DE69607385T2 - PANELING ELEMENTS, PARTITIONS AND PANELS MADE FROM THESE ELEMENTS, AND THEIR PRODUCTION METHOD - Google Patents

Abstract

A facing element (1) consisting of a galvanised steel sheet (3) provided in the workshop with a plaster body (7) applied to one surface thereof in the form of batched plaster. The batched plaster body may be cast or sprayed onto the galvanised sheet. Alternatively, the batched plaster may be cast on paper or cardboard, whereafter the sheet is pressed onto the plaster. Such elements may be assembled back-to-back in pairs to form partitions, or applied on a wall to form a lining.

Description

TECHNOLOGICAL BACKGROUND 1. TECHNICAL FIELD OF THE INVENTION

The present invention relates to a new type of construction element, called a cladding element, which allows various advantageous technical and economic features to be combined.

It covers the use of these cladding elements for the realisation of partition walls and doublings, as well as the process for manufacturing and the technology for applying or using these cladding elements.

The partition walls used in the construction sector must fulfil a certain number of specific functions simultaneously:

- the separation function, which is not only of a geometric nature, but which also aims to ensure the disappearance or limitation of certain physical phenomena (light, temperature, noise, ...),

- the aesthetic function,

- the supporting function for technical equipment (continuity of the networks and subsequent connections),

- the mechanical or structural function (even in the case of non-load-bearing partitions, which must withstand the various stresses encountered during use and whose connections with the load-bearing elements of the building must be provided),

- the intrusion or burglary protection function in the case of a separation between two apartments in shared apartments.

Considerations of the same kind apply to doubling (covering) walls with this type of product.

Of course, the usual technical requirements and economic requirements must also be taken into account in order to deliver a quality product that has an affordable price and is easy is to be applied.

To meet these various requirements, particularly in terms of acoustic insulation, the most commonly used system is to build a solid wall (simple concrete wall type). This concept has the main disadvantage that the wall is heavy (approximately 600 kg/m²). To overcome this disadvantage, a new system of lightweight partitions ("double walls") has been proposed in accordance with the state of the art. This system, based on the "mass - spring - mass" arrangement, makes it possible to obtain better acoustic properties and smaller dimensions (for example, reducing the total thickness from 260 to 220 mm) with mass values that are ten times smaller. This system generally consists of a metal framework made up of posts and crossbeams, on which are fixed cladding made of panels made of plaster and cardboard or of another material; the cavity is filled with an insulating material. Systems of this type have the following main weak points:

- Large-sized plasterboards break easily, especially during transport and installation.

- Relatively thick structures are necessary if good insulation properties are desired (doubling of plasterboard, design and separation of cladding, ...).

2. DESCRIPTION OF THE STATE OF THE ART

Document US-A-3,866,376 proposes a composite wall element consisting of a hollow plaster assembly with metallic foils glued to its outer surfaces.

Document US-A-4,736,566 describes a modular panel system consisting of a core in the form of a "corrugated" plasterboard sandwiched between cover sheets such as vinyl sheets.

Document GB-A-2 148 972A describes a fire barrier assembly consisting of foil and plaster blocks, the plaster blocks being reinforced with glass fibres and covered with stainless or galvanised steel plates.

In these three documents, the external surfaces of the partitions are made of metal or vinyl material, and the plaster that forms the core of the panel is either glued or mechanically held in place by fasteners. The manufacture of such elements is difficult, and the external metal or vinyl surface is generally suitable for apartments not suitable for either internal or external walls.

OBJECTIVES OF THE INVENTION

The invention aims to avoid the disadvantages of the prior art and, in particular, to propose claddings made of steel and plaster which are prefabricated in the workshop, forming a unit which reduces the risk of damage during transport and installation on site and which can be installed easily and quickly.

An additional aim of the invention is to reduce the amount of gypsum used, compared to the prior art solution, in particular the conventional gypsum boards.

In particular, the aim is to combine acoustic and thermal insulation, fire resistance, rigidity, ease of transport, and a reduction in weight and price with other functionalities, in particular the ease of assembly and fastening of technical equipment.

CHARACTERIZING ELEMENTS OF THE PRESENT INVENTION

According to the invention, a cladding element is proposed which is characterized in that it consists of a galvanized steel sheet, which is provided in the workshop on at least one surface with a plaster mass which is applied in the form of mixed plaster.

The galvanized steel sheet can be profiled, forming stiffening ribs to obtain a self-supporting panel.

In addition, it is possible to attach an insulating layer, in particular a thermal insulating layer, to the surface of the sheet opposite the surface to which the plaster is applied, which can also be advantageously applied in the workshop, but can also be applied on site.

Depending on the properties required, the cladding element consists of a galvanised steel sheet with a thickness of between approximately 0.4 and 3.0 mm, which may be profiled, and on which at least one surface is applied mixed plaster or a mixture based on mixed plaster with a thickness of preferably between 5 and 50 mm.

