Construction system and method having integrated plank and framing members

Abstract

A system and method of manufacturing synthetic construction elements that replaces lumber. A synthetic composition is provided containing cementitious material, synthetic fibers, and low-density particulate material. At least one polymer may be added to improve performance. The density of the synthetic composition is controlled by varying the volume of the low-density particulate material in the mix. Reinforcement elements are provided. The reinforcement elements are preferably pre-stressed or post-stressed in tension. The synthetic compound is molded around the reinforcement elements to form a construction element of a particular shape. The molding of the synthetic material around the reinforcement elements can be a two-step process. In the first step, a first synthetic compound of a high density is molded into a rough form around the reinforcement elements. A second synthetic compound of a lower density and strength is then molded around the rough form to complete the construction element.

Dependencies are inferred from the claim text.