US20220403653A1

US20220403653A1 - Prefabricated building panels and methods for constructing buildings

Info

Publication number: US20220403653A1
Application number: US17/843,907
Authority: US
Inventors: Michael Anthony Dombowsky; Braden Louis DOMBOWSKY
Original assignee: Nexii Building Solutions Inc
Current assignee: Nexii Building Solutions Inc
Priority date: 2021-06-18
Filing date: 2022-06-17
Publication date: 2022-12-22
Also published as: CA3224659A1; WO2022261787A1

Abstract

Example embodiments of the described technology provide a prefabricated building panel. The prefabricated panel may comprise a rigid insulative core having first and second opposing surfaces. A first cementitious material may at least partially cover the first surface of the insulative core. A second cementitious material may at least partially cover the second surface of the insulative core. At least one embedded element may extend along a peripheral edge of the insulative core.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit under 35 U.S.C. § 119 of U.S. application No. 63/212604 filed 18 Jun. 2021 and entitled PREFABRICATED INSULATED BUILDING PANELS AND METHODS OF CONSTRUCTING BUILDINGS which is hereby incorporated herein by reference for all purposes.

FIELD

This invention relates to building panels and in particular cementitious prefabricated building panels such as cementitious Structural Insulated Panels (SIPs). Example embodiments provide prefabricated panels for achieving desired performance characteristics and methods for constructing buildings with the prefabricated panels.

BACKGROUND

Constructing a building is typically an extensive project involving significant amounts of time and/or resources (labour, energy, materials, etc.). Moreover, the carbon footprint of a building built using existing systems and methods can be large.
Reducing the amount of time and/or resources required to construct a building can be desirable. Reducing the carbon footprint of a building can also be desirable. With more environmentally stringent building codes being passed regularly, reducing the amount of resources used to construct a building and the carbon footprint of the building is increasingly becoming a requirement to be in compliance with new building codes.
One way the amount of time and/or resources required can be reduced is by constructing the building using prefabricated panels. Existing prefabricated panels however are heavy, cannot provide the required performance characteristics, etc. Additionally, existing prefabricated panels may be difficult to maneuver into place and to couple together.
There remains a need for practical and cost effective ways to construct prefabricated building panels using systems and methods that improve on existing technologies.

SUMMARY

This invention has a number of aspects. These include, without limitation:

- non-load bearing prefabricated panels;
- load bearing prefabricated panels;
- prefabricated roofing panels;
- methods for constructing a single story building;
- methods for installing a roof of a building; and
- methods for coupling prefabricated panels to a structure of a building, such as a foundation and a metal framework installed on the foundation.

Further aspects and example embodiments are illustrated in the accompanying drawings and/or described in the following description.
It is emphasized that the invention relates to all combinations of the above features, even if these are recited in different claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings illustrate non-limiting example embodiments of the invention.

FIG. 1A is a perspective view of a panel according to an example embodiment of the invention described herein.

FIG. 1B is a cross-sectional view of the panel of FIG. 1A.

FIG. 1C is a side view of the panel of FIG. 1A.

FIGS. 1D-1I are cross-sectional views of panels according to example embodiments of the invention described herein.

FIG. 1J is a partial cross-sectional view of a panel according to an example embodiment of the invention described herein.

FIGS. 2A and 2B are perspective views of an example building constructed according to an example method of the invention described herein.

FIG. 3 is a block diagram illustrating a method for constructing a building according to an example embodiment of the invention.

FIGS. 3A-3F are perspective views of various steps of the method of FIG. 3 .

FIG. 4A is a back view illustrating a coupling of a panel to a structural post according to an example embodiment of the invention described herein.

FIG. 4B is a side view and FIG. 4C is a perspective view of a connector according to an example embodiment of the invention described herein.

FIG. 4D is a perspective view and FIG. 4E is a back view of a structural post according to an example embodiment of the invention described herein.

FIGS. 4F to 4I are perspective views of example couplings of a panel to a structural post according to example embodiments of the invention described herein.

FIG. 4J is a schematic illustration showing example movement of a structural post relative to a panel which is coupled to the post during a seismic event (or other exertion of force).

FIGS. 4K to 4M are perspective views of example couplings of panels to an underlying structure of a building according to example embodiments of the invention described herein.

FIG. 5A is a perspective view of a brace-bay panel (or load bearing panel) according to an example embodiment of the invention described herein.

FIG. 5B is a front view of the panel of FIG. 5A.

FIG. 5C is a back view of the panel of FIG. 5A.

FIG. 5D is a cross-sectional view of the panel of FIG. 5A.

FIG. 5E is an exploded perspective view of the panel of FIG. 5A.

FIG. 6A is a perspective view of a roof panel according to an example embodiment of the invention described herein.

FIG. 6B is a cross-sectional view of the panel of FIG. 6A.

FIG. 6C is a perspective view of Q-deck sheeting of a prefabricated panel according to an example embodiment of the invention described herein.

FIG. 7 is a block diagram illustrating a method according to an example embodiment of the invention described herein.

