AU612849B2

AU612849B2 - Panel with thermo-acoustic insulation characteristics, particularly for constructing walls

Info

Publication number: AU612849B2
Application number: AU36077/89A
Authority: AU
Inventors: Angelo Candiracci
Original assignee: Monolite Srl
Current assignee: Monolite Srl
Priority date: 1989-06-06
Filing date: 1989-06-06
Publication date: 1991-07-18
Anticipated expiration: 2009-06-06
Also published as: AU3607789A

Description

COMMONWEALTH OF AUSTRALIA 61 Z49 CO P PETE

COMPLETE

atent Act 1952

SPECIFICATION

(ORIGINAL)

Class Int. Class Application Number Lodged Complete Specification Lodged Accepted Published S Priority: S Related Art 1 4

II

54t 44' Name of Applicant Address of Applicant MONOLITE S.r.l.

Via G. Filippini, 3 61032 Fano (province of Pesaro) Italy Angelo Candiracci Actual Inventor a I Address for Service F.B. RICE CO., Patent Attorneys, 28A Montague Street, BALMAIN. 2041.

Complete Specification for the invention entitled: "PANEL WITH THERMO-ACOUSTIC INSULATION CHARACTERISTICS, PARTICULARLY FOR CONSTRUCTING WALLS" The following statement is a full description of this invention including the best method of performing it known to Us:la The present invention relates to a panel with thermo-acoustic insulation characteristics, particularly for constructing walls.

As is known, in the field of building there is currently the need to construct partitions and load-bearing walls capable of ensuring high thermal and acoustic insulation. For this purpose, the use of prefabricated panels in association with conventional construction systems has been proposed; said panels, 10 however have limited strength and are generally complicated to install.

o.0 It would be advantageous to provide a panel which allows to rapidly and easily install load-bearing walls o having characteristics of considerable strength and high S 15 thermo-acoustic insulation.

In one broad form the invention provides a panel with thermo-acoustic insulation characteristics, comprising an insulating layer made of foamed plastic material, vertical undulations formed on both sides of said layer and o o 20 extending parallel to each other, and a framework comprising a pair of metallic grids, each of said grids being in tangential contact with the crests of said undulations on one of said sides of said insulating layer, said grids being mutually connected by transverse elements, said transverse elements traversing said insulating layer and being connected to each of said grids.

A

2 The details of the invention will become apparent from the detailed description of a preferred embodiment of the panel for constructing walls with thermo-acoustic insulation characteristics, illustrated only by way of non-limitative example in the accompanying drawings, wherein: figure 1 is a horizontal sectional view of a panel according to the present invention; figure 2 is a horizontal sectional view of a formwork produced by means of a pair of the panels according to the invention; figures 3 and 4 are horizontal sectional views of a corner wall produced respectively with single and double 4 t panels; o, figures 5 and 6 are horizontal sectional views of a T- 5 shaped coupling of walls, provided respectively with single and double panels; figure 7 is a vertical sectional view of a portion of a building made with the panels according to the invention.

With particular reference to said figures, the reference numeral 1 generally indicates the panel for constructing walls with thermo-acoustic insulation characteristics.

The panel 1 is constituted by a metallic framework 2 ,which bears an insulating layer 3 made of foamed material such as polystyrene. More in particular, the frame 2 comprises a pair of electrically welded metallic grids 4 and with rectangular mesh, between which the insulating layer 3 is interposed.

The metallic grids 4, 5 are preferably constituted by rods of hot-galvanized, cold-redrawn high-strength steel L i-

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0 o 0 Q o o 0 0 0

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0 0 0 0? o with low carbon content; the vertical rods advantageously have a diameter of 3.5 mm and the transverse ones have a diameter of 2.5 mm; said rods are electrically welded with an average pitch of 75 or 130 mm respectively, so as to form an asymmetrical rectangular mesh.

The insulating layer 3 is preferably made of highdensity, self-extinguishing, virgin polystyrene varying in thickness between 30 and 250 mm. Other materials, such as lead, cork and the like, may furthermore be interposed within the polystyrene.

The insulating layer 3 has parallel undulations, so as to define an alternatini4 succession of crests 3a and troughs 3b intended to be vertical in the installation position.

