/16 inch) 110 of cement board, OSB, metal or MgO. The outer surface or skin is pressure adhered with a Type II, Class 2 structural adhesive.
Waterproof construction adhesive 5 may be applied to both sides of the lap joint. A ⅛ inch air gap 130 is recommended between the joined SIP wall panels. The horizontal off set 135 of the block projecting tongue combination may be approximately 4 inches.
Panel lapping of three roof panels 20A, 20B, 20C is also illustrated in FIGS. 16. Each roof panel comprises a series of individual SIP panels joined in the block projecting tongue lapping configuration.
The SIP panel 20D, 20E illustrated in FIG. 17 may be various thicknesses, including the cement bonded particle board, OSB, metal or MgO layer. Also illustrated is the recommended ⅛ inch expansion joint 130 and the approximate 4 inch offset 135 of the lap joint. The placement of the adhesive 5 is also illustrated.
SIP panel lapping is used on all vertical (wall) panel joining and may be used horizontally at gable ends of the structure.
The system utilizes a unique compression fastener comprising a bolt that can be mounted flush to the SIP panel surface or “skin”. The compression fastener is illustrated in FIG. 2D comprising a bolt component 1 and a nut component 2. The two part combination is designated 3.
The large chamfer or square sided head on both bolt and nut ends of the compression fastener and engage with the SIP panel skins facilitates compression of the SIP panel. The head and nut components are threaded and can be tightened. This is a more secure connection that staples, nails or screws. This also enhances the stability of the structure, including stability in earth movement or high wind conditions. The construction technique forms a box beam effect on the panel wall connection.
Composition of fasteners can be either non-metallic, e.g., fiberglass, or metallic, e.g., stainless steel. The compression fasteners may be of any appropriate length consistent with the thickness of the SIP panel. In one embodiment, the fasteners are 7 inches to 10 inches in length. The diameter of the rod portion of the fastener may, in one embodiment, be ¼ inch. In one embodiment, the chamfer or square ends may have a 1 inch diameter. The chamfer ends may include hex slot for tightening.
The system described herein permits the installation of vertically oriented concrete columns within constructed SIP panels. See FIG. 3. In one embodiment, the molded expanded polystyrene 105 can be molded or cut to create the form or annulus for the concrete. The shape of the concrete column is formed using pre-formed voids or annulus within the SIP panels. Also illustrated in FIG. 3 are the double layers of outer skin 110 (first skin on one side of the panel and a second skin on the opposite side of the panel). The compression fastener 3 spanning across the form is also illustrated. These compression fasteners are utilized to stabilize and secure the sides of the form when the concrete is poured. These compression fasteners may be placed vertically every 2 feet although other configurations may be selected.
A rectangular or other shaped void 140 is placed vertically in a wall panel for the purpose of pouring a structural concrete column. The void extends the entire length of the SIP panel. If a horizontal concrete beam is to be installed, the concrete column will not extend to the top of the panel. The form or void may be 5¼ inches by 13½ inches in a panel that is 7¼ inch wide. The rectangular shape is shown as an example only and is not a limitation.
Recall that compression fasteners and adhesive will be applied at each lap joint. The compression fasteners may be placed vertically every two feet. The series of joined wall panels, having fasteners traversing through the thickness of the lapped panels and the large chamfered ends engage the outer surface of each skin of the joined panels to pull them together which thereby becomes rigid and unified.
In addition to the building of vertical concrete columns, horizontal concrete beams may be constructed across the top of some or all panels. Two options are illustrated.
FIG. 4 illustrates the top section of a vertically oriented SIP panel comprised of the interior molded expanded polystyrene 105 and exterior skins 110. The panel includes a void 145 creating a form used for the purpose of pouring a horizontal concrete beam. In one example, the form 145 may be 13½ inch deep. It is intended that the concrete be reinforced with rebar and that this rebar be tied into the rebar of adjacent vertical columns.
In the second variation, FIG. 5, a “U” shaped molded expanded polystyrene (MEPS) 105 form or void 145 that snugly fits over the top 215 of a SIP wall panel for the purpose of pouring a horizontal concrete bond beam. The detachable beam 125 form is clad with facings, 110 e.g., cement board, OSB, metal or MgO that project downward past the base 150 of the MEPS to create a securing mechanism for setting the beam form on a wall panel 220.
To assist securing the detachable beam form, compression fasteners 3 are utilized to stabilize and secure the sides of the form 145 when concrete is poured as illustrated in FIG. 6. Also illustrated in FIG. 6 are the compression fasteners 3 extending through both layers of skin 110. Also shown is the horizontal rebar extending through the top beam 150 and the vertical rebar 155 extending through the vertical concrete column.