DETAILED DESCRIPTION

Throughout the following description, specific details are set forth in order to provide a more thorough understanding of the invention. However, the invention may be practiced without these particulars. In other instances, well known elements have not been shown or described in detail to avoid unnecessarily obscuring the invention. Accordingly, the specification and drawings are to be regarded in an illustrative, rather than a restrictive sense.
One aspect of the technology described herein provides an exterior cladding panel. A plurality of panels may be used to quickly and efficiently assemble exterior walls of a building under construction. In some cases the cladding panel is coupled to an underlying structure that has been assembled on site (e.g. a steel I-beam structure). In some cases the cladding panel is coupled to other pre-fabricated panels which form part of the structure of the building under construction. Advantageously the cladding panel described herein may be coupled flush against structural posts, beams and/or the like.
The exterior cladding panel is preferably plant finished (e.g. fully manufactured at a factory). A plurality of the exterior cladding panels may also preferably be easily and quickly shipped to a construction site (e.g. on a flatbed truck, within shipping containers, on railway cars, etc.). Once the panels arrive at the construction site they may be easily and quickly assembled together.
FIG. 1A is a perspective view and FIG. 1B is a cross-sectional view of an example cladding panel 10. Example panel 10 comprises an insulative core 12 having opposing faces 12A and 12B. Insulative core 12 provides a thermal break between face 10A and face 10B of panel 10. Insulative core 12 may also at least partially structurally support panel 10. Insulative core 12 may also at least partially dampen sound transmission through panel 10. Insulative core 12 preferably comprises a single piece of insulation. However, this is not necessary. In some embodiments insulative core 12 is made of two or more pieces of insulation.
In some embodiments insulative core 12 comprises rigid foam insulation. In some embodiments insulative core 12 comprises expanded polystyrene (EPS), polyisocyanurate (polyiso), extruded polystyrene (XPS) and/or the like. In some embodiments insulative core 12 at least partially comprises mineral fiber rigid insulation.
In some embodiments insulative core 12 is at least about 3 inches thick (e.g. for warmer climates, etc.). In some embodiments insulative core 12 is at least about 24 inches thick (e.g. to comply with passive housing standards, for cold climates, etc.). In some embodiments insulative core 12 is between 3 and 24 inches thick.
Insulative core 12 typically has an insulative R-value of about R4 per inch. In some embodiments insulative core 12 has an insulative R-value of at least R12. In some embodiments insulative core 12 has an insulative R-value of at least R96. In some embodiments insulative core 12 has an insulative R-value between R12 and R96.
One or both of opposing surfaces 12A and 12B of insulative core 12 may at least partially be covered by a cementitious material. For example, surface 12A may be covered by a cementitious layer 13A and surface 12B may be covered by a cementitious layer 13B (see e.g. FIG. 1 B). In embodiments where both of surfaces 12A and 12B are covered by a cementitious material, the same cementitious material need not cover both of surfaces 12A and 12B (e.g. surface 12A may be covered by a different cementitious material than surface 12B).
In some embodiments one or both of surfaces 12A and 12B are covered by two or more different cementitious layers. In such embodiments the different cementitious layers may have different properties. For example, one or both of surfaces 12A and 12B may each be covered with two or more different cementitious layers. A first one of the cementitious layers may be more fire resistant (e.g. comprises a more fire resistant cementitious material thereby increasing fire resistance of panel 10) while a second one of the cementitious layers may be structurally stronger (e.g. comprises a higher strength cementitious material thereby increasing structural strength of panel 10).
In some embodiments a cementitious material which covers at least one of surfaces 12A or 12B of insulative core 12 comprises a lower density (e.g. 5-35 megapascals (MPa)) cementitious material. The lower density cementitious material may provide high fire protection characteristics (e.g. at least 2 hours at 1800 degrees Fahrenheit, is compliant with fire resistant standards (e.g. CAN/ULC-S101 Fire-Resistance Ratings, etc.) and/or the like). Additionally, or alternatively the lower density cementitious material may provide high amounts of sound dampening (e.g. at least 50 STC (sound transmission class)).
In some embodiments a cementitious material which covers at least one of surfaces 12A or 12B of insulative core 12 comprises a higher density (e.g. 35-90 p MPa) cementitious material. The higher density cementitious material may provide increased amounts of structural strength (e.g. a compressive strength in the range of about 120 to 160 Pound-force per Cubic Foot (PCF)). In some embodiments the higher density cementitious material has a density in the range of about 90 to 200 MPa and provides even higher amounts of structural strength.
As described above, in some embodiments at least one of surfaces 12A and 12B of insulative core 12 is covered by both a lower density cementitious layer and a higher density cementitious layer.
In some embodiments a cementitious material which covers at least one of surfaces 12A or 12B (or any other portion) of insulative core 12 is curable. For example, the cementitious material may be poured or cast over at least one of surfaces 12A or 12B (or any other portion) of insulative core 12 and cured. As the cementitious material cures, the cementitious material may bond directly to insulative core 12 (e.g. forming a “wet bond”).
As shown in FIG. 1 B, which is an example cross-sectional view of panel 10, one or more side or peripheral edges 16 of panel 10 may comprise one or more embedded elements 14. Side or peripheral edges 16 may, for example, extend between surfaces 10A and 10B of panel 10. In some embodiments embedded elements 14 extend along all peripheral edges 16 of panel 10 (e.g. embedded elements 14 enclose the peripheral edges of core 12). In some embodiments embedded elements 14 extend only along some edges 16 of panel 10.
The one or more embedded elements 14 may structurally couple opposing faces 10A and 10B together with insulative core 12 thereby increasing overall strength of panel 10. Additionally, or alternatively, the one or more embedded elements 14 may provide a thermal break between opposing faces 10A and 10B. Additionally, or alternatively, the one or more embedded elements 14 may enclose insulative core 12 preventing leakage of insulative core 12 thereby improving fire resistance of panel 10 (e.g. insulative core 12 may be flammable in liquid form).
In some embodiments connectors for coupling panel 10 to structural elements of a building, to adjacent panels, and/or the like are coupled directly to one or more of the embedded elements 14. In some embodiments panel 10 comprises a connector in each corner of panel 10. In some embodiments panel 10 comprises a connector in at least two corners of panel 10. In some embodiments one or more of the connectors are hidden (e.g. a person cannot readily see the connector when the panel is finished or installed). In some embodiments one or more of the connectors are flush with one or more surfaces of a panel (e.g. panel 10).
Additionally, or alternatively, one or more hoisting points for lifting panel 10 (e.g. with a crane) may be directly coupled to at least one embedded element 14. In some embodiments one or more hoisting points are coupled to at least one embedded element 14A. In some embodiments one or more hoisting points are coupled to at least one embedded element 14B. In some embodiments one or more hoisting points are coupled to at least one embedded element 14A and at least one embedded element 14B.
The one or more embedded elements 14 may comprise (non-limiting):

- an extruded fibreglass channel (e.g. a C-shaped channel);
- a custom fibreglass extrusion (e.g. shaped to incorporate additional elements such as a dry seal gasket);
- a steel or other metal channel (e.g. a C-shaped channel);
- a structural steel or other metal (e.g. HSS, etc.) element;
- a custom steel or other metal element;
- custom aluminum, vinyl, PVC, steel, fibreglass, carbon fiber, basalt or the like extrusions (preferably low or no thermal conductivity);
- combinations of any two or more of the above;
- etc.

