North Star Group, Inc.

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701-770-9118

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White Paper: Patent Pending Fully

Integrated Reinforced Modular SIP System

(FIRM)

Introduction

Imagine a system where you can purchase fully assembled modules for super fast construction

with a crane or purchase the components on a ﬂatbed truck and connect the components

together like big Lego blocks. Factory-built parts reduce waste, minimize labor time, and provide

near-perfect ﬁts.

Background

Traditional Structural Insulated Panels (SIPs) oﬀer an energy-eﬃcient alternative to conventional

framing, but their adoption has been limited due to complexities in planning electrical, plumbing,

and trade work. Many builders and tradespeople struggle with the required pre-planning, making

SIPs more challenging to implement despite their potential beneﬁts. However, these panels often

require secondary support systems, leading to increased costs and construction time. The FIRM

system eliminates these redundancies by embedding full-depth reinforcement directly within the

SIP panels.

Technical Overview

● Embedded Reinforcement: Floor joists and reinforcement elements are integrated

directly into the SIP.

● Elimination of Secondary Framing: No need for separate structural support, reducing

material and labor costs.

● Utility Consolidation: A centralized utility chase streamlines HVAC, electrical, plumbing,

and sprinkler systems.

● Scalability and Versatility: Adaptable for a wide range of applications, from small

balconies to multi-story buildings.

System Description

The Fully Integrated Reinforced Modular SIP System is built around embedded joists that provide

structural support and eliminate a secondary ﬂooring system.

North Star Group, Inc.

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Manufacturing and Assembly

● Precision Production: Automated CNC cutting and robotic adhesive application ensure

accuracy.

● Time Eﬃciency: Factory pre-assembly reduces on-site labor.

● Cost Savings: Optimized production processes contribute to construction costs around

$100 per square foot.

Cost Comparison

Below is an updated cost comparison table that now includes three methods—SIPs with FIRM,

Standard SIP Dry-In Shell, and Traditional Stick-Built Dry-In Shell—with estimated cost ranges in

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dollars per square foot (including both material and labor costs). These ranges (low, medium, and

high) are approximate values that can vary by region and project speciﬁcs.

Construction Method

Low Range ($/sf)

Medium Range ($/sf)

High Range ($/sf)

SIPs with FIRM

~$45 – $50

~$60 – $65

~$80 – $85

Standard SIP Dry-In Shell

~$50 – $55

~$70 – $75

~$90 – $95

Stick-Built Dry-In Shell

~$75 – $80

~$100 – $105

~$130 – $140

Narrative:

The innovative SIPs with FIRM methodology leverages fully integrated, reinforced panels and

built-in utility chases to streamline construction. Although the individual panels may have a

slightly higher material cost due to embedded reinforcement, the elimination of secondary

framing and separate utility installations results in signiﬁcantly lower labor expenses. Overall,

these savings translate to an estimated cost range of about $45–$50 per square foot at the low

end, making it the most cost-eﬀective solution among the three methods when considering both

material and labor factors.

Standard SIP Dry-In Shell construction still beneﬁts from the eﬃciencies of factory prefabrication

and reduced on-site labor compared to traditional methods, but it typically requires additional

components—such as secondary framing and separate utility installations—that can add to the

overall cost. As a result, these systems are estimated at roughly $50–$55 per square foot at the

low end, with mid- and high-range costs climbing to around $70–$75 and $90–$95 per square

foot respectively. Although competitive, standard SIP systems do not match the integrated

cost-saving potential provided by the FIRM approach.

In contrast, the traditional stick-built dry-in shell method, while sometimes oﬀering lower

component costs on paper, demands intensive on-site labor and coordination, extended

construction timelines, and higher material waste due to on-site adjustments. These factors drive

up the overall cost signiﬁcantly, with estimates ranging from approximately $75–$80 per square

foot on the low end to $130–$140 per square foot at the high end. For developers and builders

aiming to maximize ﬁnancial eﬃciency—especially in aﬀordable housing projects—the FIRM

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methodology represents a compelling advancement that not only simpliﬁes the build process but

also delivers measurable dollar savings over conventional methods.

Conclusion

The Fully Integrated Reinforced Modular SIP System (FIRM) is a transformative construction

technology that enhances eﬃciency, reduces costs, and ensures high-quality building

performance. With the ability to help lower construction costs, FIRM is positioned to revolutionize

the aﬀordable housing market.

