Building system utilizing integrated technology with molded expanded polystryrene cores

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.

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.