An embedded element 14 may span an entire edge of panel 10. However this is not mandatory. In some embodiments an embedded element 14 only partially extends along an edge of panel 10. In some embodiments panel 10 comprises no embedded elements 14.
Preferably an embedded element 14 has a low thermal conductivity (e.g. maintains thermal break between faces 10A and 10B of panel 10).
The example panel 10 shown in FIG. 1B comprises embedded elements 14 comprising an extruded fibreglass channel 14A and a steel channel 14B. In such embodiments where panel 10 comprises both a fibreglass channel and a steel channel, connectors for connecting panel 10 to other elements of a building under construction may be coupled directly to steel channel 14B. In some embodiments both fibreglass channel 14A and steel channel 14B extend along all peripheral edges of panel 10.
As described above, one or more of embedded elements 14 may comprise a C-shaped channel structure or the like. In some embodiments the open end of the C-shaped channel structure may face inwards towards insulative core 12. In some embodiments the open end of the C-shaped channel structure may face outwards away from insulative core 12. For example, the open ends of embedded elements 14 which extend along the top and/or bottom edges of panel 10 may face inwards to create flat edges. The open ends of at least some of embedded elements 14 may, for example, face outwards along side edges of panel 10 (for better coupling against a column or post, to accommodate bolts which are present in a column or post, etc.). In some embodiments the open end which faces outwards away from insulative core 12 is filled with an insulative foam or the like. In some embodiments two adjacent embedded elements may have open ends which face in opposite directions (see e.g. FIG. 1B).
FIG. 1C is a side view of example panel 10.
FIGS. 1 D-11 are schematic cross-sections of panel 10 illustrating different example configurations of embedded elements 14. FIGS. 1D-1F and 11 illustrate example embodiments where panel 10 comprises both fibreglass channel 14A and steel channel 14B. FIG. 1G illustrates an example embodiment where panel 10 comprises just a fibreglass channel 14A. In such embodiments the fibreglass channel(s) 14A may provide a structural frame for such panel 10. FIG. 1H illustrates an example embodiment where panel 10 comprises a custom fibreglass channel 14A configured to receive a sealing gasket 14C (e.g. a rubber gasket that provides a seal between two adjacent panels when they are coupled together).
In some embodiments a pin, mechanical fastener or the like may couple two adjacent embedded elements 14 together (see e.g. FIG. 1J where example pin 14D couples fibreglass channel 14A with steel channel 14B).
In some embodiments one or more pins, fasteners, rods, etc. extend through an embedded element 14 into cementitious material that is bonded (directly or indirectly) to insulative core 12. The one or more pins, fasteners, rods, etc. may, for example, increase the strength of the coupling between the embedded element 14 through which the pin, fastener, rod, etc. extends through, the cementitious material and/or insulative core 12.
One or more embedded elements 14 may also extend along edges of an aperture within panel 10 (e.g. a window or door opening). For example, both a fibreglass channel 14A and a steel channel 14B may extend around a window or door opening. Preferably window or door frames being coupled to such panel 10 are secured to steel channel 14B due to the steel channel's increased ability to withstand shear forces (e.g. wind shear, etc.). If steel channel 14B is embedded deeper than the window or door frame, the window or door frame may, for example, be coupled to steel channel 14B using an “L” shaped angle connector. In some embodiments a window or door frame may be secured to fibreglass elements 14A (or another embedded element 14). In some such embodiments elements 14A may transfer load (e.g. wind shear, etc.) to a structural framework of panel 10. In some embodiments elements 14A transfer load to elements 14B which may be adjacent or proximate to the elements 14A.
Panel 10 comprises reinforcing elements 15 (e.g. a mesh such as a welded wire mesh, epoxy coated wire mesh, glass mesh and/or the like) which are embedded into the cementitious material covering surface 12A and/or 12B of insulative core 12. Reinforcing elements 15 may extend from the cementitious material, pass under an embedded element (or elements) 14 and into cementitious material on an opposing side of the embedded element (or elements). Reinforcing elements 15 may, for example, comprise an “S-like” shape (see e.g. FIGS. 1B-1G). In some embodiments a cementitious material encloses reinforcing elements 15. In some embodiments pins, fasteners, rods, etc. which extend through an embedded element 14 increase the strength of the coupling between reinforcing element 15 and the embedded element 14.
In some embodiments reinforcing element 15 and embedded element(s) 14 are together fused to insulative core 12 (each of elements 15 and elements 14 may be individually or together fused to insulative core 12). For example, reinforcing element 15 and embedded element(s) 14 may be fused together to insulative core 12 with an adhesive or other bonding agent and/or cementitious material. In some embodiments reinforcing element 15 and embedded element(s) 14 are fused to insulative core 12 with the cementitious material that covers a surface of insulative core 12. In some embodiments reinforcing element 15 and embedded element(s) 14 are fused together to insulative core 12 with an epoxy resin. In some embodiments a reinforcing element 15 is coupled to a surface (or surfaces) of an embedded element 14 (e.g. with a bonding agent (e.g. epoxy), a mechanical coupling method (e.g. fastening, weaving or sewing mesh onto surface (or surfaces) of embedded element 14, etc.), etc.
By fusing reinforcing element 15 with embedded element(s) 14 and insulative core 12 the strength of panel 10 may be increased in areas of panel 10 where reinforcing element 15 is present. Increasing the strength of panel 10 in such areas of panel 10 facilitates having a thinner insulative core 12 in those areas of panel 10. For example, it may be desirable to have a thinner insulative core 12 (non-limiting):

- along an interior edge of panel 10 to facilitate flush mounting of the panel against a structural post (e.g. as shown in FIG. 1 B insulative core 12 is thinner in region 17 facilitating flush mounting of the panel against a structural post (the structural post may abut embedded element 14B proximate to region 17);
- along an interior edge of panel 10 to facilitate flush mounting of the panel against roof trusses, roofing panels or other roof assemblies and/or the like (e.g. a parapet portion of panel 10 which may be adjacent a plurality of roof trusses may be thinner than the remaining wall portion of panel 10 below the roof trusses (see e.g. FIGS. 1A and 1C which illustrate upper portion 18 of panel 10 having a thinner insulative core)).