It has been found that when mixed gypsum is applied to galvanized steel sheet, good adhesion of the gypsum is obtained, which makes it possible to use a large number of manufacturing processes. In the case of galvanized steel, one can speak of a true chemical zinc-gypsum compound.

The adhesion can be improved by a suitable surface treatment or a mechanical bond, which in particular comprises pressing the mixed plaster onto the sheet, a process known per se in order to improve the adhesion of the mixed plaster to a support, such as a cardboard.

The gypsum mass is applied directly to the galvanized steel sheet using well-known methods. The gypsum mass can be poured or sprayed onto the sheet, which is, for example, arranged on a horizontal base.

It is also possible to pour the plaster onto paper or cardboard and then apply the galvanized sheet to this plaster, for which the sheet is applied using a pressing device, i.e. a sheet unwinder, in which a certain pressure force is exerted on the plaster.

According to a further variant of the method, first, as described above, a layer of mixed plaster is applied to paper or cardboard, or to another support, then the galvanized sheet is applied, being pressed onto the still wet plaster (for example, when it passes through the pressing device), and then the galvanized sheet is covered with a layer of mixed plaster on the other surface using a suitable technique, this latter layer then preferably being covered with a covering layer, for example of paper or cardboard.

This solution is particularly advantageous because it avoids certain disadvantages linked to the problem of drying the plaster (the sheet is of course impermeable) and the problem of crumbling the plaster applied to the sheet when cutting the panels or drilling holes on site.

Preferably, a sheet is used that has been profiled either during its manufacture or immediately before its use.

The term mixed gypsum refers to a mixture of water and gypsum. According to another embodiment, mixed gypsum consists of a mixture of water and gypsum with additives in small quantities, i.e. in a quantity that generally does not exceed 50% by weight.

According to one variant, a gypsum-based mixture is used, containing additives with low density and high thermal insulation capacity, such as perlite or vermiculite.

According to another variant, a mixture based on gypsum which contains a proportion of Portland cement or ferrous cement. These variants, which can be combined with each other, aim to achieve one or more of the following objectives:

- Reducing the mass of the component to facilitate its handling;

- Optimization of thermal insulation capacity;

- Increasing the mechanical strength of the gypsum-based mixture;

- Increasing the density so that better acoustic insulation is achieved.

The cladding element thus created can be easily transported with a minimum of protective packaging, for example a shrink-on protective film, since the sheet metal greatly reduces the risk of breakage of the plaster mass.

The use of a galvanised sheet, which may have been subjected to one or other surface finish to increase its resistance to oxidation (white rust) during storage, is also a factor that contributes significantly to protecting this sheet from the formation of rust over time and during the drying of the plaster.

The term "galvanized" should be understood in a broad sense and should also apply to a coating made of zinc and aluminum-based alloys. This can, for example, be more or less strongly alloyed zinc or aluzinc, or even products of the GALFAN type (registered trademark).

The direct physical-chemical steel/gypsum bond is obtained by pouring or spraying the gypsum onto the galvanized steel in the workshop, or by applying the galvanized sheet onto the gypsum previously applied to a support such as paper or cardboard, preferably in a horizontal position. This avoids the use of wire mesh, which is necessary for adhesion in the case of vertical spraying, which is sometimes recommended for construction sites according to the state of the art.

It may be advisable to provide an additional mechanical connection to increase the performance of the element in use. This is achieved using well-known procedures such as increasing the roughness of the sheet, making projections or recesses in the sheet, screwing, incorporating metallic elements into the plaster mass, etc., or incorporating any other element to anchor the plaster mass to the sheet.

It may also be planned to add adhesive to the plaster before or after mixing it to improve adhesion after drying and/or to apply an adhesion coating to the surface of the galvanized sheet.

The finishing on the plaster side can also take various forms. The surface can have the raw appearance of untreated plaster, but it is also possible to provide covering layers such as cardboard, sheet metal or metal foil, possibly pre-painted. Any other form of finishing is also possible which fulfils the function of temporary protection or provides a surface which facilitates use (for example, allowing a coat of paint to be applied immediately, without the need for a primer).

The plaster used obviously depends on the intended application (water-repellent, decorative plaster, quick-hardening plaster, lightened plaster containing perlite or with a finish such as fiberglass, etc.).

The cladding elements according to the invention can be used for the realization of generally non-load-bearing, lightweight partition walls for various purposes, such as partition walls between apartments, or partition walls for subdivision within an apartment.

They can also be used to create doublings (internal walls of external walls, counter-partitions, ceilings, components involved in the realization of the floors).

