Changing the Nature of Construction™

PanelBuild’s proprietary building system is centered around a revolutionary new insulated concrete wall that aims to disrupt the traditional tilt up industry. Our system and process has been protected with multiple international patents, including numerous patents in the U.S.

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At our core, our system increases the structural value of a building, namely providing superior insulation, while simultaneously decreasing the costs and time of construction. The system incorporates a series of rebar trusses, held together by molded foam which combined delivers an structural panel. Once shotcrete is applied to the panel it creates a highly insulated structure that uses less building material than traditional methods, with a much quicker time of construction (e.g., 88% faster than the tilt-up process).

We’ve taken thousands of hours of engineering efforts, and development experience and combined them to bring a product to market that aims to forever change how we build on this planet. Join us on our plans to conserve energy by reducing the use of scarce resources such as lumber, by providing superior insulation value, and by creating a marketplace that can positively impact our lack of affordable housing.

Insulation Advantages

• Due to the incorporation of foam replacing the concrete core of the walls, our building system can drastically increase insulation value and reduce heating and cooling costs by an estimated 35% annually. Read More

Whereas, a typical concrete structure’s porous nature allows the air to simply excrete and literally creates a scenario where money is being blown out the walls.

• During our manufacturing process, we can control the core size and width of our EPS (foam) which provides us flexibility to control the insulation value of a building, as necessary without any added effort (i.e. cost).

• Superior insulation (R-40 performance) allows builders to install cooling and heating machines, should they choose to, providing them additional cost savings.

Reduced Cost of Construction

• Because the building process is drastically sped up by our efficiently assembled panel system, we reduce the time of construction from twelve months, of a commercial box unit, down to one and a half months.

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• Also, the concrete allocation is 50% less than the standard tilt-up building, thus reducing the cost on that point alone.

• Our building system also requires no cranes, which can drastically reduce costs of labor and equipment.

• The shotcrete application that we leverage to apply the concrete is much faster than the normal tilt-up process. Conversely, we also recommend leveraging a dry-mix pneumatic plaster, both of which reduce the concrete allocation, and water usage which also reduces costs.

Speed of Construction

• Our building system allows us to erect a commercial warehouse building in 1.5 months, whereas the tilt-up process typically takes 12 months. Read More

We’re able to to accomplish building in a more expedited manner due to our system not requiring any forming on the jobsite. A requirement that is typical when compared to Tilt-Up construction methods.

• PanelBuild’s building system offers flexibility for onsite adjustments if needed, by allowing to be easily cut or modified based on updated specificity. These sort of last-minute adjustments will not hold up construction timelines.

Production & Manufacturing Advantages

• Our panels are injection molded, allowing for one solid piece of panel and the ability to “print” endless panels. This advantage creates ease of construction, and erecting the panels without much effort.

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• Our panels have a metal truss imbedded into the panel. The metal truss engineering system is widely used in the construction industry. It allows for structural value, which allows it to carry more structural load.

• Our panels do not have “cold bridge” issues. Cold bridge occurs with the competition since they shoot a metal wire through their foam, and weld it on both sides to create a cage with a foam center. The problem with this is that the wire can transmit temperature changes from the exterior of the wall to the interior. Therefore when the temperature is cold outside, and the interior is warm, you will see humidity spots in the place of the wires (otherwise known as “cold bridge”). PanelBuild solves this issue by imbedding the wire with EPS, and the material acts as an insulator to the wire itself, thus avoiding cold bridge, even without adding the concrete.

• Our panels also don’t allow for erosion to occur, since our foam is imbedded with the aforementioned wire truss. Erosion is a common problem with the competition’s building systems.

• PanelBuild manufactures it’s panels in a straight line production process. Our wire truss welding machines mold and cut the components of the product in one straight line, which allows us to get to a finished panel at the same time it takes our competition to produce just the foam block. This creates a tremendous cost advantage in space allocation, equipment processing and cycle times.  

Field Advantages

• Our panels, unlike the competition, do not have a wire mesh, and instead we incorporate wire trusses that protrude through our panels. This allows plumbers, and electricians to easily use our clip channels to attach their boxes Read More

and run their cables and pipes through the openings. The fixed trusses allow for the boxes to be leveled, thus there is no need for additional leveling.

• Contractors that use a competitor’s panels would have to cut the cage, fill cement in the location where the box is necessary, then position the box and level it until the cement dries. Next, they’ll have to work the wires (behind the cage) to the desired location. This process is more time-consuming, tedious, and allows for errors in leveling. All of this is avoided in the field when leveraging PanelBuild’s competitive advantages.

Labor Advantages

• Due to our straightlined manufacturing process, PanelBuild requires much less factory employees, while the competition requires three times as much due to the handling requirements they have with multiple workstations.

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• The end product requires significantly less labor force when compared to the incumbent’s tilt up process. Typically we require 40% less manpower than the tilt up process, and we get to our final stage of construction 12x faster.

Cost Advantages & Comparisons

• PanelBuild’s patent has material cost advantages such as using a truss system instead of a cage (around it’s panels), which uses much less metal. We achieve better structural integrity while using less metal with our panels. Read More

Our material cost savings, on the metal truss system alone, is ~60% less than the competition’s costs.

• Our building system also leverages less than 50% of the incumbent’s concrete allocation, thus decreasing labor and material costs.

IP & Other Product Advantages

• One of our key IP advantages is our ability to “print” endless panels, while also being able to cut at precise angles and specific sizes with door and window openings. The competition has to accomplish the cutouts at the jobsite Read More

which creates a lot of wasted material. PanelBuild’s continuous panel manufacturing system allows us to reduce waste, get to speed of erection in a much more expedited manner, and requires less skilled labor at the jobsite.

• Panel thickness can be changed and adapted to the need of each project.

• Rebar or truss size (metal thickness) can be adjusted to fit almost all structural specs.