Insulative core 12 may, for example, be about 5%-35% thinner in areas where reinforcing element 15 is present compared to areas of insulative core 12 where reinforcing element 15 is not present. In some embodiments insulative core 12 may be about 5%-80% thinner in areas where reinforcing element 15 is present compared to areas of insulative core 12 where reinforcing element 15 is not present. In some embodiments insulative core 12 is about 50% thinner in areas where reinforcing element 15 is present compared to areas of insulative core 12 where reinforcing element 15 is not present. In some embodiments insulative core 12 is about 75% thinner in areas where reinforcing element 15 is present compared to areas of insulative core 12 where reinforcing element 15 is not present.
In some embodiments an interior edge of panel 10 is custom shaped to match the profile of a post, beam or other structural element against which panel 10 will be flush mounted when panel 10 is installed.
The cementitious layer on face 10A of panel 10 may comprise a decorative pattern (see e.g. FIG. 1A which illustrates a plurality of decorative grooves 19). Face 10A of each panel 10 may, for example, correspond to a corresponding portion of the exterior of a building being constructed. As described elsewhere herein, panels 10 may generally be installed as exterior wall panels of a building under construction. However it is not necessary that panel 10 correspond to an exterior wall panel in all cases.
FIGS. 2A and 2B are perspective views of an example single story commercial building 20 which comprises panels 10. Although panels 10 may be used in the construction of a single story commercial building 20, panels 10 may also be used for other buildings as well and should not be limited to the example case illustrated in FIGS. 2A and 2B.
FIG. 3 is a block diagram illustrating an example method 21 of erecting example building 20.
In block 22 a plurality of prefabricated brace-bay panels (e.g. brace-bay panels 30) are coupled to a pre-built foundation 36 (see e.g. FIG. 3A). The brace-bay panels comprise a finished exterior surface as well as embedded structural elements (e.g. structural posts, beams, cross-bracing, etc.). The brace-bay panels are load bearing and may assist with dissipating shear forces (e.g. wind forces, seismic forces, etc.) which may be exerted on building 20. In some embodiments at least one brace-bay panel is placed on each side of building 20 to assist with dissipating shear forces exerted on building 20.
The more load bearing panels (e.g. brace-bay panels) a building comprises, the more uplift on a foundation of building 20 may be limited, enabling reduction of structural connections between building components and the foundation and/or the like. For example, the more load bearing panels are installed in a building the amount or size of anchor rods that are required to be installed within the foundation at points where structural posts are coupled to the foundation may be reduced (e.g. less anchor rods, smaller diameter anchor rods, shorter length anchor rods and/or the like). In some embodiments at least all of the exterior wall panels of a building are load bearing. In some embodiments all of the wall panels of a building are load bearing. In some embodiments all of the load bearing wall panels comprise brace-bay panels.
In some embodiments building 20 comprises 10 or fewer brace-bay panels. In some embodiments building 20 comprises about 6 brace-bay panels. In some embodiments building 20 comprises 5 or fewer brace-bay panels. In some embodiments building 20 comprises at least one brace-bay panel. In some embodiments building 20 comprises greater than 20 brace-bay panels.
In some embodiments a building comprises alternating load-bearing panels (e.g. brace-bay panels) and non-load-bearing panels (e.g. every second panel is a load-bearing panel). Cladding panel 10 is one example of a non-load-bearing panel. In some embodiments non-load-bearing panels such as cladding panel 10 may comprise cross-bracing or other similar embedded structural elements. Such cross-bracing may increase the structural strength of the non-load-bearing panels thereby requiring less underlying support structure. In some embodiments a cladding panel 10 which comprises at least one embedded structural element may at least partially support load of the building it is installed in.
The pre-built foundation 36 may be constructed using any present or future construction practice for making building foundations. For example, concrete may be poured into forms to construct the foundation. A concrete base pad may then be poured over the foundation. As another example, a foundation may be assembled using prefabricated panels. As another example, a foundation may be based on pilings which have been inserted into the ground.
In block 23 vertical structural posts (posts 31) are coupled to the pre-built foundation. Structural posts 31 may comprise steel posts or the like. Typically the distance between two adjacent posts 31 matches the width of a panel 10 which will be installed between the two adjacent posts.
In block 24 structural rim beams 32 are coupled to posts 31. Structural rim beams 32 may, for example, comprise steel beams such as steel “I” beams. Rim beams 32 may support (e.g. provide a ledge, etc.) a roof of the building and/or transfer forces from the roof onto other components of the underlying structure of a building (e.g. posts, columns, etc.) to the foundation of the building.
FIG. 3B illustrates the coupling of structural posts 31 and rim beams 32 to building 20.
Trusses 33 may be coupled to rim beams 32 in block 25 (see e.g. FIG. 3C). Trusses 33 may, for example, comprise steel trusses. In some embodiments trusses 33 comprise wood beams or the like. The number of trusses 33 may be dependent on the width of roof panels 34 which will be coupled to trusses 33. The wider roof panels 34 are, the fewer trusses 33 may be required in some cases.
In block 26 exterior cladding panels 10 are coupled to structural posts 31 and rim beams 32 to form the exterior walls of building 20 (see e.g. FIG. 3E). In some cases panels 10 are coupled flush against structural posts 31 and rim beams 32 (e.g. an interior wall formed by panel 10 is flush with an interior surface of post 31 and/or beam 32). In some cases panels 10 hang from one or both of post 31 and rim beam 32. For example, a panel 10 may comprise a header panel. The header panel may be coupled to hang from rim beam 32 (e.g. using angle connectors (e.g. L shaped connectors) or the like).
In some cases panel 10 comprises a sill panel. The sill panel may be coupled to the pre-built foundation of building 20. For example, the sill panel may be coupled to the pre-built foundation of building 20 using angle connectors (e.g. L shaped connectors) or the like.
Although panels 10 have been illustrated as being installed in block 26, panels 10 may be installed at any time after rim beams 32 have been installed. In some cases installation of panels 10 is not continuous and other elements of building 20 may be installed intermittently. For example, trusses 33 or roof panels 34 may be installed intermittently between installation of two panels 10. In some cases roof panels 34 are installed prior to installing cladding panels 10 (e.g. as shown in FIGS. 3D and 3E).
A roof may be installed in block 27 (see e.g. FIG. 3D). Typically the roof comprises a plurality of pre-fabricated roof panels 34. However, this is not mandatory in all cases. In some embodiments a conventional roof is installed (e.g. a base is built over trusses 33 and the base is covered with a roofing material such as an asphalt membrane, shingles, a steel roof, etc.).
Windows and/or doors may be installed in block 28. In some cases however windows and/or doors are installed upon a corresponding panel 10 being installed. In some cases windows and/or doors are pre-installed within panels 10. Any remaining fixtures (awnings, canopies, decorative towers (e.g. decorative tower 37 shown in FIG. 3F), etc.) may be installed in block 29.