Brief Description of Drawings

Figure 1: Two-Story Quadruplex with Embedded Structural SIP Panels

North Star Group, Inc.

19901 Quail Circle

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Overview:

Figure 1 illustrates a two-story modular quadruplex that demonstrates the eﬃciency of using

embedded structural SIP panels to reduce material usage while increasing strength and

safety. This embodiment serves as an example of how modular construction techniques can

signiﬁcantly lower costs compared to traditional methods.

Key Features & Embodiments:

1. Modular Design for Aﬀordable Housing:

○ The building consists of four separate units, each made from two SIP-based

modules.

○ This standardized, repeatable design allows for rapid construction and

scalability.

North Star Group, Inc.

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2. Embedded Structural SIP Panels – No Secondary Framing:

○ Structural members are consolidated within the SIP panels, eliminating

secondary framing.

○ This increases strength and safety while reducing material costs.

○ The entire structure is designed to be self-supporting, removing the need for

additional support beams.

3. Cost-Eﬀective Pier Foundation:

○ The building is designed to sit on piers, minimizing excavation and concrete

usage.

○ This reduces foundation costs while maintaining structural integrity.

○ Other foundation types (slab-on-grade, deep piles) can be used but are not

necessary due to the strength of the embedded SIP system.

4. Scalability & Flexibility:

○ The quadruplex design can be replicated for large-scale aﬀordable housing

developments.

○ Other conﬁgurations (single-family homes, multi-story complexes) can be

adapted from this model.

○ The prefabricated modular approach allows for mass production and rapid

deployment.

___________________________________________________________________________

________

Figure 2: Mirrored 750 sq. ft. Apartments for a Quadruplex

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Overview:

Figure 2 illustrates a ﬂoor plan for two mirrored 750 sq. ft. apartments, representing one ﬂoor

of a quadruplex. The design is optimized for modular construction to enable fast

transportation and assembly.

Key Features & Embodiments:

1. Quadruplex Layout for Aﬀordable Housing:

○ Each ﬂoor consists of two mirrored 750 sq. ft. apartments.

○ The total footprint of the ﬂoor plan is 1,500 sq. ft.

○ When stacked, this design can create a two-story quadruplex with four

independent units.

2. Modular Construction for Rapid Assembly:

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○ Each apartment can be divided into two modules (~30' x ~20' each).

○ The modules are transported on trucks and assembled on-site.

○ Reduces labor and construction time, making it eﬃcient for aﬀordable housing

projects.

3. Flexible Floor Plan Options:

○ While this embodiment focuses on a foreplex design, other conﬁgurations can

be used.

○ The modular system allows for alternative layouts without modifying the

structural concept.

______________________________________________________________________

Figure 3: SIP Floor Panel with Embedded Joists – Eliminating Secondary

Structure

North Star Group, Inc.

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Overview:

Figure 3 illustrates the structural composition of a SIP ﬂoor panel with embedded joists,

eliminating the need for a secondary framing system for ﬂoor or ceiling support. This design

signiﬁcantly reduces material costs, speeds up construction, and enhances eﬃciency in both

factory production and on-site assembly.

Key Features & Embodiments:

1. SIP Floor Panel Composition:

○ Top Layer: OSB/MGO (Oriented Strand Board or Magnesium Oxide Board) for

structural integrity.

○ Core Layer:

■ Foam Insulation (EPS/XPS) provides thermal eﬃciency.

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■ Embedded Joists (Wood or Engineered) replace traditional secondary

framing.

○ Bottom Layer: OSB/MGO for additional strength and enclosure.

2. Elimination of Secondary Framing:

○ Traditional SIP ﬂoors require additional structural joists or subﬂoor framing.

○ This embodiment embeds joists within the SIP itself, removing the need for

secondary framing.

○ Results in cost savings due to reduced labor, fewer materials, and faster factory

production.

3. Structural Integration with I-Beam Foundation:

○ Ledger board is bolted directly to the I-beam, simplifying installation.

○ Steel I-Beam (WF A992 or equivalent) supports the SIP ﬂoor panel.

○ Anchor bolts secure the I-beam to a reinforced concrete slab or pier system.

4. Delivery & Installation Options:

○ Factory pre-assembly ensures higher precision and faster deployment.

○ On-site assembly is simpliﬁed, requiring fewer materials and labor.