Note that the form fits over the top of the SIP wall panel 215. This can be a method for raising the wall height as well as increasing the wall strength and wind resistance.
The use of concrete columns and beam can allow the construction of multi-story structures. Appropriate engineering of the column, beam and wall thickness dimensions would be required.
FIGS. 7 and 8 illustrate two examples of a structural connector plate 320, 321. The plate extends across the top 215 of the SIP panel. It contains holes for tying the connector plate to the panel using at least one compression fastener 3. The top of the panel also includes a cut out 316 for access to a bolt 310 extending through the horizontal roof I-beam 305 that includes a U shaped collar 311 for holding the beam to the connector.
FIGS. 9A, 9B and 9C illustrate alternate side views of the structural connector 320. FIG. 9C illustrates a cross section of a roof system I-beam and a U shaped collar holding the I-beam to the wall.
FIG. 10 illustrates a structural connector plate 325 attached to the top of a horizontal concrete beam constructed as described above in conjunction with FIGS. 5 and 6. The connecting plate is sloped or wedge shaped. Illustrated is the concrete 312 within the form 145, the MEP 105 and skin 110 creating the form and the top 215 of the SIP panel. Also illustrated is a sloped roof structure illustrated here to include an I-beam 305.
The structural connector is tied to the concrete bean by a bolt 311 vertically oriented within the concrete 312. A U shaped collar 313 extends from the structural fastener over the I-beam. The mechanism may include a flat plate bolted 310 over the I-beam.
FIGS. 12A, 12B, and 12C illustrates three views of the structural connector 325.
FIG. 11 illustrates a flat roof system fastened over a horizontal concrete beam 312 placed on top of a SIP panel 215. The form 145 comprises the MEPS 105 creating the concrete form and the outer skins 110. The roof system is illustrated to include an I-beam 305 attached to the concrete beam with a bolt or similar attachment 310 embedded in the concrete.
FIG. 13 also illustrates another embodiment of a sloped roof system attached to the top 215 of the SIP wall panel. The illustrated roof system includes an I-beam 305. The structural connector 326 is dimensioned to fit between the molded expanded polystyrene (MEP) 105 and the two layers of outer skin 110. The structural connector includes holes for accommodating one or more compression fasteners 3 proximate to the top of the SIP wall panel. The structural fastener is also sloped compatible with the roof system. The I-beam can be held by a U shaped collar 313 spanning over the I-beam. It may also be held by a bolt traversing the I-beam. A wedge shaped block of MEPS may be inserted into the void 331 of the sloped structural fastener.
FIG. 14 illustrates a similar system with the structural connector 327 dimensioned to fit over the two skin layers 110. FIG. 15A, 15B, and 15C illustrate 3 views (front, side and back respectively) of the structural connector 326. The remaining components have been identified by the numbering sequence of FIG. 13 FIG. 16 illustrates SIP panels lapped together and used for a roofing system. The lap joints are unified into a single piece using adhesive and compression fasteners. Recall compression fasteners may be installed a various intervals depending upon the load factor. This load factor may be wind associated with storms. The roof can be constructed for high wind resistance by the placement of compression fasteners, structural connector at the top and bottom of the walls and connected to horizontal beams and fastener connecting the wall to the concrete slab.
FIG. 17 illustrates another detail of the lap joining method. The SIP panel may be of various thicknesses. Illustrated is the compression fastener 3. The adhesive 5 is also illustrated. The offset for the lap structure is approximately 4 inches. The recommended expansion gap 130 of ⅛ inch is also illustrated.
FIG. 18 illustrates another embodiment of a lap joint wherein a “Z” shaped component 8 is inserted between the two lapped panels 18-1 and 18-2. The component may be fiberglass. This strengthens the bond between the joined panels. This component 8 is also shown in FIG. 24.
FIG. 19 illustrates the preparation of the bottom 219 of the SIP wall panel and bottom plate 220 fabricated from MgO or similar water impervious material (See FIG. 20). Illustrated is the molded expanded polystyrene 105 and the outer skin 110 of cement board, oriented strand board, metal or magnesium oxide. The void 224 manufactured for placement of the structural connector (not shown) to be installed between the MEP and outer skin is also shown.
FIG. 20 illustrates the SIP board bottom assembled on a concrete pad 175 and held in place with a bolt 170 embedded within the concrete. The structural connector 225 is installed on top of the bottom plate 220 and held with a compression fastener 3 and adhesives 5.