As described elsewhere herein, panels 10 may be coupled to structural posts 31. In some embodiments a panel 10 may be coupled to a corresponding post 31 as shown in FIG. 4A. A top end of panel 10 pay be coupled to a top end of post 31 with a connector 41. Connector 41 may comprise a slot 42 as shown in FIGS. 4B and 4C. A bolt or other fastener may pass through an aperture of post 31 and slot 42 to couple the top end of panel 10 to post 31.
As shown in FIGS. 4B and 4C connector 41 (or any other connector of panel 10) may be coupled to one or more embedded elements 14. For example, a connector may be coupled to embedded elements 14B. In some embodiments a connector is coupled to an embedded element 14 with bolts or other fasteners (e.g. bolts 48 shown in FIG. 4C).
A bottom end of panel 10 may be coupled to a corresponding bottom end of post 31 with a connector 43. Connector 43 may be the same as connector 41 or different.
In some embodiments a middle portion of panel 10 may also be coupled to post 31 with a connector 45 as shown in FIG. 4A. This is not mandatory in all cases. Connector 45 may comprise a slot through which a bolt or other fastener may pass through to couple the middle portion of panel 10 to post 31.
As described elsewhere herein, in some embodiments one or more of the connectors ( e.g. connectors 41, 43, 45) are hidden (e.g. a person cannot readily see the connector when the panel is finished or installed). In some embodiments one or more of the connectors ( e.g. connectors 41, 43, 45) are flush with one or more surfaces of a panel (e.g. panel 10).
FIGS. 4D and 4E illustrate an example post 31.
FIG. 4F illustrates an example coupling of a panel 10 to a top portion of post 31. As another example, FIG. 4G illustrates an example coupling of a top part of a panel 10 to a post 31. FIG. 4H illustrates an example coupling of a panel 10 to a bottom portion of post 31. FIG. 4I illustrates an example coupling a panel 10 to a middle portion of post 31.
One or more of connectors 41, 43 and 45 may comprise a commercially available OrbiPlate™ coupling or the like (see e.g. FIG. 4H).
A connection of panel 10 to a post 31 (e.g. via a corresponding plate on the post and a corresponding connector on the panel) may comprise at least one bolt or other fastener passing through a slot. Such bolt and slot coupling may permit movement of post 31 relative to panel 10. The slot may be part of the connector of panel 10, part of the corresponding plate of post 31 or part of both the connector of panel 10 and the corresponding plate of post 31.
Advantageously, the slots of the connections between panels 10 to an underlying structure of building 20 may permit members of the underlying structure of building 20 (e.g. a post 31, etc.) to pivot relative to panel(s) 10 during a seismic event (or other exertion of force on building 20) or the like as shown in, for example, FIG. 4J. Permitting pivoting of members of the underlying structure of building 20 relative to panel(s) 10 improves and maintains the structural integrity of building 20 during and after a seismic event (or upon the exertion of any other force (or forces) which may cause an underlying structure of building 20 to move relative to panels 10). For example, a gap (e.g. gap 47 shown in FIG. 4A) may be intentionally left between panel 10 and post 31 such that post 31 can pivot relative to panel 10. In some embodiments the gap is less than about 1 inch. In some embodiments the gap is less than about 0.5 inches.
In some embodiments connector 43 also comprises a slot which permits movement of panel 10 relative to post 31.
FIG. 4K illustrates an example of a panel 10 (e.g. a sill panel) which is coupled to posts 31 with angle connectors. As another example, FIG. 4L illustrates an example of a panel 10 (e.g. a header panel) which is coupled to an underlying structure of building 20 with angle connectors. FIG. 4M illustrates an example of a panel 10 which is coupled to a post 31 with an angle connector and an OrbiPlate™ coupling.
In some embodiments a panel 10 comprises at least one post (e.g. post 31) embedded within the panel. In some such embodiments rim beams (e.g. rim beams 32) and/or trusses (e.g. trusses 33) are exposed elements of a building.
FIG. 5A is a perspective view of an example load-bearing panel such as brace-bay panel 30. FIG. 5B is an exterior front view of brace-bay panel 30. FIG. 5C is an interior back view of brace-bay panel 30. FIGS. 5D and 5E illustrate cross-sectional and exploded views respectively of example brace-bay panel 30.
Brace-bay panel 30 comprises an embedded structural frame 50 comprising posts 51, a header beam 52 and cross-bracing 53 (optional). Different embodiments of panel 30 may not comprise all of posts 51, beam 52 and cross-bracing 53. Posts 51 may be like structural posts 31. Header beam 52 may be like rim beam 32. Cross-bracing 53 may comprise any cross-bracing between posts 51 and header beam 52. In the illustrated embodiment cross-bracing 53 comprises two beams (53A and 53B) which are diagonally arranged relative to one another to form an “X” like shape. In some embodiments cross-bracing 53 comprises beams 53A and 53B arranged in a chevron pattern (e.g. an upside down “V”). In some embodiments cross-bracing 53 comprises a single beam. In some embodiments cross-bracing 53 comprises three or more beams.
In some embodiments cross-bracing 53 may move freely relative to any cementitious layer of panel 30 (e.g. cross-bracing 53 may freely move during a seismic event relative to the cementitious layers which may cover panel 30). Allowing cross-bracing 53 to move freely may advantageously preserve the structural integrity of building 20, avoiding damage to panel 30 and/or the like.
Structural frame 50 is embedded within an insulative core 54 of panel 30. Insulative core 54 may be like insulative core 12 of panel 10 described elsewhere herein (e.g. may comprise an EPS foam or the like). Structural frame 50 may be coupled to insulative core 54 with a cementitious material. The same or a different cementitious material may at least partially cover one or both of faces 54A and 54B of insulative core 54. In some embodiments a cementitious material (the same or different than the cementitious material covering at least one of faces 54A and 54B) covers at least a portion of structural frame 50. Such cementitious material(s) may have any one or more of the characteristics and/or properties of cementitious materials described herein.
Plates 55 may be coupled to bottom ends of posts 51. Plates 55 may, for example, comprise apertures 56 through which bolts may pass through. The bolts may be inserted into corresponding apertures in the building foundation thereby coupling panel 30 to the building foundation.
In some embodiments brace-bay panel 30 is like cladding panel 10 described elsewhere herein except that brace-bay panel 30 additionally comprises an embedded structural frame 50.
As described elsewhere herein, a plurality of roof panels 34 may form a roof of building 20. In some embodiments roof panels 34 comprise prefabricated panels having an insulative core as described elsewhere herein (e.g. an EPS foam core or other suitable material) and at least one surface of the insulative core at least partially covered by a cementitious material. Such cementitious material may have any one or more of the characteristics and/or properties of cementitious materials described herein. In some embodiments roof panel 34 is like the panel shown in FIGS. 6A and 6B.
FIG. 6A is a perspective view of an example composite roof panel 34. FIG. 6B is a cross-sectional view of composite roof panel 34.
Panel 34 comprises an insulative core 62 (e.g. an EPS foam or other material as described elsewhere herein). Q-deck sheeting 63 may be coupled to a surface 62A of core 62 with a cementitious material 64. In some embodiments an inner surface 63A of Q-deck sheeting 63 comprises texture features 65 (e.g. holes, bumps, ridges, etc.) as shown in FIG. 6C. Textured features 65 may facilitate bonding of cementitious material 64 to Q-deck sheeting 63. Q-deck sheeting 63 typically comprises metal sheeting. In some embodiments Q-deck sheeting 63 comprises steel sheeting. Cementitious material 64 may have any one or more of the characteristics and/or properties of cementitious materials described herein.
