The walls, floors and roofs are structural insulated panels (SIPs) made in our factory: magnesium-oxide board faces, a phenolic-foam insulating core, and stainless-steel outer layers.
Gen-Built panels are structural insulated panels with magnesium-oxide (MgO) board faces bonded to a phenolic-foam core, finished with stainless-steel outer layers. Magnesium oxide board is a non-combustible, mould- and moisture-resistant mineral board; phenolic foam is a closed-cell insulation with one of the highest R-values per inch and very low smoke emission; and the stainless-steel skin gives a hard, weather-proof, corrosion-resistant exterior that never needs painting. Each panel is cut to its exact place in the frame and bolts on.
Magnesium-oxide board does not burn, rot, swell or feed mould or termites, and it stays dimensionally stable in humid and coastal climates where wood-faced panels degrade. It is also silica-free and emits no formaldehyde, so the inside of a Gen-Built building has no off-gassing from its structure.
Phenolic foam gives more insulation per millimetre than EPS, XPS or polyurethane, so a thinner panel reaches the same R-value, which saves container space and shipping cost. It is also fire-resistant with low smoke and low toxicity when exposed to flame, and it does not absorb water.
The stainless-steel outer layers protect the panel core from weather, impact and UV, and give the building its long-life exterior finish. Stainless does not rust, chalk or need recoating, so there is no exterior maintenance cycle like painted steel or timber cladding.
Three panel thicknesses: R-7 at 40 mm, R-14 at 64 mm and R-21 at 96 mm. R-21 is the warmest and the right choice for a year-round home in a cold climate; R-7 suits warm climates, greenhouses and event structures. Thicker panels cost more and pack fewer per container, and the studio shows both effects as you switch.
They are the three panel lines in the studio. GEO is the permanent-building line, with insulated solid panels and glass glazing. BIO is the greenhouse line, with light-transmitting polycarbonate glazing. EVE is the events line, the lightest and lowest-cost, with PVC glazing for temporary or seasonal structures. Every line comes in solid and clear panels and uses the same frame.
Yes, panel by panel. Every 8 ft wall panel in a cube home, and every face tile of a pyramid, can be set to solid, window, full glass or door in the studio, and the bill of materials updates with it. Pyramids take small, medium or large doors on any of the four walls.