When the above-mentioned cladding elements are covered with a plastering compound on only one surface, the other surface possibly being covered with a layer of insulating element, they are generally used in practice as half-partitions, in the sense that two elements of this type are placed "back to back", that is to say with the plastering compound placed on the outside.

Depending on the circumstances, only one of the two cladding elements can be provided with an insulating layer on its free side. This insulating layer can also be provided on both elements, or the insulating layer can also be provided in the form of rigid panels placed between these elements without being firmly connected to them. For example, bracing elements can be provided between the half-partitions, which also serve to hold the rigid panels in place.

The respective thicknesses of the cladding elements, their spatial separation and the type of gypsum used depend on the requirements to be met in terms of rigidity, fire resistance, weight and heat and sound insulation.

Various conventional techniques can be used for assembling the cladding elements on site.

The final work, such as applying screed to the floor, plastering the ceiling or plastering, is generally carried out after the partition walls have been installed.

The use of these cladding elements allows a further reduction in the overall thickness of the partitions while maintaining the same level of acoustic performance, and is associated with other significant technical and economic advantages, among which we can mention:

- Improved rigidity of the panels compared to traditional plasterboards to reduce the risk of breakage during transport, installation and use,

- maintaining fire resistance characteristics, functionalities (adhesion, subsequent plastering, ...), and insulation by incorporating "traditional" materials (plaster, insulating materials of the foam or rock wool type, balls, cellular glass),

- Reduction of assembly costs: easy assembly of elements manufactured in the workshop, reduction of the vertical grid in the form of galvanized C-profiles,

- The separation, due to the continuity of a cladding that includes a continuous metal part, fulfils an anti-intrusion function that is not present in traditional partitions made using plasterboard.

If it is particularly desirable to achieve an anti-burglary function, it is desirable that the steel, according to a preferred variant of the invention, has a high strength and a high elastic limit so that it can withstand mechanical attacks and/or contains elements that retard oxygen cutting (in order to withstand chemical attacks), such as at least 2% chromium, at least 0.5% silicon, or even vanadium, nickel or tungsten.

In this regard, it should be mentioned that the use of steels with a high chromium content (about 15%) can prove useful in making flame cutting impossible and, at the same time, giving the sheet a natural noise-damping capacity due to the internal friction in the material.

DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION

The invention will now be described in more detail with reference to preferred embodiments which are given for illustrative purposes, without representing any limitation. In the various figures, identical reference numerals are used for identical elements or elements with the same function.

BRIEF DESCRIPTION OF THE DRAWINGS

Fig. 1 shows a sectional view of an embodiment of a cladding element.

Fig. 2 shows an enlarged view of the connection between two adjacent panels.

Fig. 3 shows a schematic perspective view of the assembly principle of a partition wall according to the invention.

Fig. 4 shows a schematic view of another embodiment of a cladding element according to the invention, in which a system of plaster and non-profiled sheet metal is implemented.

Fig. 5 corresponds to Fig. 4, but shows a system made of plaster and profiled sheet metal.

Fig. 6 corresponds to Fig. 5, but shows a system made of plaster, profiled sheet metal and plaster.

DETAILED DESCRIPTION

The cladding element according to the invention (Figs. 1 to 3), designated by the general reference numeral 1, consists of a profiled, galvanized sheet 3, generally of standardized dimensions, and of such a length that it can be installed vertically between a floor and a ceiling. This sheet is stiffened by a series of profiles in the form of "ribs" or grooves 5, for example 30 mm wide, which are spaced 100 mm apart.

In cross-section, the sheet metal has the shape of a practically rectangular wave profile.

The shape of the lateral ends of this sheet is described below with reference to Figs. 2 and 3. A plaster mass 7 was poured onto this sheet to form the cladding element.

Due to the zinc layer on the sheet and the profiling of the sheet, the plaster 7 adheres well to the sheet 3.

As can be seen in the figures, the profiled sheet ends on the right side with a little more than half a groove 11, and on the left side with a practically complete groove 13. On the right side, the plaster 7 practically completely fills the groove, and on the left side the plaster fills less than half of the practically complete groove 13.

This makes it possible to join two cladding elements together laterally by overlapping part 11 with part 13, whereby the plaster layer of each element is practically brought into lateral contact (see Figs. 2 and 3).

Fig. 3 specifically illustrates how cladding elements can be installed on site to create a partition wall.

In this embodiment, the insulation material was not previously applied to the cladding elements.

The view shows the lower part of the elements to obtain a clear drawing.

Here, a mounting rail 21 has been provided on the floor, on which an insulation panel 23 is arranged. The partition consists of a series of cladding elements 1A, 1B, ..., intended to be arranged next to one another in the configuration of Fig. 2, with the plaster 7 facing forward in the drawing and the opposite surface formed by the galvanized sheet 3 facing the insulation panel.

