WO2017125855A1

WO2017125855A1 - Composite panel of a building, method for manufacturing and use

Info

Publication number: WO2017125855A1
Application number: PCT/IB2017/050252
Authority: WO
Inventors: Henrikas SARGELIS
Original assignee: Uab "Trd Lt"
Priority date: 2016-01-20
Filing date: 2017-01-18
Publication date: 2017-07-27
Also published as: LT2016008A; LT6474B

Abstract

The described composite building wall carcass can be positioned upright in due place at the construction site and filled with concrete. The carcass comprises two outer layers (1, 1') of pre-formed formwork and an insulation material layer comprising insulation layer elements (8) hold in place by a reinforcement, such that two layers of concrete sandwiching the isolation material layer are formed between the layers of formwork. The reinforcement comprises: a first reinforcement mesh (2) and a second reinforcement mesh (5) arranged within an inner layer of the layers of concrete; a third reinforcement mesh (6) arranged within the other outer layer of concrete; a plurality of first folds (3) fixed to the first and second reinforcement meshes; a plurality of third folds (7) fixed to the third reinforcement mesh; and second folds (4) fixed to the first and third reinforcement meshes and thus holding the insulation elements in place before concrete is added in situ.

Description

COMPOSITE PANEL OF A BUILDING, METHOD FOR MANUFACTURING AND USE

Field of the invention This invention relates to concrete structures of prefabricated buildings and, more particularly, to reinforcement carcasses of prefabricated reinforced concrete elements with a fixed insulation layer, their manufacturing and use.

Background of the invention

Pre-casted at the construction site or at the factory, mounting-ready concrete structures are widely used for construction of various types of buildings. Construction of houses using this type of structural elements has many advantages, which allow reducing the initial construction cost and increasing the lifetime of the building while using relatively cheap, low-maintenance building elements. Wall panels of this type are usually fully prepared at the factory, i.e. the formed carcass is poured with concrete mixture. Such solution is suitable for local transportation of wall elements only because of high transportation costs due to their heavy weight.

Usually a pre-casted, mounting-ready structural element of building wall is produced in a horizontal position by making a carcass from metal elements, forming a reinforcement mesh of the structure with delimiting sides, wherein the reinforcement carcass is further poured with the concrete mixture. After the structure solidifies, it is brought into upward position by means of lifting machines and temporarily fixed in its place until the other elements are formed to further complete the walls of the building. This type of elements, i.e. mounted single-layer wall elements are characterized by poor thermal insulation properties: good transfer of heat to the interior of the building in summer and easy transfer of heat to the outside of the building in winter. This type of elements requires additional heat insulation of the building after the walls of it are constructed from such elements.

Also, multi-layer concrete wall elements are known. They include an insulation layer between the concrete layers. Such element has a thicker layer of concrete facing to the inside of the building, a thinner layer of concrete facing to exterior of the building, and an insulating layer placed between the said two concrete layers. Such panels are quite heavy, resulting in high transport costs when they are manufactured at the factory. Making of multi-layer panels at the construction site is a complex and time-consuming process, which includes formation of reinforcement mesh, casting of the first concrete layer, placing of thermal insulation material and, finally, casting of the second concrete layer. The reinforcement structure must be extremely tough and high-quality welded, as the layer of thermal insulation material that is placed between concrete layers may cause structural defects of the wall construction element, which can affect both the strength of the wall and thermal properties.

Patent US 5 758 463 (A) describes a modular concrete building panel, which comprises a frame of metal profiles and a layer of thermal insulation material placed between the frame elements, which is poured with a concrete mixture in order to form the concrete layer and where the concrete layer is additionally secured to the insulating material layer using nails. The major disadvantages are that the panel does not have a common inner reinforcement carcass and in critical areas, adjacent to inner frame profiles, it can easily crack during the installation or while using the building; also, there is high temperature transfer through the metal frame (such a cold bridge can cause frost on the wall).

