EA000887B1 - Prefabric fiber reinforced cement wallpanel - Google Patents

Abstract

1. A self heat isolated composite light wallpanel comprising FTB/GRC (glass fiber reinforced concrete), foamed concrete, special designed carrier steel stude frame (c) and steel wire mesh (g) having different characteristics, characterized in that the carrier steel stude frame (c) and the steel wire mesh (g) placed inside the heat isolated light wallpanel is totally covered with foam concrete and therefore does not constitute a heat bridge whereby the saturation on outer surfaces of panels caused by temperature differences is prevented. 2. Self heat isolated GRC panel according to the preceding claims, characterized in that it comprises the following: GRC shell (b), omega sectioned steel stude frame (c), flexible anchorage rods (d), pads that connect flexible anchorage rods to shell inner face, foam concrete filling (f), foam concrete mounting steel wire mesh (g), anchorage plates (h) by which panel will be welded to four corners of the panel, diagonal profile (i) which is welded to anchorage plate. 3. Self heat isolated GRC panel according to claim 1 and claim 2, characterized in that the GRC shell (b) for the aim of providing heat isolation is filled with foam concrete before said GRC shell has set and during the same manufacturing process so that the light wallpanel is producted in one and same process. 4. Self heat isolated GRC panel according to the preceding claims, characterized in that GRC shell (b) can be produced with requested form, design and shape and such that it can include every kind of detail such as window spaces, strip windows, blind frames, fringe, surface texture etc. 5. Self heat isolated GRC panel according to the preceding claims, characterized in that steel stude frame (c) (Figure 6) which is placed inside GRC shell (b), carries GRC shell (b) by means of flexible anchorage rods (d) and also provides panel to be fixed to building tablier (a) by means of diagonal profile (m) which is placed on anchorage plate (h). 6. Self heat isolated GRC panel according to the preceding claims, characterized in that flexible anchorage rods (d) are placed on steel stude frame (c) with sufficient space. 7. Self heat isolated GRC panel according to the preceding claims, characterized in that the steel stude frame is narrower to reduce the thermal transfer and that sufficiently thick foam concrete has been placed on both sides of the steel stude frame. 8. Self heat isolated GRC panel according to the preceding claims, characterized in that flexible anchorage rods (d) are welded to steel stude frame (c) from one end and fixed to GRC shell from the other end and there is provided flexibility by means of the free 6-8 cm section (Figure 5-c) and as a result of this panel is not effected by ground and building movements. 9. Self heat isolated GRC panel according to the preceding claims, characterized in that mounting of said panel to building tablier (a) is provided by fixing the diagonal profile (Figure 2,3,4-L) which is fixed to anchorage plates (Figure 6) on the corners of the panel, to steel strap on the building tablier (Figure 2,3,4-J). 10. Self heat isolated GRC panel according to the preceding claims, characterized in that it functions as mounting to foam concrete filing (f) and there is a layer of steel wire mesh (g) placed in steel stude frame (c) in order to prevent the possible cracks and openings on foam concrete. 11. Self heat isolated GRC panel according to the preceding claims, characterized in that finished panel thickness is about 1015 cm. 12. Self heat isolated GRC panel according to the preceding claims, characterized in that finished panel weight is 80-100 kg for each meter square. 13. A method for producing self heat isolated GRC panel according to the preceding claims, it comprises the steps of: a) first panel mold made of steel or glass reinforced plastic is prepared with desired architectural form, design and detail; b) 10-12 mm thick GRC shell (b) is formed by spraying GRC mortar into said panel; c) steel stude frame (c) (Figure 6) which is constructed so that it can receive wind load, particular weight and mechanic characteristics, is placed; d) sufficiently spaced flexible anchorage rods (d) (50 cm from each other) and anchorage plates (h) Figure 6-n) which have 4 steel corners are provided over steel stude frame; e) flexible anchorage rods (d) are padded to GRC shell by means of GRC mortar; f) a layer of steel wire mesh (g) which functions as mounting to foam concrete filing (f) is placed on steel stude frame (c); g) a panel is formed by filling foam concrete into GRC shell (b); h) a panel which is inside the mold is sent to a treatment chamber, i) after treating period panel is removed from the mold and becomes ready to transport to the construction area where it is going to be mounted.

Description

The present invention relates to a wall panel of fiber-reinforced cement with foam insulation, and to the method of its manufacture.