FIG. 21 is an isometric drawing of a SIP wall comprised of multiple SIP panels 11. Illustrated is the structural base connector 225 as part of the system that unifies or solidifies the multiple panels into a single structural wall. Also illustrated is the anchor bolt 170 fastened to the MgO base plate 220. Also illustrated are the multiple compression fasteners placed vertically at each lap joint. The FIG. 21 shows by phantom lines the placement of vertical cement columns 141 and containing rebar. Also shown is the horizontal beam 312 also containing rebar 150. Illustrated is the MEP 105 and outer skin 110. A portion of the roof system is illustrated, particularly its connection to the wall. A threaded rod 313 is placed in the horizontal concrete beam with a hub nut 311 that holds down the roof. The structural connector is not, however, shown. See FIGS. 7, 8, 10, 11.
FIG. 22 is a detail from 21 and illustrates the inter-joining lap joints of SIP wall panels. Each SIP panel contains a block lap juncture or lap joint. Panel 11 fits with the second panel 11 A. The lap joint block 115 of each joint fits adjacent to the next adjoining panel. The joint is structurally unified by a series of compression fasteners 3A, 3B, 3C. Adhesives may also be used (not shown). The void 140 for the concrete form is illustrated along with the MEP 105 from which the void is formed. Also shown is a fascia board 325 with drip ledge.
FIG. 23 is another isometric view of the SIP wall construction. Illustrated are the top structural connecting plates 320. These components can span each juncture between two SIP panels. Also illustrated are the bottom structural base connections 225 in FIGS. 20 and 21. These components can also span each juncture of two SIP panels. These top and bottom components, combined with the compression fasteners vertically oriented along each juncture and tying together of lap joints, the structural Z component 8 at each juncture, and further combined with adhesives at the juncture, form a structurally unified wall. The concrete pad 175 and bolt 170 traversing through the MgO plate 115
FIG. 24 illustrates a detail of the lap juncture of two panels. Illustrated is the top structural fastening plate 320 that spans the panel juncture. The plate is held in place by two compression fasteners 3A, 3B, 3C. Also inserted between the lap blocks 115 is the Z component 8.
It will be appreciated that the same manufacturing techniques are used in creating the wind resistant roof system. The result is a structurally unified roof system strongly connected to the wall system (optionally containing concrete columns and beams). The complete structure is well adapted to area subject to earth movement and to storm prone areas where wind damage is experienced. The manufacturing system also permits rapid construction of structures. Since components are factory manufacture, costs are minimized.
FIG. 25 is an overhead view of the manufacturing equipment layout for fabricating SIP panels. The process begins with in feed of mold expanded polystyrene (MEP) 426 to a gravity roller conveyor and then to an adhesive spreader 424 and water mister 423. The skins are next fed 422 to the exterior of the panels to a pit mounted scissors lift with roller deck 420. Included is an overhead truss vacuum lift 427. Transfer carts on trolley rails 412 carry the combined panel (MEP panel with adhesive attached “skin” e.g., CB, MgO, etc.) to a press 400. Also shown is the area 410 in which additional presses can be added to increase production (due to the time required for the adhesive to cure under pressure of the press). With more presses, more panels can be curing simultaneously. The equipment configuration forms a T-formation with the heated presses forming the top of the “T”.
FIG. 26 provides a side view of the manufacturing layout. The same item numbers are used for the counter part equipment.
FIG. 27 is a front view of the press unit 400 used to bond the skin to the MEPS component. The press may be termed a “T-press” 406 since one vertical structure is used for two presses. The press includes steel wide flange beams 401 and a base plate bolted to the slab floor 402. Included are two hold down rods 403. FIG. 29 illustrates the presses 400 and hold down rods. The presses are operated by hydraulic cylinders 404 attached to a structural box channel 405. Other type or designed cold presses can be substituted for the “T-press” as long as they meet the standard and production requirements.
FIG. 28 is a side view of the T-press assembly.
In addition, this specification is to be construed as illustrative only and is for the purpose of teaching those skilled in the art the manner of carrying out the invention. It is to be understood that the forms of the invention herein shown and described are to be taken as the presently preferred embodiments. As already stated, various changes may be made in the shape, size and arrangement of components or adjustments made in the steps of the method without departing from the scope of this invention. For example, equivalent elements may be substituted for those illustrated and described herein and certain features of the invention maybe utilized independently of the use of other features, all as would be apparent to one skilled in the art after having the benefit of this description of the invention.
While specific embodiments have been illustrated and described, numerous modifications are possible without departing from the spirit of the invention, and the scope of protection is only limited by the scope of the accompanying claims.