US patent 7 681 368 (B1 ) describes a composite concrete wall panel for constructing external walls of the building. Said panel includes an assembly of the separate concrete and thermal-insulation-material panels, where concrete panels are pre-manufactured at the factory and have openings for windows and doors. Insulation layer between the concrete panels is attached by mechanical fasteners to the both concrete panels. The main disadvantage of this panel is that the technology is tailored for low- rise buildings due to thin layer of concrete and lack of suitable reinforcement capable of withstanding loads of floors above. Due to the fact that parts are threaded, it is not possible to use temperature- proof reinforcement material (e.g. fiberglass). In case of alternative, low-cost technology where the low-rise building is assembled without a formwork of insulation materials, internal and external walls are reinforced with a mesh and covered by sprayed concrete, which puttied immediately after spraying.

Patent US 8 555 584 (B2) describes a multi-layer tilt-up concrete wall element and method of production thereof. The method comprises casting of the first concrete layer in horizontal position, forming the insulating layer of thermal insulation material, which is equivalent to at least 2.7 cm polyester foam layer and casting of the second concrete layer on said insulating layer. Insulation material layer is attached to the concrete layers using anchor elements. Nailing of insulating material to the brickwork wall and facade lining is the cheapest classical solution; however, it requires a lot of equipment (e.g., scaffolding, mixers, lifts, etc.) and a team of different experts.

Patent application US 201 1/0061329 (A1 ) describes the closest to this invention prototype, comprising reinforced concrete panels with an insulating-material panel in between, where corrugated metal elements extending through the insulation panel enter deeply into the concrete panel when it is formed by casting liquid concrete. The main disadvantage of such panel and forming thereof is that during the formation of its first and second layer of concrete, there is no rigid connection provided between both the first and the second reinforcement meshes on both sides of the insulation layer. Both layers are bound one to the other with concrete layer only. In case of critical loads, concrete ruptures and dissections are possible.

The invention eliminates all of the said drawbacks: the reinforcement structure acts as a single carcass through both external concrete layers; it has no critical edges or cold bridges. It can withstand the required loads when keeping to the same technology and production method. And also, in order to transport the products at minimal cost, container molds with reinforcement and insulation carcasses are filled on-site by supplying concrete from a local manufacturer or mobile mixers. Reinforcement carcass structure is arranged to act as a brace, preventing movement of insulating layer from its original position when the mold is being filled with concrete and as an integral reinforcing carcass connecting both concrete layers. According to predetermined loads, the reinforcement frame and the layers are prepared in a container-type mold. One standard marine container-type box can be used for placement and transportation of 7 three-layer panels.

Multi-layer wall panels according to the present invention have the advantage that they already have the insulation and there is no need for additional thermal insulation during construction of the building. Thermal insulation is usually formed of rock wool or expanded polystyrene and its thickness ranges from 50 to 200 mm. In turn, reinforced concrete wall plates provide greater fire resistance and also reduce noise transfer. Not to mention that the reinforced concrete construction is durable.

Brief description of the invention

Composite building wall carcass can be transported over long distances due to quite insignificant weight. Then it can be immediately positioned upright in due place at the construction site, where said carcass in container-type mold is filled with concrete mixture. The casted-panel carcass is made of formwork and reinforcement carcass attached thereto, which is formed of reinforcement meshes and sinus-shaped folds that lean against the formwork wall through the spacer elements on both sides of insulation-material layer. This way meshes and folds delimit the insulation material elements and prevent them from slipping and breaking inside the carcass of multi-layer panel when it is evenly filled with concrete. The reinforcement carcass is interconnected between layers.

Brief description of the drawings Other features and advantages of the invention are described in the detailed description of the invention with reference to the following drawings:

Fig. 1 represents a cross-section segment of composite building panel

Fig. 2 represents a cross-section segment of composite building panel in 3D

Before submitting a detailed description of the invention with reference to embodiment example drawings, we note that identical elements are indicated by the same numerals in all the drawings.

Detailed description of the invention

It should be understood that numerous specific details are set out in order to provide a complete and comprehensive description of the embodiment example of the invention. However, the skilled person will understand that the level of details of embodiment examples does not limit the embodiment of the invention, which can be embodied without such specific instructions. Well-known methods, procedures and components have not been described in detail to make sure that embodiment examples are not misleading.