In some embodiments only about ¼ inch of cementitious material between a top surface of Q-deck sheeting 63 and surface 62A is required to properly bond Q-deck sheeting 63 to core 62. In some such embodiments roof panel 34 has a total weight that is less than about 20 pounds per square foot.
In some embodiments not every trough of Q-deck sheeting 63 is filled with cementitious material 64. For example, every second trough may be unfilled (e.g. the troughs alternate between filled and unfilled). By not filling every trough of Q-deck sheeting 63, an overall weight of roof panel 34 may be reduced. Foam inserts (e.g. Styrofoam, EPS, etc.) or similar may be placed in the unfilled troughs. Cementitious material 64 may bond together all of Q-deck sheeting 63, the foam inserts and insulative core 62 to form the composite roof panel 34.
Opposing surface 62B of core 62 may be covered by a weather-resistant roofing element or roofing membrane. In some embodiments surface 62B is covered by a cementitious material. In some embodiments surface 62B is covered by a commercially available roofing membrane. In some embodiments the roofing membrane extends past outer edges of surface 62B of panel 34 (e.g. past two edges of surface 62B). When adjacent panels 34 are coupled together, the roofing membrane which extends past the edges of surface 62B may be placed over surface 62B of the adjacent panel 34. The overlapping roofing membranes may be joined together (e.g. welded, bonded, etc.) to seal the roofing membrane. Extending a roofing element over an adjacent panel may improve the quality of the seal between adjacent panels 34 thereby reducing the likelihood of any leaks forming. Typically the roofing elements or portions of the membrane are sealed such that higher roofing elements or portions of the membrane are placed over lower roofing elements or portions of the membrane. In some embodiments the roofing element or membrane extends past the back and right edges of a panel 34 (not mandatory).
In some embodiments surface 62B of insulative core 62 is shaped to direct water in a desired manner. For example, surface 62B may be sloped downwards from one end to an opposing end of panel 34. As another example, surface 62B may be shaped as a “V”.
In some embodiments one or more roof panels 34 comprise one or more drainage ports to direct water away from the roof surface. In some embodiments surface 62B may be shaped to direct water towards the drainage port(s). In some embodiments surface 62B comprises a trough-like channel to direct water towards the drainage port.
In some embodiments panel 34 may be coupled to building 20 by welding portions of Q-deck sheeting 63 to roof trusses 33 or the like. In some embodiments panel 34 may be coupled to building 20 by fastening panel 34 to building 20. For example, panel 34 may be fastened to one or more of trusses 33, rim beams 32, posts 31 and/or panels 10 or 30. In some embodiments adjacent panels 34 may be coupled (e.g. by fastening) together. In some embodiments panel 34 comprises one or more connectors embedded within and/or coupled to insulative core 62. For example, panel 34 may comprise a connector in each corner of panel 34. At least one of the connectors may be used to hoist or lift panel 34. Such connectors may be flush with one or more surfaces of the panel as described elsewhere herein.
In some embodiments Q-deck sheeting 63 is about 18-22 gauge. Typically the longer the span between trusses (e.g. trusses 33) the lower the gauge of Q-deck sheeting 63 is.
Q-deck sheeting 63 may, for example, be about 2 feet wide and about 24-30 feet long. Such Q-deck sheeting may have troughs or corrugations which are about 3 inches deep. Panels 34 in such cases may, for example, be about 8, 10 or 12 feet wide and about 24-30 feet long.
As another example, Q-deck sheeting 63 may be about 3 feet wide and about 24-30 feet long. Such Q-deck sheeting may have troughs or corrugations which are about 2 inches deep. Panels 34 in such cases may, for example, be about 9 feet wide and about 24-30 feet long.
FIG. 7 is a block diagram illustrating an example method for manufacturing a roof panel (e.g. roof panel 34).
In block 71 Q-deck sheeting (e.g. Q-deck sheeting 73) is placed into a form. Optionally, inserts (e.g. the foam inserts described elsewhere herein) may be placed in troughs or corrugations of the Q-deck sheeting which are not to be filled with the cementitious material in block 72.
Cementitious material is poured over the Q-deck sheeting in block 73. An insulative core (e.g. insulative core 62) may be placed over the poured cementitious material in block 74. In some embodiments the cementitious material is allowed to partially set prior to placing the insulative core.
If an opposing surface of the insulative core is sloped or otherwise shaped to direct water in a desired manner, the form may be re-positioned such that the opposing surface of the insulative core is level (e.g. forms a straight line) in block 75.
In some embodiments a block or the like is positioned under one end of the form (e.g. the end of the form to be raised). In some embodiments the components of the panel already in the form are allowed to set and then an end of the Q-deck sheeting is raised directly (e.g. by placing a block under the Q-deck sheeting.
In block 76 a cementitious material is poured over the opposing surface of the insulative core. The cementitious material may be the same or different than the cementitious material poured in block 73.
A roofing membrane or roofing elements may be coupled to the opposing surface of the insulative core in block 77. In some embodiments the cementitious layer poured in block 76 couples the roofing membrane or roofing elements to the insulative core. In some embodiments the cementitious layer poured in block 76 is allowed to partially set prior to coupling the roofing membrane or roofing elements.
Although roof panel 34 has been described in the context of a roof for a single story commercial building (e.g. building 20), roof panel 34 may be used to construct any roof of a building. Roof panel 34 may, for example, be used to build a roof of a commercial building, residential building, industrial building, mixed commercial and residential building, etc. In some cases roof panels 34 are used to construct a roof for a building that does not otherwise use prefabricated building panels (e.g. a building which was built according to alternative construction practices except for the roof). In some cases roof panels 34 are used to retrofit any existing roof of a building.
As described elsewhere herein brace-bay panel 30 may comprise a structural frame 50. Such structural frame may be partially or fully covered by cementitious material. In some embodiments one or more cladding panels 10 comprise a structural frame or structural elements (e.g. one or more of structural posts, rim beams, cross-bracing, etc.). The structural frame or structural elements of a cladding panel 10 may at least partially be covered by cementitious material. In embodiments where cementitious material covers at least partially a structural frame or structural element of a panel, the structural frame or structural element may be able to move relative to the cementitious material. In some such embodiments the structural frame or structural element may be de-coupled from the cementitious material. The cementitious material may however prevent the structural frame or structural element(s) from moving relative to the insulative core by more than a threshold amount.
The systems and methods described herein may include coupling various prefabricated panels together. Joints between adjacent ones of the prefabricated panels may be sealed. In some embodiments the joints are sealed in a manner that matches a surrounding facade. In some embodiments the joints are sealed using a commercially available expanding foam (e.g. a spray foam) or caulking substance.
In some embodiments adjacent panels are welded together. In some embodiments one or more panels are welded to a structure of the building.