As clearly shown in the horizontal sectional views of figs. 1-4, the crests 3a and troughs 3b are provided on both °i faces of the layer 3 and have a vertical orientation. Each crest 3a at one face of the layer 3 is located opposite a trough 3b at the opposite face of the layer 3. The crests 3a and troughs 3b at one face of the insulating layer extend a 20 parallel to each other and also parallel to the crests and troughs at the opposite face of the insulating layer 3.

The metallic grids 4 and 5 are associated with the insulating layer 3 in tangential contact with the crests 3a of the opposite faces thereof. In particular, the troughs 3b of each face are arranged in a middle position with respect to the correspondingly parallel rods of the metallic grid associated with said face.

The grids 4 and 5 are conveniently provided, along their opposite sides intended to be vertical, with respective wings 4a and 5a which protrude with respect to 0 0 0 a o oa o 0 Ci 0 0 r f 4 'i I o

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4 the layer 3. Said wings are adapted to overlap, during installation, onto the adjacent panels, so that there is in practice no discontinuity in the product thus obtained.

The metallic grids 4 and 5 are mutually connected by means of iron elements 6 driven transversely through the insulating layer 3. Said elements 6 are similarly made of high-strength galvanized steel rods with a diameter of 3 mm, chisel-cut so as to perforate the insulating layer 3 without breaking it; the rods 6 are welded to the grids 4, so as to constitute a rigid and hyperstatic coupling which prevents relative motions. The grids are advantageously asymmetrically connected to one another, so as to be offset by 80 mm on their two sides. In ocher words, the upright members of the grid 4 are each located 80mm from a plane 1. 5 extending perpendicularly to the longitudinal extension of the grid 5 and passing through the longitudinal axis of one of the upright members of the grid The described panel allows to easily build walls with high thermo-acoustic insulation characteristics which are 0 easy to install and adaptable to different constructive requirements.

In particular, the panel 1 can be used as basic element of a sandwich obtained by applying on the opposite faces a layer 7 of structural mortar or concrete with appropriate strength characteristics. This is allowed by the presence of the metallic grids 4 and 5, which are embedded in the layer 7 (see figure also by virtue of the shape of the insulating layer 3.

This operation allows to produce vertical elements which have structural load-bearing characteristics suitable YU~~I__II_ i i J i 7 i o C 0o for building walls of building of up to two stories with ordinary spans and center distances. The sandwich can also be used as infill panels, curtain wall sections, or internal partition etc., to complete a building built using conventional and similar methods.

It is also possible to join a pair of panels 1 with appropriate spacer elements 8 of variable length, so as to provide a formwork suitable for constructing supporting walls, as illustrated in figure 2. Said formwork defines a 0 cavity or interspace 9 adapted to contain a concrete casting.

The concrete casting can be integrated, if necessary, by falsework reinforcements made of longitudinal and/or transverse bars. The hydrostatic thrust of the cement during 5 the casting steps is supported by the considerable rigidity of the pair of panels 1, which are mutually joined by the spacers 8 by welding the mutually outwardly directed grids.

It should be noted that the undulations of the insulating layer 3 allow, even in tmis case, a firmer 0° coupling of the metallic grids 4, 5, thus increasing the strength of the constructed walls.

o0 The vertical supporting element is substantially constituted by a partition made of reinforced concrete 0, variable in thickness according to the static requirements 5 and covered on both faces by a layer of thermc-acoustic insulating material ready to receive a finishing layer of mortar or plaster, as shown in figure 7. By virtue of the metallic grids provided on the outer faces, said finishing layer is supported and bound by said grids.

0 Figure 2 illustrates the vertical coupling of a pair of 02 o 0 0 0 0 0 2 3 ra i; 1oo 0 1 0o 0 0 4000 U9"xl adjacent panels. The presence of the overlapping metallic members in the plane which is perpendicular to the coupling plane of the panels provides a continuity in the support of the plaster which contrasts the forming of cracks at said critical region. The continuity of the metallic reinforcement internal to the interspace 9 is conveniently ensured by the installation of appropriate additional horizontal reinforcements of such a diameter and length as to allow the overlap of the supporting metallic reinforcements.

The corner walls are provided as illustrated in figures 3 and 4, related respectively to single and double panels.

In particular in the case of double panels, the corner is obtained by shortening the internal basic panel by an amount equal to the thickness of the interspace. This shortening is conveniently provided by removing only the insulating material, while the framework is conveniently folded to constitute the required corner reinforcement.

