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The present invention is a polymeric panel system and method for production and use thereof, enabling the rapid construction of a building foundation wall or other structure and in particular a below-grade foundation. The polymeric foundation system includes polymeric wall panels and other component

The present invention is a polymeric panel system and method for production and use thereof, enabling the rapid construction of a building foundation wall or other structure and in particular a below-grade foundation. The polymeric foundation system includes polymeric wall panels and other components suitable for withstanding lateral and end compression loads. The walls include two parallel faces separated by a series of webs or ribs, where the webs and faces of the wall panels may be formed of a similar polymer material such as polyvinylchloride (PVC). The wall panels and/or other components may be extruded so as to enable the rapid production of sections of wall panels, where the panels may be cut to length and then affixed to adjacent panels to form a foundation wall. The method of affixing adjacent panels may include welding, gluing or other techniques and may be performed on the job site or in a pre-fabrication facility. Furthermore, the wall panels may be co-extruded with an insulating material inserted in the voids between the parallel faces so as to provide improved thermal performance of the foundation as well.

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What is claimed is: 1. A method for constructing a below-grade foundation, comprising: providing a pre-fabricated wall panel having a hollow frame member with first and second faces generally parallel to one another, said faces being connected by a plurality of ribs spanning a space therebetween, s

What is claimed is: 1. A method for constructing a below-grade foundation, comprising: providing a pre-fabricated wall panel having a hollow frame member with first and second faces generally parallel to one another, said faces being connected by a plurality of ribs spanning a space therebetween, said first and second faces and ribs consisting essentially of a polymeric material; placing said pre-fabricated wall panel at least partially below-grade such that at least one of said faces of said wall panel is in contact with soil and bears sustained lateral soil loading, where said pre-fabricated wall panel concurrently bears sustained compressive loading from additional structural elements supported by said wall panel; placing a sill comprising a polymeric material on a below-grade surface, said sill being suitable for receiving a lower end of the wall panel, said sill having a generally continuous interior surface supporting both faces and the ribs of the wall panel and thereby distributing a wall panel compressive load over an area greater than a cross-sectional area defined by the lower end of the wall panel; anchoring, at least temporarily, the lower end of the wall panel to the below-grade sill; and affixing to a top of the wall panel a top plate for attaching the additional structural elements thereto. 2. The method of claim 1, further comprising the steps of: providing a second pre-fabricated wall panel; and attaching said second pre-fabricated panel to the first panel. 3. The method of claim 2, wherein the step of attaching said second pre-fabricated panel to the first panel includes attaching the panels with an adjoining member. 4. The method of claim 1, wherein said wall panel includes an extruded hollow frame member cut to length to produce wall panels of varying heights. 5. The method of claim 1, further comprising the steps of: affixing to the wall panel a foundation component that is at least partially formed using a polymeric material, wherein said foundation component is placed at least partially below-grade in association with a wall panel. 6. The method of claim 5, wherein the foundation component is selected from the group consisting of: a window frame member; an expansion joint; a vertical seam; wall/column supports; an electrical box assembly; a window frame; a door frame; a beam pocket; a mechanical device pass-through; a vertical end cap; and a masonry ledge. 7. The method of claim 1, further comprising the steps of: cutting at least one vertical edge of the wall panel so as to provide a wall panel of a desired length; and affixing to the wall panel an adjoining member that is at least partially formed using a polymeric material, wherein said adjoining member is placed at least partially below-grade in association with the wall panel. 8. The method of claim 7, wherein the adjoining member is selected from the group consisting of: an expansion joint; a vertical seam; and wall/column supports. 9. The method of claim 7, wherein the adjoining member includes an angled corner member. 10. The method of claim 1, where receiving a lower end of the wall panel occurs prior to placing the sill on the below grade surface. 11. A wall panel system for use below-grade, comprising: a first face, at least a portion of one surface of which is maintained in contact with soil; a second face; and a plurality of ribs spanning a space between said first and second faces and holding said first and second faces in a generally parallel relationship, said wall panel faces and ribs being formed of a polymeric material suitable for exposure to below-grade soil, wherein said panel system is capable of withstanding sustained lateral loading applied to at least the first face thereof as well as a compressive load applied to an upper end of the wall panel; and a sill, comprising a polymeric material, located on a below-grade horizontal surface, said sill receiving a lower end of the wall panel therein, said sill having a generally continuous interior surface supporting both faces and the ribs of the wall panel and thereby distributing the compressive load to the horizontal surface over an area greater than that defined by the lower end of the wall panel. 