○ The modular approach allows for quick transportation and installation on

various foundation types.

Figure 4: I-Beam and Foundation Layout for Modular SIP Structures

North Star Group, Inc.

19901 Quail Circle

Fairhope AL 36532

701-770-9118

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Overview:

Figure 4 illustrates a structural beam layout for supporting modular SIP units. The drawing

suggests a perimeter I-beam with a central longitudinal beam, supported by foundation piers

for cost-eﬀective installation.

Key Features & Embodiments:

2. Beam Support System:

○ Perimeter I-Beam (Black Line): Deﬁnes the outer edges of the structural support

system.

○ Center I-Beam (Red Line): Provides mid-span structural reinforcement for

evenly distributing loads.

○ Beam Materials Can Vary:

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■ I-beams, W-beams, wood beams, steel web beams, manufactured

beams, or composite beams.

■ Material choice depends on structural engineering needs, and the

invention does not claim a speciﬁc beam type.

Figure 5: Stacked Modular SIP Quadruplex on an I-Beam Foundation

Overview:

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Figure 5 illustrates a quadruplex composed of four modular SIP units placed on an I-beam

foundation supported by piers. This conﬁguration allows for a fast and stable installation

while providing ﬂexibility in ﬂoor construction methods.

Key Features & Embodiments:

1. I-Beam Foundation with Piers (502)

○ Provides a fast and solid way to secure modules to the ground.

○ Ensures stability and weight distribution for the stacked modular system.

2. Four Modular SIP Units (Each Representing an Apartment)

○ Each module forms an individual apartment within the quadruplex.

○ The double wall in the center (504) allows for modular joining.

3. Flooring Conﬁgurations:

○ Single-Floor System (as shown at 504):

■ The ﬂoor was installed on-site, requiring additional labor in the ﬁeld.

■ This method reduces material usage but adds complexity to assembly.

○ Double-Floor System (Factory Pre-Built Alternative):

■ If pre-assembled in a factory, the modules could be craned directly into

place.

■ This would simplify on-site work but use more materials.

4. Alternative Transit & Assembly Considerations:

○ Modules could be transported with a metal frame securing them until they

reach the site.

○ Another method would be to pre-frame the structure, allowing for partial

pre-assembly before transport.

○ The simplest approach is a fully self-contained module (pre-built ﬂoor + walls).

○ The most complex approach would involve additional framing for transport

stability, allowing for pre-assembly before reaching the site.

●

Figure 6: Stacked Modular SIP Units with Embedded Joists

Overview:

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Figure 6 illustrates four modular SIP units stacked to - either with double ﬂooring for

independent transport or with a single shared ﬂoor to reduce material usage and costs.

Key Features & Embodiments:

1. Stacked Modular Design:

○ Each module is constructed as a self-contained unit for easy transportation.

○ Modules can be bolted, strapped, or otherwise connected, but the invention

does not claim the connection method itself.

○ The goal is strength, modularity, and eﬃciency in construction.

2. Flooring Conﬁgurations (602 & 600):

○ Option 1: Double Floor (Independent Modules)

■ Each unit is fully enclosed with its own ﬂoor and roof.

■ Enables easy transport and installation using a crane.

North Star Group, Inc.

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■ No need for on-site ﬂooring installation.

■ Downside: More materials are used, leading to higher costs.

○ Option 2: Single Floor (Material Saving Embodiment)

■ Instead of doubling the ﬂoors, only one shared ﬂoor is used between

stacked modules.

■ Reduces material costs but requires on-site ﬂooring installation.

■ SIP wall panels are installed on-site after modules are placed.

3. Material & Labor Trade-Oﬀ:

○ Double ﬂoor = more material, less labor (prefab and crane-set).

○ Single ﬂoor = material savings, but requires on-site work.

○ Either approach ﬁts within the core innovation of embedding joists in SIPs.

Figure 7: Modular SIP Construction with Embedded Joist System

North Star Group, Inc.

19901 Quail Circle

Fairhope AL 36532

701-770-9118

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Description:

Figure 7 illustrates a single module of a structural insulated panel (SIP) construction, which

can function independently or as part of a multi-module assembly. The depicted module could

represent half of a 750 sq. ft. apartment, a standalone unit, or one section of a larger modular

home.

Key Features & Embodiments:

1. Modular Flexibility:

○ The illustrated module measures 32' x 15'.