The walls are connected as illustrated in figures 5 and 6, which relate respectively to single and double panels. In particular in the case of double panels, the T-shaped coupling is provided by removing a portion of the insulating layer of the internal basic panel corresponding to the width of the panel to be coupled. The coupling is conveniently reinforced by means of angular frame elements 11.

In the case of multi-story buildings, the upper stories are built by installing the panels as described, placing connecting reinforcements in the sections which close the underlying walls, as indicated by 12 in figure 7. The thickness of the walls mav be varied from one storv to the 4 7 next according to the calculated dimensions.

The panel according to the present invention can furthermore be used, if appropriately integrated, as a component for the production of horizontal structures, as illustrated in figure 7, which illustrates the construction of a floor 13. In this case the single panel is integrated with blocks 14 made of foamed polystyrene and is then completed, when installed, with concrete castings 15 after plac-ng therein the appropriate integrating reinforcements as derived from calculation.

A metallic grid, connected by means of welded metallic couplings to the metallic grid provided on the lower face of 0o the panel, is conveniently installed above the polystyrene Sblocks 14 interposed between the electrically welded frameworks. In this manner a single composite structure is provided which has considerable rigidity and a moment of inertia which allows integrating castings without resorting to props differing from conventional ones.

The finished product is therefore a floor with joists and topping made of reinforced concrete, with an insulated and soundproofed soffit ready to be completed with mortar or plaster.

Finally, the basic panel can be used to produce parapets. In this case it is installed with the thicker steel rods arranged horizontally. The metallic rods which protrude beyond the insulating material are folded and used to fix the parapet to the lower horizontal elements and to support the finishing box.

The parapet is then completed by applying a layer of structural mortar or concrete with suitable strength ~YI~ I characteristics to each of the two faces.

To summarize, the constructive system constituted by the described vertical and horizontal elements allows to build monolithic structural complexes having high characteristics of rigidity, lightness and adaptability to any constructive form, as well as adapted to provide a complete covering with insulating material.

The fact is furthermore stressed that the various kinds of panel may be produced horizontally with the same machine.

In the practical embodiment of the invention, the materials employed, as well as the shapes and dimensions, 9 <may be any according to the requirements.

C O a o C 4O 'i t 0 i

Claims

2. Panel according to claim i, characterized in that said parallel undulations define an alternating horizontal succession of vertical crests and troughs, intended to be vertical in an installed position, said grids having vertical rods, the troughs of each face being longitudinally bisected by said vertical rods.
3. Panel according to claim i, characterized in that said metallic grids have, along the opposite sides intended to be vertical, respective wings which protrude with respect to said insulating layer, said wings being adapted to overlap, when installed, onto the adjacent panels, so as to have in practice no discontinuity in the product thus obtained.
4. Panel according to claim i, characterized in that said panel has two mutually opposite faces, each of said faces being adapted for having applied thereto layers of high-strength structural mortar, whereby to embed said metal grids in said layers of high-strength structural (orqr L/1 0 a 4n C C C j L: 4l 0 Pa el according to claim 1, characterized in that it is coupled by means of appropriate spacer elements to a I second panel so as to provide a formwork which defines an interspace adapted to contain a concretee
6. Panel according to claim 5, characterized in that said interspace is adapted to contain a concrete casting having embedded therein, reinforcement members made of longitudinal and/or transverse rods.
7. Panel according to claim 1, characterized in that said metallic grids are constituted by rods made of cold-redrawn, high-resistance galvanized steel with a low carbon content and electrically welded so as to form, an asymmetrical rectangular mesh.
8. Panel according to claim 1, characterized in that said transverse elements are provided by high-resistance o galvanized steel rods, chisel-cut so as to perforate said oinsulating layer without breaking it.
9. Panel according to claim 1, characterized in that said metallic grids are mutually connected in an asymmetrical manner so as to be offset on their two sides. Pane according to claim 4, characterized in that it further comprises blocks of foamed polystyrene located r °adjacent said insulating layer and being placed between said metallic grids, concrete castings formed on said blocks of polystyrene, and integrating reinforcements placed in said concrete castings for producing horizontal elements such as floor slabs, etc. i 11. Panel for constructing walls with thermo-acoustic insulation characteristics as hereinbefore described with reference to and as shown in the accompanying drawings. DATED this 4 day of March 1991 MONOLITE S.r.l. ~Patent Attorneys for the Applicant: RICE CO.