Interpretation of Terms

Unless the context clearly requires otherwise, throughout the description and the claims:

- “comprise”, “comprising”, and the like are to be construed in an inclusive sense, as opposed to an exclusive or exhaustive sense; that is to say, in the sense of “including, but not limited to”;
- “connected”, “coupled”, or any variant thereof, means any connection or coupling, either direct or indirect, between two or more elements; the coupling or connection between the elements can be physical, logical, or a combination thereof;
- “herein”, “above”, “below”, and words of similar import, when used to describe this specification, shall refer to this specification as a whole, and not to any particular portions of this specification;
- “or”, in reference to a list of two or more items, covers all of the following interpretations of the word: any of the items in the list, all of the items in the list, and any combination of the items in the list;
- the singular forms “a”, “an”, and “the” also include the meaning of any appropriate plural forms.

Words that indicate directions such as “vertical”, “transverse”, “horizontal”, “upward”, “downward”, “forward”, “backward”, “inward”, “outward”, “left”, “right”, “front”, “back”, “top”, “bottom”, “below”, “above”, “under”, and the like, used in this description and any accompanying claims (where present), depend on the specific orientation of the apparatus described and illustrated. The subject matter described herein may assume various alternative orientations. Accordingly, these directional terms are not strictly defined and should not be interpreted narrowly.
While processes or blocks are presented in a given order, alternative examples may perform routines having steps, or employ systems having blocks, in a different order, and some processes or blocks may be deleted, moved, added, subdivided, combined, and/or modified to provide alternative or subcombinations. Each of these processes or blocks may be implemented in a variety of different ways. Also, while processes or blocks are at times shown as being performed in series, these processes or blocks may instead be performed in parallel, or may be performed at different times.
In addition, while elements are at times shown as being performed sequentially, they may instead be performed simultaneously or in different sequences. It is therefore intended that the following claims are interpreted to include all such variations as are within their intended scope.
Where a component (e.g. an insulative core, connector, structural post, etc.) is referred to above, unless otherwise indicated, reference to that component (including a reference to a “means”) should be interpreted as including as equivalents of that component any component which performs the function of the described component (i.e., that is functionally equivalent), including components which are not structurally equivalent to the disclosed structure which performs the function in the illustrated exemplary embodiments of the invention.
Specific examples of systems, methods and apparatus have been described herein for purposes of illustration. These are only examples. The technology provided herein can be applied to systems other than the example systems described above. Many alterations, modifications, additions, omissions, and permutations are possible within the practice of this invention. This invention includes variations on described embodiments that would be apparent to the skilled addressee, including variations obtained by: replacing features, elements and/or acts with equivalent features, elements and/or acts; mixing and matching of features, elements and/or acts from different embodiments; combining features, elements and/or acts from embodiments as described herein with features, elements and/or acts of other technology; and/or omitting combining features, elements and/or acts from described embodiments.
Various features are described herein as being present in “some embodiments”. Such features are not mandatory and may not be present in all embodiments. Embodiments of the invention may include zero, any one or any combination of two or more of such features. This is limited only to the extent that certain ones of such features are incompatible with other ones of such features in the sense that it would be impossible for a person of ordinary skill in the art to construct a practical embodiment that combines such incompatible features. Consequently, the description that “some embodiments” possess feature A and “some embodiments” possess feature B should be interpreted as an express indication that the inventors also contemplate embodiments which combine features A and B (unless the description states otherwise or features A and B are fundamentally incompatible).
It is therefore intended that the following appended claims and claims hereafter introduced are interpreted to include all such modifications, permutations, additions, omissions, and sub-combinations as may reasonably be inferred. The scope of the claims should not be limited by the preferred embodiments set forth in the examples, but should be given the broadest interpretation consistent with the description as a whole.

Claims

What is claimed is:

1. A prefabricated building panel, the panel comprising:

a rigid insulative core having first and second opposing surfaces;

a first cementitious material at least partially covering the first surface of the insulative core;

a second cementitious material at least partially covering the second surface of the insulative core; and

at least one embedded element extending at least partially along a peripheral edge of the insulative core.

2. The panel as defined in claim 1, wherein the at least one embedded element extends at least partially between the first and second opposing surfaces.

3. The panel as defined in claim 1, wherein the at least one embedded element is selected from the group consisting of a fibreglass channel, a metal channel, a fibreglass extrusion, an aluminum extrusion, a vinyl extrusion, a PVC extrusion, a steel extrusion, a carbon fiber extrusion and a basalt extrusion.

4. The panel as defined in claim 3, wherein the at least one embedded element is generally C-shaped and comprises a wall section and an open end defining a channel.

5. The panel as defined in claim 1, wherein the at least one embedded element comprises a fibreglass channel or fibreglass extrusion.

6. The panel as defined in claim 5, wherein the at least one embedded element further comprises a metal channel.

7. The panel as defined in claim 6, wherein the wall section of the fibreglass channel is aligned with the wall section of the metal channel.

8. The panel as defined in claim 6, wherein the wall section of the fibreglass channel is offset from the wall section of the metal channel.

9. The panel as defined in claim 4, wherein the at least one embedded element comprises a first embedded element and a second embedded element, and wherein the open ends of the first and second embedded elements are oriented in the same direction.

10. The panel as defined in claim 4, wherein the at least one embedded element comprises a first embedded element and a second embedded element, and wherein the open ends of the first and second embedded elements are oriented in opposite directions.

11. The panel as defined in claim 3, wherein the at least one embedded element is a fibreglass extrusion shaped to receive a seal.

12. The panel as defined in claim 11, wherein the seal is a dry seal gasket.

13. The panel as defined in claim 1, comprising at least one reinforcing element located proximate to the at least one embedded element to strengthen the panel in the vicinity of the at least one embedded element.

14. The panel as defined in claim 13, wherein the thickness of the insulative core is reduced in a first region of the panel in the vicinity of the embedded element in comparison to a second region of the panel removed from the embedded element.

15. The panel as defined in claim 13, wherein the at least one reinforcing element is a wire mesh.

16. The panel as defined in claim 15, wherein the wire mesh is selected from the group consisting of a welded wire mesh, an epoxy coated wire mesh, and a glass mesh.

17. The panel as defined in claim 13, wherein the reinforcing element is generally S-shaped.

18. The panel as defined in claim 13, wherein the at least one reinforcing element and the at least one embedded element are individually or together fused to the insulative core.

19. The panel as defined in claim 18, wherein the at least one reinforcing element and the at least one embedded element are individually or together fused to the insulative core with an adhesive or other bonding agent.

20. The panel as defined in claim 18, wherein the at least one reinforcing element and the at least one embedded element are individually or together fused to the insulative core with an epoxy resin.

21. The panel as defined in claim 18, wherein the at least one reinforcing element and the at least one embedded element are individually or together fused to the insulative core with a cementitious material.

22. The panel as defined in claim 13, wherein the at least one reinforcing element extends into one or more of the first cementitious material and the second cementitious material in the vicinity of the at least one embedded element.

