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Methods of manufacturing a modular, monolithic, integrated, multi-layered, mold building structure including the steps of constructing a dismantleable mold having an outer rigid matrix and an inner inflatable plug, wherein the inside dimensions of the matrix correspond to the outside dimensions of t

Methods of manufacturing a modular, monolithic, integrated, multi-layered, mold building structure including the steps of constructing a dismantleable mold having an outer rigid matrix and an inner inflatable plug, wherein the inside dimensions of the matrix correspond to the outside dimensions of the structure and the outside dimensions of the plug correspond to the inside dimensions of the structure, placing high strength fibers between the plug and the matrix, injecting hardenable material between the matrix and the plug, curing the hardenable material into a hard shell, removing the matrix, deflating the plug, and installing walls, doors or windows. The structures may be joined together on-site in various combinations and configurations to create different types and styles of buildings.

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An assembly-line method for manufacturing a monolithic building structure at a plurality of stations comprising the steps of: inflating an inflatable plug formed by an envelope comprising a plurality of rigid, foldable, panel sections joined by means of hinges; installing blockouts commensurate with

An assembly-line method for manufacturing a monolithic building structure at a plurality of stations comprising the steps of: inflating an inflatable plug formed by an envelope comprising a plurality of rigid, foldable, panel sections joined by means of hinges; installing blockouts commensurate with desired door and window openings on an outer surface of said plug; applying a layer of gypsum material to said outer surface of said plug; curing said layer of gypsum material; surrounding said plug with a matrix formed by a plurality of movable panels joined together in a parallelly-spaced-apart position from said layer of gypsum material to define a space between said outer surface of said plug and said matrix; covering said gypsum layer with mats of loosely packed filiform reinforcing elements, said mats being dimensioned to fill said space unoccupied by said blockouts between said plug and said matrix; injecting a hardenable cementitious slurry between said plug and matrix and said into said mats; allowing said slurry to cure into a hard shell; separating said matrix panels from said hardened slurry; deflating said plug to separate said rigid sections from said layer of gypsum material; and moving said hard shell to a separate station for further processing.