Claims

1. A structure comprising

a) at least one wall comprising a plurality of SIP wall panels each comprised of a core of molded expanded polystyrene contained between a first and opposing second outer skin of cement board, OSB, metal or MgO and the panels are joined together to form the wall with lap junctures and adhesive and further comprising compression fasteners wherein the compression fastener extends through the thickness of the wall panel and comprises a male threaded portion and a female nut portion wherein each end comprises a large chambered component facilitating holding each skin layer.

b) a roof comprised of a plurality of panels comprising a core of molded expanded polystyrene and first and second outer skins of cement board, OSB, metal or MgO and the panels are joined together utilizing lap joints, compression fasteners extending through the thickness of the skins of the panel and adhesives; and

c) the roof is attached to the wall panels comprising structural connectors attached to the top of the wall panel with compression fasteners extending through the attachment device and the skins of the wall panel and the attachment device is attached to the roof panel with a bolt.

2. The structure of claim 1 further comprising at least one SIP wall panel containing a void vertically oriented through the panel that can be filled with concrete.

3. The structure of claim 1 further comprising a horizontally oriented mold oriented proximate to the top of the SIP wall that can be filled with concrete.

4. A method of constructing a structure comprising

a) assembling at least one wall comprised of separate wall panels of molded expanded styrene with a least one first outer skin of MgO, cement board, metal or OSB and the adjoining panels have a lap joint joined with adhesive and at least one compression fastener extending through the thickness of the lap joint wall thickness to join the second skin of the joined panels;

b) attaching a plurality of a roof support components having two side panels fitting over the outer skin of the wall with a compression fastener extending through the wall skin and the side panels of the components;

c) attaching roof panels joined together with lap joints, compression fasteners and adhesive wherein the individual roof panels are joined together to form a single roof surface that is wind resistant.

5. The method of claim 4 further comprising:

a) creating vertically oriented voids in the molded expanded styrene core of the wall panel;

b) assembling rebar that can fit within the void;

c) pouring concrete into the void containing rebar to create a vertical column extending from a foundation pad;

d) installing a plurality of compression fasteners through the both the first and second skins of the wall panel through the void.

6. The method of claim 5 further comprising the rebar of the vertical column connected to rebar extending from the foundation pad.

7. The method of claim 5 further comprising:

a) creating a horizontally oriented void within the molded expanded styrene core at the top of one or more wall panels;

b) assembling rebar that can fit within the void spanning multiple wall panels;

c) pouring concrete into the void containing rebar creating a horizontal concrete column; and

d) installing a plurality of compression fasteners through both the first and second skins of the wall panel through the void.

8. The method of claim 7 further comprising the horizontal concrete column attached to at least one of the vertical concrete columns.

9. A method of manufacturing expanded wall panels comprised of a core of molded expanded polystyrene and a first and second outer skin of cement board, OSB, metal or MgO further comprising:

a) balancing twin hydraulic “T” presses or other cold presses wherein one vertical structural member is used for two presses retracting rollers located in the base of one or more presses that allow a rack of panels to enter at the end of the press and be removed after the panel curing, the press base is made of wide flange steels beams placed perpendicular to the panel length, and the roller flange steels beams placed perpendicular to the panel length;

b) placing roller assemblies on steel lifting rails on each side of the press, wherein two hydraulic cylinders or high tension springs are placed under each lifting rail to raise or lower the roller assemblies between the wide flange beams, and when the rails/rollers assemblies are raised or the high tension springs rise it allows for the cured panels to be removed from the press;

c) feeding product from the front and discharging cured product from the rear of the press; and

d) flexibility to install multiple presses within the T-formation alignment of lay-up and laminating line and the ability to cycle presses for continuous operation.

10. The method of claim 9 wherein hydraulic type cold presses are used.