23. The panel as defined in claim 22, wherein the at least one reinforcing element extends between the first cementitious material and the second cementitious material.

24. The panel as defined in 14, wherein the first region of the panel is configured to be flush-mounted to a support structure.

25. The panel as defined in claim 1, wherein the at least one embedded element stiffens the panel along the peripheral edge.

26. The panel as defined in claim 1, wherein the at least one embedded element provides a thermal break between the first and second opposing faces.

27. The panel as defined in claim 1, wherein the at least one embedded element at least partially encloses the insulative core to enhance the fire resistance of the panel.

28. The panel of claim 1, wherein the insulative core is thinner on one side of the peripheral edge than the other side of the peripheral edge.

29. A composite prefabricated load-bearing panel, the panel comprising:

a rigid insulative core having first and second opposing surfaces;

a first structural post at least partially embedded on a first side of the insulative core;

a second structural post at least partially embedded on a second side of the insulative core, the second side opposite the first side;

a beam extending from an upper portion of the first post to an upper portion of the second post, the beam at least partially embedded in the insulative core;

a first cementitious material at least partially covering the first surface of the insulative core; and

a second cementitious material at least partially covering the second surface of the insulative core;

wherein the first and second cementitious materials at least partially bond the insulative core, the first and second structural posts and the beam together.

30. The panel of claim 29 further comprising cross-bracing coupled to at least two of the first post, the second post and the beam.

31. The panel of claim 30 wherein the cross-bracing is X-shaped.

32. The panel of claim 30 wherein the cross-bracing is chevron-shaped.

33. The panel of claim 29, wherein at least one of the first post, the second post, the beam and the cross-bracing may move relative to one or both of the first and second cementitious materials.

34. An assembly comprising a first non-load bearing panel and a second load-bearing panel, wherein the first non-load-bearing panel comprises:

a rigid insulative core having first and second opposing surfaces;

35. The assembly as defined in claim 34, wherein the first non-load bearing panel is mechanically connected to the second load-bearing panel.

36. The assembly as defined in claim 35, wherein the second load-bearing panel comprises embedded structural elements, wherein the embedded structural elements are selected from the group consisting of structural posts, beams and cross-bracing.

37. The assembly as defined in claim 34, wherein the second load-bearing panel comprises:

a second rigid insulative core having first and second opposing surfaces;

a first structural post at least partially embedded on a first side of the second insulative core;

a second structural post at least partially embedded on a second side of the second insulative core, the second side opposite the first side;

a beam extending from an upper portion of the first post to an upper portion of the second post, the beam at least partially embedded in the second insulative core;

a third cementitious material at least partially covering the first surface of the second insulative core; and

a fourth cementitious material at least partially covering the second surface of the second insulative core;

wherein the third and fourth cementitious materials at least partially bond the second insulative core, the first and second structural posts and the beam together.

38. The assembly as defined in claim 34, wherein the first non-load bearing panel and the second load-bearing panel are pre-fabricated.

39. The assembly as defined in claim 37, wherein the first non-load bearing panel and the second load-bearing panel are pre-fabricated.

40. A building comprising a plurality of wall components, wherein at least some of the wall components comprise:

(a) a panel comprising:

a rigid insulative core having first and second opposing surfaces;

at least one embedded element extending at least partially along a peripheral edge of the insulative core; and/or

(b) a panel comprising:

a second rigid insulative core having first and second opposing surfaces;

wherein the third and fourth cementitious materials at least partially bond the second insulative core, the first and second structural posts and the beam together; and/or

(c) an assembly as defined in claim 34.

41. The building as defined in claim 40, wherein at least some of the structural framework of the building is selected from the group consisting of columns, posts, beams, anchors, bracing, and frames is embedded within the panel(s) and/or the assembly.

42. A prefabricated composite roofing panel, the panel comprising:

a rigid insulative core; and

Q-deck sheeting coupled to a first surface of the insulative core with a cementitious material.

43. The panel of claim 42, wherein inner surfaces of the Q-deck sheeting which oppose the first surface of the insulative core comprise one or more textured elements.

44. The panel of claim 42, wherein the textured elements increase a bond strength of the cementitious material with the Q-deck sheeting.

45. The panel as defined in claim 42, wherein the Q-deck sheeting comprises a plurality of troughs, wherein only some of the troughs are filled with the cementitious material.

46. The panel as defined in claim 42, wherein the thickness of the cementitious material located above the inner surface of the Q-deck sheeting immediately adjacent the first surface of the insulative core is less than 0.5 inches.

47. The panel as defined in claim 46, wherein the thickness of the cementitious material is approximately 0.25 inches.

48. The panel as defined in claim 42, comprising a roofing element coupled to a second surface of the insulative core, the second surface opposite the first surface.

49. The panel as defined in claim 48, wherein the roofing element comprises a cementitious material.

50. The panel as defined in claim 48, wherein the roofing element comprises a weather-resistant roofing membrane.

51. The panel as defined in claim 48, wherein the roofing element extends past outer edges of the second surface of the insulative core for overlapping with adjacent roofing panels or other adjacent structures when the panel is installed.

52. The panel as defined in claim 48 wherein the second surface of the insulative core is shaped to direct water according to a desired specification.

53. The panel as defined in claim 52 wherein the insulative core is wedge-shaped.

54. The panel as defined in claim 42, wherein the panel has a weight that is less than about 20 pounds per square foot.

55. A building assembly comprising:

a foundation; and

a load bearing panel coupled to the foundation, the panel providing a shear wall for the building, the panel comprising:

a rigid insulative core having first and second opposing surfaces;

56. The building assembly of claim 55 further comprising a non-load bearing panel, the non-load bearing panel comprising:

a second rigid insulative core having first and second opposing surfaces;

a third cementitious material at least partially covering the first surface of the second insulative core;

a fourth cementitious material at least partially covering the second surface of the second insulative core; and

at least one embedded element extending at least partially along a peripheral edge of the second insulative core.

57. The building assembly of claim 56 wherein the non-load bearing panel is coupled to the load-bearing panel.

58. The building assembly of claim 55 wherein the non-load bearing panel is coupled to a structural post of the building assembly, the structural post coupled to the foundation.

59. The building assembly of claim 58 wherein a surface of the non-load bearing panel is coupled generally flush against the structural post.

60. The building assembly of claim 55 comprising a roof panel, the roof panel comprising:

a third rigid insulative core; and

Q-deck sheeting coupled to a first surface of the third insulative core with a fifth cementitious material.

61. A building, the building comprising:

a structural post coupled to a foundation; and

a panel according to claim 1, the panel coupled to the structural post, the structural post pivotable relative to the panel.

62. The building of claim 61 wherein coupling the panel to the structural post leaves a gap between the structural post and the panel.