12. The wall panel system of claim 11, wherein said plurality of ribs are attached to said first face and said second face at an acute angle, and wherein at least two ribs intersect at least one of said faces at positions adjacent one another. 13. The wall panel system of claim 12, wherein the acute angle is within the range of about 20 degrees to about 85 degrees. 14. The wall panel system of claim 11, wherein the polymeric material includes a reinforcing fiber additive. 15. The wall panel system of claim 11, wherein the polymeric material includes polyvinyl chloride. 16. The wall panel system of claim 11, further comprising a foundation component permanently affixed to at least one wall panel face to form a structural foundation. 17. The wall panel system of claim 16, wherein the foundation component is selected from the group consisting of: a window frame member; an expansion joint; a vertical seam; a horizontal seam; wall/column supports; an electrical box assembly; a window frame; a door frame; a mechanical device pass-through; and a masonry ledge. 18. The wall panel system of claim 11, further including a faceplate affixed to the face of the wall panel, wherein said faceplate has an aperture therein providing access to an electrical wiring box. 19. The wall panel system of claim 11, further including a pass-through penetrating both faces of the wall panel, said pass-through include a faceplate bonded to each of the first and second faces to maintain the structural integrity of the wall panel. 20. A below-grade foundation wall system, comprising: at least one wall panel, at least a portion of which is formed using a polymeric material; a sill comprising a polymeric material, said sill receiving a lower end of the wall panel therein, said sill having a generally continuous interior surface supporting both faces and the ribs of the wall panel and thereby distributing a compressive load applied to an upper end of the wall panel to a below-grade horizontal surface over an area greater than that defined by the lower end of the wall panel; a foundation component, also at least partially formed using a polymeric material, positioned in contact with said at least one wall panel and said sill to form a structural foundation, wherein at least a portion of the foundation component is permanently affixed to the wall panel; and soil backfilled against at least an outer surface of said at least one wall panel, wherein said wall panel withstands a sustained lateral load applied over at least a portion of the wall panel by said soil, and where said wall panel concurrently supports the compressive load, such that said foundation wall system is suitable for use below grade. 21. The foundation wall system of claim 20, wherein the foundation component is selected from the group consisting of: a window frame member; an expansion joint; a vertical seam; a horizontal seam; wall/column supports; an electrical box assembly; a window frame; a door frame; a mechanical device pass-through; and a masonry ledge. 22. A method for producing a load-bearing, foundation, comprising: placing a sill comprising an extruded polymeric material on a below-grade, generally horizontal, surface; providing a first extruded wall panel section and a second wall panel section, wherein at least the first wall panel section includes a hollow frame member with first and second face sheets generally parallel to one another and connected by a plurality of alternating vertical ribs spanning a space therebetween at an acute angle with respect to the face sheets, and wherein at least two ribs intersect at least one of said faces at positions adjacent one another; positioning the second wall panel section adjacent an edge of the first extruded wall panel section; placing a lower end of each of said first and second wall panel sections into a sill, said sill being suitable for receiving the lower end of each wall panel section, said sill having a generally continuous interior surface supporting both faces and the ribs of the wall panel and thereby distributing a compressive load applied to the wall panel sections over an area greater than a cross-sectional area defined by the lower end of the wall panel sections; and permanently affixing the second wall panel section to the edge of the first extruded wall panel section so as to produce a wall of the foundation. 23. The method of claim 22, wherein said method of permanently affixing the second wall panel to the edge of the first wall panel includes a process selected from the group consisting of: ultrasonic welding; solvent welding; gluing with an adhesive; plate welding; friction stir welding; thermal bonding; and extruder/wire feed welding. 24. The method of claim 22, wherein said extruded hollow frame member is cut to produce wall panels of varying heights. 25. The method of claim 24, wherein an insulating material is co-extruded within hollow regions of the hollow frame member. 26. The method of claim 24, wherein an insulating material is subsequently applied within hollow regions of the hollow frame member. 27. The method of claim 25, wherein the insulating material is placed in contact with at least one of the first and second face sheets of the hollow frame member. 28. The method of claim 26, wherein the insulating material only partially fills the hollow frame member, and where the insulating material is placed in contact with at least one of the first and second face sheets of the hollow frame member. 