Method, System, and Apparatus for Modular Wall Construction with EPS Light Concrete Mould-Pressed Half Panel Blocks

(10) US20260158702A1

(22) 11.12.2025

(43) 11.06.2026

(57) Methods, systems, and apparatuses for modular wall construction using lightweight, mould-pressed half-panel blocks made from expanded polystyrene (EPS) or EPS-based mortar, with or without rib-lath steel mesh reinforcement. The panels may provide energy-efficient, lightweight, and structurally robust solutions for load-bearing and non-load-bearing walls. EPS beads embedded in a cement-sand mortar mix may offer thermal and acoustic insulation while reducing panel weight. The panels may be manually assembled by two workers, minimizing the need for heavy machinery. Each half-panel block may measure approximately 1200×600 mm and cover roughly 0.72 square meters of wall surface. The panels may be used as walls, footings, formwork, lintels, or cladding, and structural concrete and reinforcing steel may be added when used as formwork. Panels may be dismantled and reused, supporting sustainable construction practices and modular offsite assembly with pre-sized kits.

(71) IDD Soleman Abdi, McLean, VA, US