Currently, there are 4 known types of factory-made wall panels manufactured in various ways:

a) Concrete panels with iron reinforcement. These panels have a weight of 400 kg per square meter, do not include thermal insulation and, due to their high weight, create problems during transportation and installation.

b) Concrete panels with thermal insulation. Such panels are obtained by placing a sheet of solid polystyrene foam 5 cm thick between two 10 cm thick panels, such panels have the same weight and create the same problems.

c) Three-layer panels. Such panels are made by covering all sides of the blocks with foam cement with fiber-reinforced cement. Such panels provide heat insulation and are lightweight, but they cannot be mounted on a concrete frame and they do not have sufficient durability. Therefore, the production of such panels is terminated.

d) Fiber-reinforced cement facing plates. They are slabs with steel frames, 12 mm in thickness, and are used to coat columns, existing walls and to create profiles on surfaces. Insulation is carried out by placing insulation plates behind them after installation.

Due to the fact that all panels of these types have a certain rigidity, they do not have any freedom of movement relative to the steel strips of the building frame and movements of the building.

In connection with the foregoing, the present invention is to eliminate the disadvantages inherent in the panels.

Known panels have a thickness of 20-25 cm, to prevent the formation of cracks and the destruction of iron reinforcement in the panel. In this case, the weight of the panel is 400-450 kg per square meter. And this causes problems during transportation and installation of large-sized panels, and also creates excessive loads on the concrete supporting structures of buildings. The thickness of the panels of the present invention does not exceed 1 0-1 5 cm, and the weight of the panel is about 90-100 kg per square meter. This facilitates the transportation and installation of panels, reduces the load on concrete structures to a minimum and reduces the amount of iron used in load-bearing reinforced concrete structures of buildings.

Known panels need subsequent thermal insulation, and this requires the use of various insulating materials and further processing, the use of additional labor and entails additional costs.

In the panels of the present invention, the cellular structure and air voids in the foam concrete act as an insulating material, and such panels do not need subsequent thermal insulation. The second advantage of thermal insulation by means of foam concrete is that it is possible to produce concrete parts of the required density, depending on temperatures where the panels will be used, and the panels may have different insulating parameters: λ values can vary from 0.065 to 0.500, K can vary from 0.29 to 3.33.

Known panels can have only basic simple forms, since the technology itself for the manufacture of concrete products does not allow obtaining products of complex shapes. In accordance with the present invention, due to the fact that fiber-reinforced cement is a material from which any shapes can be cast, the panels can be given any shape in accordance with the architect's intent.

Famous panels are heavy and tough. They do not have the freedom to move outside the movements of the building itself, nor are they capable of absorbing movements, such as building movements, displacement of soil, and displacement of steel strips of the building framework. Therefore, over time, cracks and tears are formed at the junction of the panels. In the panels of the present invention, the fiber-reinforced cement sheath that forms the outer sides of the panel is attached to the steel structure in the form of a frame located in the panel with a flexible anchor connection, and the steel structure in the form of a frame is attached to the building frame with anchor plates. Therefore, when transmitting building movements to the body of the panel, the flexible rods of the anchor connection bend, and the movements of the building do not damage the panel.

In practice, fiber-reinforced cement panels can be very different, depending on the architectural concept, and the subject matter of the invention is further described in more detail with reference to the attached drawings, which are given only to clarify the essence of the invention, but which are not limited in scope.

FIG. 1 is a view from the outside of the monoblock panel with a finished window opening. In this front view, lines A-A and B-B show cuts lines; The corresponding sectional views are given in the subsequent drawings.

FIG. 2 - vertical section of the panel along the line A-A:

and - a framework of the building;

b - sheath of fiber reinforced cement;

с - steel structure in the form of a frame, in the cross section having the shape of the letter “omega”

d - flexible anchor connection rods; e - lining connecting the flexible rods of the anchor connection with the inner surface of the shell of fiber-reinforced cement;

f - foam concrete aggregate; g - steel mesh, which serves as reinforcement for foam concrete;

h - anchor plates in the four corners of the panel where the panel will be welded;

i - support clamp welded to the anchor plate;

j - steel strip screwed to the building frame;

k - insulating material that fills the junction between the panels (polysulfite);

m - supporting clamp, which will be placed on the top panel;

FIG. 3 - vertical section of the panel along the line B-B:

and - a framework of the building;

b - sheath of fiber reinforced cement;

с - steel structure in the form of a frame, in the cross section having the shape of the letter “omega”

d - flexible anchor connection rods; e - lining connecting the flexible rods of the anchor connection with the inner surface of the shell of fiber-reinforced cement;

f - foam concrete aggregate; g - steel mesh, which serves as reinforcement for foam concrete;

h - anchor plates in the four corners of the panel where the panel will be welded;

i - support clamp welded to the anchor plate;

j - steel strip screwed to the building frame;

k - insulating material that fills the junction between the panels (polysulfite);

m - supporting clamp, which will be placed on the top panel;

FIG. 4 - section of the panel section, in the place of connection to the building frame:

and - a framework of the building;

b - sheath of fiber reinforced cement;

с - steel structure in the form of a frame, in the cross section having the shape of the letter “omega”;

d - flexible anchor connection rods; e - lining connecting the flexible rods of the anchor connection with the inner surface of the shell of fiber-reinforced cement;

f - foam concrete aggregate; g - steel mesh, which serves as reinforcement for foam concrete;

h - anchor plates in the four corners of the panel where the panel will be welded;

i - support clamp welded to the anchor plate;

j - steel strip screwed to the building frame;

k - insulating material that fills the junction between the panels (polysulfite);

m is the support fixture on which the top panel will be placed.

