Precast modular building panel and vertically oriented method of manufacturing same

A method of forming a building panel, comprising the steps of:

• providing a mold having a mold cavity, disposed vertically, that defines the mold surface for forming the exposed finish surface of a molded wall panel, where the mold cavity bottom and side edge walls define the edge walls of the molded wall panel;
• positioning and securing a foam insert in said mold cavity;
• forming a slurry of concrete, sand, and reinforcing fiber strands to produce a homogeneous panel mixture;
• filling said mold cavity with said panel mixture and leveling said panel mixture with the mold side edge walls;
• effecting the cure of said panel mixture in said mold and the bonding of said mixture to said foam insert;
• and,
• removing the integral assembly of cured panel mixture and foam insert from said mold cavity.

A method of forming a building panel, comprising the steps of:

• providing a mold having a mold cavity, disposed vertically, that defines the mold surface for forming the exposed finish surface of a molded wall panel, where the mold cavity bottom and side edge walls define three of the edge walls of the molded wall panel;
• positioning and securing a foam insert in said mold cavity;
• mixing a liquids component including water;
• mixing thoroughly about 14 percent by weight of said liquids component with about 86 percent by weight solids component consisting of cement, sand and strengthening fiber components to produce a homogeneous panel mixture;
• filling said mold cavity with said panel mixture and leveling said panel mixture with the mold side edge walls;
• effecting the setup and initial cure of said panel mixture in said mold and the bonding of said mixture to said foam insert;
• and,
• removing the integral assembly of partially cured panel mixture and foam insert from said mold cavity.