○ Multiple modules can be combined to achieve wider layouts (e.g., 30’ width

with two modules, 45’ width with three modules, etc.).

○ The design is adaptable to quadruplexes, single-family homes, or large

multi-module structures.

North Star Group, Inc.

19901 Quail Circle

Fairhope AL 36532

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2. Embedded Joist System (702, 704, 706, 708, 710):

○ Joists are fully integrated into both the ﬂoor and the roof structure, eliminating

the need for a secondary support system.

○ The same embedded joist system appears in both ﬂoor and ceiling, ensuring

structural uniformity.

○ The embedded system can be constructed from various materials, including

wood, steel, plastic, or composite web structures.

○ The primary goal is strength and load-bearing capacity, not the speciﬁc

material.

3. SIP Wall Panels (712, 714):

○ Standard SIP panels used for walls and ceilings.

○ No vertical structural members are required in this embodiment.

○ If additional vertical support is necessary (per engineering analysis), minimal

structural elements can be added (e.g., one rafter per panel or one embedded

stud per SIP).

4. Transport & Assembly:

○ The modular unit can be transported via truck, making it ideal for

prefabrication.

○ Assembly with long bolts, quick-connect straps, or even weldable/screw-in

connectors enables rapid on-site construction.

Figure 8 Explanation for Provisional Patent Drafting:

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Figure 8 illustrates an assembly of four structural insulated panels (SIPs) joined together,

emphasizing the integration of double joists. These joists serve multiple purposes in

panel-to-panel connections and can be adjusted based on manufacturing and assembly

preferences.

Key Features & Embodiments:

1. Double Joists for Strength

○ Positioned at the edges for increased load-bearing capacity.

○ Can be moved inward for spline-based connections if desired.

2. Alternative Joining Methods:

○ Instead of edge-mounted joists, splines can be used for traditional SIP joining.

○ Bolted assembly: The entire panel system can be secured using bolts before

adding the bottom SIP skin.

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○ Pre-existing latching or mechanical connections can be incorporated, ensuring

a secure and load-bearing joinery method.

3. Manufacturing Considerations:

○ Can be built on a long production table, ensuring precise joist alignment and

pre-assembled SIP joins.

○ Bottom skin application happens after joists and connections are secured,

allowing for precision adjustments.

4. Structural Flexibility:

○ Panels can be used for ﬂooring or rooﬁng with similar connection techniques.

○ Any mechanically strong connection method is considered acceptable,

ensuring stability, load-bearing eﬃciency, and ease of assembly.

Key points from Fig. 9:

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1. Embedded Structural Joists: The joists are placed inside the SIPs for strength,

removing the need for additional ﬂoor and ceiling support systems.

2. Flexible Placement:

○ Joists can be closer to the edge for direct load-bearing.

○ Alternatively, they can be set further from the edge to allow for traditional

spline connections.

○ Another approach allows joists to extend beyond the panel edge, acting as an

integrated spline system.

3. Horizontal vs. Vertical Embedding:

○ Vertical members provide compression strength.

○ Horizontal members provide joist strength for spans.

4. Manufacturing Considerations:

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○ Traditional blocking or framing methods (as in Fig. 10) improve precision in the

factory.

○ Optimizing for mass production while keeping SIPs structurally superior to

conventional SIP assemblies.

FIG. 10: SIP Wall Panel with Internal Reinforcements

Pre-framing: Assembling a traditional wood or metal frame separately, then gluing it onto the

SIP surface.

Foam Inﬁll: Cutting the foam to ﬁt inside the frame after placement.

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Delamination Prevention: Using embedded screws (either fully penetrating or stopping before

the outer surface) to enhance adhesion and structural integrity while minimizing thermal

bridging.

Alternative Embodiments: This is just one way to integrate structural elements inside SIPs,

particularly for ﬂoor joists and, if necessary, studs for compression.

For more technical details or the full provisional patent ﬁling, please contact us.

North Star Group, Inc.

19901 Quail Circle

Fairhope AL 36532

701-770-9118

michaelh@nsgia.com

North Star Group, Inc.

19901 Quail Circle

Fairhope AL 36532

701-770-9118

michaelh@nsgia.com

North Star Group, Inc.

19901 Quail Circle

Fairhope AL 36532

701-770-9118

michaelh@nsgia.com