FIG. 5. Detail of the flexible anchor connection: a - steel structure in the form of a frame; b - flexible rod;

d - fiber reinforced cement pad; e - sheath of fiber reinforced cement;

c - the area that will provide flexibility due to bending.

FIG. 6 shows a steel structure in the form of a frame on which flexible anchor rods and anchor plates are located in 4 corners:

с - steel structure in the form of a frame, in the cross section having the shape of the letter “omega”;

d - flexible anchor connection rods; h - steel plates, by means of which the frame construction will be connected to the building frame.

The invention is explained below.

The fiber-reinforced cement panel of the present invention, obtained as a composite product by combining two separate elements that have different characteristics and have different purposes, has the advantage of combining the characteristics of the two elements, resulting in a new insulated lightweight monoblock wall panel factory made from fiber reinforced cement.

Known fiber-reinforced cement is a cement that contains alkali-resistant fiberglass, and has the strength of a reinforced cement-sand mortar, it can be molded and cast from it products with a thickness in the section of 10-12 mm. On the other hand, foam concrete is foamed concrete, which is obtained by foaming a liquid foaming agent with an air generator and mixing this foam with cement mortar. Due to air bubbles, this material provides excellent thermal insulation, and in addition, it is light.

The present invention relates to heat-insulating lightweight monoblock wall panel of factory production of reinforced cement, obtained by combining these two materials in the form of a panel, and to the method of its manufacture.

A shell of fiber-reinforced cement with a thickness of 10-12 mm is obtained (Fig. 2, 3b) by spraying a solution of fiber-reinforced cement inside a steel or glass-fiber-reinforced plastic panel mold made in accordance with the required architectural form. Spraying the solution of fiber-reinforced cement is carried out by means of a cement pump or a cement gun made for this purpose.

The steel structure in the form of a frame (Fig. 2, 3-c) (Fig. 6), designed to withstand wind load, substantial weight and having other mechanical characteristics, is placed inside the molded shell of fiber-reinforced cement. On this design in the form of a frame, flexible anchor rods are placed at a distance of 50 cm from each other. Also on the four corners of the steel structure in the form of a frame are mounted steel anchor plates (Fig. 2-3-h) (Fig. 6-h), which will be attached to the steel strips of the building framework. In this way, a fiber reinforced cement panel is obtained, in which a steel frame-like structure inside supports the cladding (b) of fiber-reinforced cement and secures the panel to the building frame. After that, the flexible anchor rods are attached to the steel structure in the form of a frame with the help of linings from a solution of fiber-reinforced cement (Fig. 2, 3, 4) (Fig. 5). One end of these flexible anchor rods with a thickness of 6-10 mm and a length of 1-15 is attached to the steel structure in the form of a frame, and the other end is attached to the shell of fiber-reinforced cement. Between them remains an empty space of 6-8 cm (Fig. 5-s). This free space around the rod provides flexibility. When building and panel movement occurs, these flexible rods bend and prevent movement from being transferred to a rigid section. As a result, the displacement of the ground and the movement of the building are not transferred to the panel.

After installing flexible anchor rods (Fig. 6-d) and a steel structure in the form of a frame (Fig. 6) containing mounting plates (Fig. 6-h) inside the shell of fiber-reinforced cement, and after each flexible anchor rod attached to the shell of fiber-reinforced cement (Fig.2, 3, 4th), place a layer of steel mesh, which serves as reinforcement for foam concrete, so that it serves as a gasket for foam, which is poured into the shell, and prevents the formation of cracks in it and voids, and this layer is attached at several points to the steel th frame (s). After that, the panel is made by pouring foam concrete into the shell of fiber-reinforced cement (Fig. 2, 3, 5-f).

The panel is sent to the curing chamber together with the mold, after curing it is removed from the mold and transported to the construction site for installation.