29. The method of claim 22, wherein the step of positioning a second wall panel adjacent an edge of the first wall panel includes: aligning an end portion of the second face from the second panel with an end portion of the first face projecting from the first panel; and aligning an end portion of the second face from the first panel with an end portion of the first face projecting from the second panel, thereby causing the respective faces of the adjacent panels to be generally coplanar. 30. The method of claim 22, further comprising the step of installing the wall in a below-grade location as at least a part of a foundation. 31. The method of claim 30, wherein the step of installing the wall further comprising the steps of: lifting the wall panel from a first elevation using an excavation device; and lowering the wall panel, with the excavation device, to a foundation structure at a second elevation lower than the first elevation. 32. The method of claim 22, further comprising the steps of: preparing the suitable, generally horizontal surface in a below-grade location; applying a top plate along a top edge of the wall panel; placing a floor against an interior lower edge of the wall panel and sill plate; and backfilling against at least a portion of an exterior lower portion of the wall panel. 33. The method of claim 32, further comprising the steps of: attaching a second level sill to said top plate; and installing a deck on said second level sill. 34. The method of claim 32, further comprising the step of permanently affixing the wall panel to the sill plate. 35. The method of claim 34, further comprising the step of permanently affixing the top plate to the wall panel. 36. The method of claim 32, further comprising the steps of inserting an adjoining element between the first and second panels. 37. The method of claim 36, wherein the adjoining element comprises an angled corner having at least a first flange extending parallel and adjacent to at least one face of the panel so as to produce an overlap therebetween. 38. The method of claim 36, wherein the adjoining element comprises a 180-degree joint. 39. The method of claim 36, wherein the adjoining element comprises an expansion joint. 40. The method of claim 36, wherein at least one of the wall panels is permanently attached to the adjoining element along at least a portion of the edge of the wall panel. 41. The method of claim 40, wherein the adjoining element is permanently attached to the wall panel using an adhesive. 42. The method of claim 36, wherein the adjoining element comprises: an interior flange adjacent and parallel to the first sheet of the wall panel so as to produce an overlap therebetween; an exterior flange adjacent and parallel to the second sheet of the wall panel so as to produce an overlap therebetween; and at least one web extending between the interior flange and the exterior flange. 43. The method of claim 22, further comprising: applying a linkage-type device at a position offset from the ends of at least one of said wall panels, said linkage-type device being suitable for applying pressure to the first and second faces of said wall panel over an area spanning a plurality of ribs to avoid damage to the panel; lifting the at least one of said wall panels using the linkage-type device. 44. The method of claim 43, further comprising the step of temporarily clamping the linkage-type device to the first and second faces of the wall panel. 45. The method of claim 43, further comprising the steps of: affixing a top cap on the wall panel, said top cap having flange members extending along the first and second faces of the wall panel; and temporarily clamping the linkage-type device to the first and second faces of the wall panel below the flanges of the top cap. 46. A wall system comprising: at least one extruded wall panel, said extruded wall panel including a hollow frame member with first and second planar sheet faces generally parallel to one another and connected by a plurality of ribs spanning a space therebetween, said wall panel faces and ribs being formed of a polymeric material; an extruded sill comprising a polymeric material, said extruded sill resting on a generally horizontal below-grade surface and receiving a lower end of the wall panel therein, said sill having a generally continuous interior surface supporting both faces and the ribs of the wall panel and thereby distributing a compressive load applied to an upper end of the wall panel to the below-grade surface over an area greater than that defined by the lower end of the wall panel; and a polymeric foundation component positioned adjacent to said at least one wall panel to form a structural foundation, wherein the polymeric foundation component is permanently affixed to the wall panel, where said structural foundation is placed at least partially below-grade and in contact with soil backfilled against at least one face of said wall panel, and wherein the at least one face of said wall panel and foundation component, in combination, concurrently bear sustained lateral loads from the soil backfilled against at least one face of said wall panel and foundation component. 47. The wall system of claim 46, wherein the polymeric foundation component is selected from the group of extruded members consisting of: a window sill; a window trim member; a door trim member; an expansion joint; a vertical seam; a horizontal seam; wall/column supports; an electrical box assembly; a window frame; a door frame; a mechanical device pass-through; and a masonry ledge. 48. The wall system of claim 46, wherein said wall panel is formed using an extrusion process to produce the hollow frame member, and where the extruded hollow frame member is cut to produce wall panels of varying heights. 49. The wall system of claim 48, further comprising a co-extruded insulating material within hollow regions of the hollow frame member. 