Opposite the cladding elements 1A and 1B, the complementary cladding elements 1C and 1D are mounted as shown, preferably offset (to avoid the "junction" between the adjacent lateral elements being located opposite the "junction" between the opposite lateral elements 1C and 1D), the cladding elements being arranged on the two sides of the insulation panel to create the complete partition.

Fig. 4 shows a variant of the manufacturing process. In this variant, a cardboard web 31, which comes from an unwinder 33, is guided between clamping rollers 34 and over a suitable base, such as a table (not shown).

A plaster hopper 35 serves to apply a layer of mixed plaster 7 to the cardboard 31 as the cardboard passes under the hopper 35. The cardboard 31 and plaster 7 unit is moved further and passes under a galvanized sheet unwinder 37 which applies the sheet 3 to the mixed plaster 7 via clamping rollers 39 and an application roller 41.

In the embodiment of Fig. 5, the steps are essentially the same, except that a metal forming device 43 is provided between the unwinder 37 and the clamping rollers 39. In this case, the Application roller 41 incorporates the deformations of the sheet (for example, wavy lines) into the mass of the mixed gypsum 7.

In the case of Fig. 6, compared to Fig. 5, a second hopper 45 with mixed plaster was provided, which applies a second layer 47 of mixed plaster, and also a paper unwinder 57, clamping rollers 59 and an application roller 61 were provided, which apply a paper web 63 to the mixed plaster 47. In this way, a cladding element is formed which consists of a galvanized sheet 3, in the present case profiled, which is provided on both sides with a layer of plaster 7 or 47, and which is covered on one side with cardboard 31 and on the other side with paper 63.

Of course, numerous modifications are possible within the scope of the invention, both in the choice of the composition of the mixtures based on mixed gypsum, in particular the finishing additives, and in the manufacturing techniques.

Various fastening techniques can be used. For example, it is possible to screw the cladding elements onto the rail 21.

It is understood that numerous techniques can be used to assemble the cladding elements, in particular all the techniques known and used for steel-based panels, such as paired interlocks which improve the stiffening between two panels, and that the invention is in no way limited to the embodiment shown.

The fastening to the floor and ceiling can, for example, be different from that indicated. It can be provided to clamp the side edges of the cladding elements together. Each of the cladding elements arranged "back to back", or only one of them, can be provided with an insulating layer in the workshop.

Spacers or simply suitable insulation allow a gap to be left between the insulation material and the rear surface (sheet metal) of the cladding element in order to obtain good sound insulation of the assemblies.

Claims (11)

1. Cladding element (1) comprising a galvanized steel sheet (3) which is provided with a gypsum mass on at least one side, characterized in that the zinc layer of the galvanized steel sheet is directly and firmly bonded to the gypsum mass solely by means of its own physico-chemical compounds. 2. Cladding element according to claim 1, characterized in that the galvanized steel sheet (3) is profiled, whereby stiffening ribs (5) are formed. 3. Cladding element according to claim 1 and 2, characterized in that the galvanized steel sheet has a thickness between 0.4 and 3.0 mm, and that the plaster mass has a thickness between 5 and 50 mm. 4. Cladding element according to any one of claims 1 to 3, characterized in that it comprises on one side of the galvanized steel sheet a mass of mixed plaster and on the opposite side an insulating layer applied in the workshop by gluing. 5. Cladding element according to any one of claims 1 to 3, characterized in that it comprises a mass (7, 47) of mixed plaster on both sides of the galvanized steel sheet (3). 6. Process for the production in the workshop of cladding elements consisting of galvanized steel sheet (3) provided with a plaster mass (7), characterized in that the plaster mass (7) is applied in the form of mixed plaster to one or more faces of the galvanized steel sheet in order to form a direct physico-chemical bond between the plaster and the zinc layer of the galvanized steel sheet. 7. Method for producing cladding elements according to claim 6, characterized in that the plaster mixed with water is poured or sprayed onto the galvanized steel sheet. 8. Method for producing cladding elements according to any of claims 6 and 7, characterized in that mixed plaster is poured onto paper or cardboard and then the sheet is applied to this plaster, exerting a compressive force on the plaster. 9. Method according to claim 8, characterized in that the still free side of the sheet is covered with a layer of mixed plaster, whereby this plaster layer is preferably then provided with a covering layer, for example of paper or cardboard. 10. Use of cladding elements according to any one of claims 1 to 5, or manufactured according to the process of any of the Claims 6 to 9, characterized in that a partition wall consisting of cladding elements is formed in which two cladding elements are arranged back to back, that is to say with the plaster mass (7) arranged on the outside, possibly with an insulating layer arranged between them which is glued to one or both cladding elements, or with an insulating layer arranged between them in the form of panels which are arranged between the cladding elements without being firmly connected thereto. 11. Use of cladding elements according to any of claims 1 to 5, or manufactured according to the method of any of claims 6 to 9, for cladding walls.