Claims (13)

CLAIM one . A heat-insulating composite lightweight wall panel, including FTB / GRC (fiberglass reinforced concrete), foam concrete, a special supporting steel structure in the form of a frame (c) and a network of steel wire (g), having different characteristics, characterized in that the supporting steel structure in the form of a frame (c) and a network of steel wire (g), placed inside a heat-insulating lightweight wall panel, are completely covered with foam concrete and, thus, a jumper is not formed for heat transfer, thereby preventing condensation on the outer surfaces of the panel, caused by temperature differences. 2. The insulated panel of fiber-reinforced concrete according to claim 1, characterized in that it includes a shell of fiber-reinforced concrete (b), a steel structure in the form of a frame having the cross section in the shape of the letter "omega" (c), flexible anchor rods (d), overlays that connect the flexible anchor rods to the inner surface of the shell, foam concrete aggregate (f), foam steel mesh network (g), anchor plates (h) through which the panel is welded from four angles, corner profile (i) welded to nkernoy plate. 3. The heat-insulating panel of fiber-reinforced concrete according to claim 1 or 2, characterized in that the shell of fiber-reinforced concrete (b) to provide thermal insulation, is filled with foam concrete until the specified shell of fiber-reinforced concrete cures during the same production process, so as to produce a lightweight wall panel in one process. 4. The heat-insulating panel of fiber-reinforced concrete according to the preceding paragraphs, characterized in that the shell of fiber-reinforced concrete (b) is made of the required shape, structure and with the required details, and includes any details, such as window openings, tape windows, frames for blinds , edging, surface texture, etc. 5. The heat-insulating panel of fiber-reinforced concrete according to the preceding paragraphs, characterized in that the steel structure in the form of a frame (c) (Fig. 6), located inside the shell of fiber-reinforced concrete (b), supports the shell of fiber-reinforced concrete (b) by means of flexible anchor rods (d) and configured to attach the panel to the frame of the building (a) by means of a corner profile (m) placed on the anchor plate (h). 6. The heat-insulating panel of fiber-reinforced concrete according to the preceding paragraphs, characterized in that the flexible anchor rods (d) are placed on the steel structure in the form of a frame (c) with sufficient clearance. 7. The heat-insulating panel of fiber-reinforced concrete according to the preceding paragraphs, characterized in that the steel structure in the form of a frame is made narrower to reduce heat transfer, and a sufficiently thick layer of foam concrete is on both sides of the steel structure in the form of a frame. 8. The heat-insulating panel of fiber-reinforced concrete according to the preceding paragraphs, characterized in that the flexible anchor rods (d) are welded to the steel structure in the form of a frame (c) from one end and attached to the shell of fiber-reinforced concrete from the other end, and flexibility is provided through a free section of 6-8 cm (Fig. 5-c), as a result of which the panel is not exposed when the soil is displaced and the building moves. 9. A heat-insulating panel made of fiber-reinforced concrete according to the preceding paragraphs, characterized in that the installation of the panel to the building frame (a) is provided by attaching a corner profile (Fig. 2, 3, 4-L), which is attached to the anchor plates (Fig. 6) at the corners of the panel and to the steel strip on the building frame (Fig. 2, 3, 4-J). 10. A heat-insulating panel made of fiber-reinforced concrete according to the preceding paragraphs, characterized in that it is configured to be mounted on a foam concrete aggregate (f), the mesh layer of steel wire (g) being connected to the steel structure in the form of a frame (c) for prevent the possible formation of cracks and voids on foam concrete. 11. A heat-insulating panel made of fiber-reinforced concrete according to the preceding paragraphs, characterized in that the thickness of the finished panel is about 10-15 cm. 1 2. Thermal insulation panel made of fiber-reinforced concrete according to the preceding paragraphs, characterized in that the weight of the finished panel is 80-100 kg per square meter. 13. A method of manufacturing a heat-insulating panel of fiber-reinforced concrete according to the preceding paragraphs, which includes the following steps: a) first, a form for a panel having the desired architectural form, structure and details is made of steel or fiberglass-reinforced plastic; b) a shell is made of fiber-reinforced concrete (b) 10-12 mm thick by spraying a solution of fiber-reinforced concrete in the specified form for the panel; C) place the steel structure in the form of a frame (c) (Fig. 6), which has such a structure that can withstand the wind load, a certain weight and has certain mechanical characteristics; d) on the steel structure in the form of a frame mount flexible anchor rods (d) spaced 50 cm apart, and 4-angle anchor plates (h) (Fig. 6-n); e) attach flexible anchor rods (d) to the sheath of fiber reinforced concrete by means of a solution of fiber reinforced concrete; f) on the steel structure in the form of a frame (c) place mesh layers of steel wire (g), which serves as reinforcement for the aggregate of foam concrete (f); g) get the panel by introducing foam into a shell of fiber-reinforced concrete (b); h) place the panel inside the mold in the processing chamber; i) after processing, the panel, ready for transportation to the construction site, where it will be mounted, is removed from the mold.