50. The wall system of claim 49, wherein the co-extruded insulating material only partially fills the hollow frame member, and where the insulating material is placed in contact with at least one of the first and second faces of the hollow frame member. 51. The wall system of claim 46, wherein an insulating material is applied, after extrusion, within hollow regions of the hollow frame member. 52. The wall system of claim 46, further comprising: compacted material including stone, said compacted material forming a generally horizontal surface in a below-grade location; a sill suitable for receiving a lower edge of the wall panel, said sill plate being anchored to the horizontal surface; a top plate applied to a top edge of the wall panel; a floor abutting an interior, lower edge of the wall panel and sill; and backfill soil, abutting at least a portion of an exterior, lower edge of the wall panel to complete a foundation. 53. The wall system of claim 52, wherein said wall panel is permanently affixed to the sill plate. 54. The wall system of claim 52, wherein said top plate is permanently affixed to the wall panel. 55. The wall system of claim 46, further comprising an adjoining element between the at least one first wall panel and a second wall panel. 56. The wall system of claim 55, wherein the adjoining element comprises an angled corner having at least a first flange extending parallel and adjacent to at least one face of the panel. 57. The wall system of claim 55, wherein the adjoining element comprises a seam. 58. The wall system of claim 55, wherein the adjoining element comprises an expansion joint permitting thermal expansion and contraction of the first wall panel and the second wall panel. 59. The wall system of claim 55, wherein the wall panel is permanently attached to the adjoining element along at least a portion of the side of the wall panel. 60. The wall system of claim 55, wherein the adjoining element is permanently attached to the wall panel using an adhesive. 61. The wall system of claim 55, wherein the adjoining element comprises: an interior flange adjacent and parallel to the first planar sheet face of the wall panel; an exterior flange adjacent and parallel to the second planar sheet face of the wall panel; and at least one web extending between the interior flange and the exterior flange. 62. The wall system of claim 55, wherein the adjoining element comprises an I-shaped joint, including: a pair of interior face flanges; a pair of exterior face flanges; and a web member separating the interior and exterior flanges, wherein the opposing interior and exterior flanges, in combination with the web, form a C-shaped region to receive a wall panel therein. 63. The wall system of claim 55, wherein the adjoining element comprises a mitered-corner joint, consisting essentially of: a pair of interior face flanges; a pair of exterior face flanges; and a web member separating the interior and exterior flanges, wherein the opposing interior and exterior flanges, in combination with the web, form a pair of three-sided regions having an angled wall panel edge inserted therein. 64. The wall system of claim 55, wherein the adjoining element comprises a corner joint, including: an interior face flange; a pair of exterior face flanges; and a web member separating the interior and exterior flanges, wherein opposing interior and exterior flanges, in combination with the web, form a C-shaped region to receive a wall panel therein. 65. The wall system of claim 55, wherein the adjoining element further comprises a removable cover, attachable to the adjoining element in a manner so as to produce an enclosed region adjacent a surface of the wall panel. 66. The wall system of claim 46, wherein a relationship between a thickness of the first and second sheet faces relative to an overall thickness of the wall panel is such that the thickness of the face sheets is less than 1/16 the overall wall thickness. 67. The wall system of claim 46, wherein a cross-sectional thickness of the ribs is less than a minimum cross-sectional thickness of either sheet face. 68. The wall system of claim 46, wherein a ratio of wall panel thickness to spacing between ribs is approximately 1:1. 69. The wall system of claim 46, wherein the arrangement of the ribs relative to the face sheets produces a cross-section having a series of adjacent triangles of a generally isosceles shape. 70. The wall system of claim 69, wherein a rib is oriented at an angle of about 60-degrees to each face sheet. 71. A wall system comprising: at least one wall panel, said wall panel including a hollow frame member with first and second sheet faces generally parallel to one another and connected by a plurality of ribs spanning a space therebetween, said wall panel faces and ribs being formed of a polymeric material; a polymeric foundation component positioned adjacent to said at least one wall panel to form a structural foundation, wherein the polymeric foundation component is permanently affixed to the wall panel, where said structural foundation is placed at least partially below-grade, such that at least one face of said wall panel and foundation component, in combination, concurrently bear sustained lateral and compressive loads; and an adjoining element between the at least one first wall panel and a second wall panel, wherein the adjoining element comprises a vertical joint, including a first member having a web and a pair of interior surface flanges to fit within and between the hollow frame member, and a second member having a web and at least one interior flange and one opposing, exterior flange, wherein the opposing interior and exterior flanges, in combination with the web, form a C-shaped region to receive a wall panel having the first member affixed therein.