Patent ID: 6230409
Filing Date: 2001-05-15
Classification: B28B,E04C,Y10T

Abstract:
A process of constructing a building panel, comprising the steps of:applying into a mold having a removable base and a preselected shape a fluid material comprising gypsum and cement which is adapted to harden after being allowed to set, said fluid material being applied in an amount to cover said base to a selected thickness to form a first surface layer of said panel;installing reinforcing mesh into the mold to reinforce said first surface layer of the panel;inserting into the mold a rigid structural framework after said fluid material has set;inserting into the mold building paper and reinforcement;securing said building paper and reinforcement to said framework;applying into the mold a fluid formulation comprising gypsum and cement which is adapted to harden after being allowed to set, said fluid formulation being applied in an amount to cover said framework to a selected thickness to form a second surface layer of said panel;mechanically attaching said second surface layer to said framework after setting of said formulation;removing said base from the mold; andmechanically fastening said first surface layer to said framework.