The composite building wall panel (100) comprises a formwork (1 ), which is pre-casted before assembly of the composite building wall panel (100); a plurality of first folds (3) for maintaining the distance between insulation layer elements (8) and the formwork (1 ); a first reinforcement mesh (2), which may be a reinforcement mesh formed of metal or composite material, arranged next to the formwork (1 ) and being attached to each of the plurality of the first folds (3) between said first formwork (1 ) and the said first folds (3); a second reinforcement mesh (5), which may be a reinforcement mesh formed of metal or a composite material, attached to said first folds (3) on the side other than the first reinforcement mesh (2); a second cold-resistant interlayer folds (4) to be connected to the first reinforcement mesh (2) to form gaps in parallel to two second interlayer folds (4) for insertion of insulating layer elements (8); a third reinforcement mesh (6), which can be formed of metal or composite-material reinforcement and which is attached to the second interlayer folds (4) and to third folds (7); a plurality of third folds (7) for support of insulation layer and reinforcement of outer layer (10); insulation layer elements (8), which are inserted into space delimited by the first (3), the second interlayer (4) and the third folds (7) in order to prevent the movement of the insulation layer elements (8) during the transportation and filling of carcass of the panel (100); an inner layer (9) and an outer layer (10) of a filler, one (9) of which is poured to fill the space, containing at least: the first reinforcement mesh (2), the second reinforcement mesh (5), the first folds (3) and some of the interlayer second folds (4). Another filling layer (10) is cast by filling the space with at least: a third reinforcement mesh (6), the third folds (7) and some of the second interlayer folds (4). Said first folds (3) are set apart from the formwork (1 ) by means of special spacing elements (1 1 ), which can be plastic or concrete elements, extending from the first folds (3) to the exterior plane of the inner layer (9), which touches the formwork (1 ). Said interlayer second folds (4) and third folds (7) are set apart from the exterior plane of the outer layer (10), designed to contact the formwork (1 ') of the next composite panel (100') having the same composition as the first composite panel (100), by means of special spacing elements (1 1 ), which can be plastic or concrete elements.

Said inner (9) and outer (10) layers are connected together by flexible links through which a load from the outer layer (10) caused by its own weight is transmitted to the inner carrying layer (9).

The carcass of the composite building wall panel (100) can be formed both on-site and at the factory. Assembly starts by fixing reinforcement meshes for the carrying layer (2, 5) to the plurality of the first folds (3). From formwork (1 ) side, gap supports (1 1 ) are installed on folds (3) to ensure even gap between the first folds (3) and respective surface of the formwork (1 ). In the next step, the interlayer second folds (4), through which the load from the outer layer (10) caused by its own weight is transmitted to the main layer (9), are fixed to the second reinforcement mesh (5). Depending on the properties of the insulation layer material, the insulation layer elements (8) can be inserted during the assembly or after the assembly of the carcass. The third supporting mesh (6) in external layer (10) is fixed to the existing interlayer folds (4). Later, the third folds (7) of the outer layer (10) are fixed thereto. Next, in order to obtain the required thickness of the product, adjacent to the plane of outer layer (10) of the first wall panel another formwork (1 ') may be placed, from which in the same sequence another panel (100') of composition identical to the first panel (100) can be formed as described above. In this way the desired thickness and thermal properties of the product can be achieved.

After installing all carcasses with thermal insulation separated by formwork panels (1 ), the mold is transported to the construction site where the gaps (9, 10) are evenly filled with concrete or other suitable construction mixture. Said carcass of the panel (100) or a set thereof is delivered to the building site in container-type box (not shown) and may include selected (with openings for windows or partitions in the required length or height by mounting plate before and behind the opening) or standard shapes/elements that comprise the building walls and partitions. When building elements stiffen sufficiently, they are lifted out of mold and ready for installation. The number of panel (100) reiterations depends on constructive and other modeling solutions. Although the present description includes numerous characteristics and advantages of the invention together with structural details and features, the description is given as an example of the invention embodiment. There may be changes in the details, especially in the form, size and layout of materials without departing from the principles of the invention, in accordance with the widely understood definition of terms used in claims.

Claims

1 . Composite building panel (100) comprising reinforcement, concrete layers and insulation material layer c h a r a c t e r i z e d in that it comprises

a separate pre-formed formwork (1 );

plurality of first folds (3), designed to maintain a distance between insulation layer elements (8) and formwork (1 );

a first reinforcement mesh (2), arranged adjacent to the formwork (1 ) and affixed to each fold of the plurality of the first folds (3) between the said first formwork (1 ) and the first folds (3);

a second reinforcement mesh (5), affixed to the said first folds (3) on the side other than the first reinforcement mesh (2);

second folds (4) of cold-proof interlayer, which are fixed to the first reinforcement mesh (2) while forming gaps in parallel to the two second interlayer folds;

a third reinforcement mesh (6), which is affixed to the interlayer second folds (4) and third folds (7);

plurality of third folds (7) for supporting insulation layer and reinforcing the outer layer (10); insulation layer elements (8), which are inserted into a space that is delimited by the first folds (3), the second interlayer folds (4) and the third folds (7);

inner layer (9) and outer layer (10) of a filler;

spacing elements (1 1 ).

2. Composite building panel (100) according to claim 1 , wherein the reinforcement meshes (2, 5, 6) are made of material selected from metal and composite reinforcement material.

3. Composite building panel (100) according to claim 1 , wherein the folds (3, 4, 7) are sinus- shaped.

4. Composite building panel (100) according to claim 1 , wherein the inner layer (9) of the filler comprises space comprising at least the first reinforcement mesh (2), the second reinforcement mesh (5), the first folds (3) and some of the interlayer second folds (4); and the outer layer (10) of the filler comprises space comprising at least the third reinforcement mesh (6), the third folds (7) and some of the interlayer second folds (4).

5. Manufacturing method of composite building panel (100) according to any of the previous claims, c h a r a c t e r i z e d in that the method comprises the following steps:

a) assembling a container mold that is used in upright position to obtain a product of at least one composite panel (100); b) inserting into the assembled container mold the the formwork (1 ), which is pre-casted before assembling the composite building wall panel (100);

c) inserting of carcass of reinforcement folds and meshes into the container adjacent to formwork (1 ), with the inner filler part (9) facing towards the formwork (1 ), which is obtained by:

c-i) providing each first fold (3) with calibration elements (1 1 ), designed to maintain equal distance between every fold and the formwork (1 );

c-ii) affixing the first reinforcement mesh (2) to each of the plurality of first folds (3) between the said first formwork (1 ) and the first folds (3);

c-iii) affixing the second reinforcement mesh (5) to the said first folds (3) from the side other than the first reinforcement mesh (2);

c-iv) affixing the cold-proof interlayer second folds (4) to the first reinforcement mesh (2) while forming gaps in parallel to the two second interlayer folds (4) for insertion of insulating layer elements (8);

c-v) affixing the third reinforcement mesh (6) to the second interlayer folds (4) and the third folds (7), designed for supporting the insulation layer and reinforcing the outer layer (10);

c-vi) affixing special spacing elements (1 1 ) to the third folds (7) for maintaining an even gap between the third folds (7) and inner surface of the outer layer (10); c-vii) during the assembly or after the assembly of the carcass - inserting the insulation layer elements (8), which are inserted into a space that is delimited by the first (3), the interlayer second (4) and the third folds (7); d) filling the space of the said inner layer (9) and the said outer layer (10) with binding construction mixture;

e) disassembling the container-mold after the fillers of the inner layer (9) and outer layer (10) become stiff.

Formation method of constructing product of plurality of composite panels according to any of the claims 1 -4, comprising the following steps:

aa) assembling a container mold in upright position for obtaining a product of plurality of composite panels (100);

bb) inserting into assembled container mold the first formwork (1 ), which is pre-casted before assembling the composite building wall panel (100);

cc) inserting the carcass of reinforcement folds and meshes into the container adjacent to the formwork (1 ), with inner filler part (9) facing towards each first formwork (1 ) with respect to the next formwork (1 '), where said carcass is obtained by performing steps from c-i to c-vii; dd) inserting into assembled container mold the second formwork (1 '), which is pre-casted before assembling the composite building wall panel (100');

ee) repeating steps aa) - dd) until the desired thickness of the product is achieved;

ff) filling with binding construction mixture the space of each said inner layer (9) and said outer layer (10) between all the formworks;

gg) disassembling the container-mold after the fillers of the inner layer (9) and outer layer (10) become stiff.