EP0000837A1 - Panneaux muraux portants et procédé pour leur fabrication - Google Patents

Panneaux muraux portants et procédé pour leur fabrication Download PDF

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Publication number
EP0000837A1
EP0000837A1 EP7878300249A EP78300249A EP0000837A1 EP 0000837 A1 EP0000837 A1 EP 0000837A1 EP 7878300249 A EP7878300249 A EP 7878300249A EP 78300249 A EP78300249 A EP 78300249A EP 0000837 A1 EP0000837 A1 EP 0000837A1
Authority
EP
European Patent Office
Prior art keywords
load bearing
layer
panel
bearing wall
fibrous concrete
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP7878300249A
Other languages
German (de)
English (en)
Inventor
Graeme John Tilly
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Individual
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Publication of EP0000837A1 publication Critical patent/EP0000837A1/fr
Withdrawn legal-status Critical Current

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
    • E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
    • E04C2/288—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and concrete, stone or stone-like material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/14—Producing shaped prefabricated articles from the material by simple casting, the material being neither forcibly fed nor positively compacted
    • B28B1/16—Producing shaped prefabricated articles from the material by simple casting, the material being neither forcibly fed nor positively compacted for producing layered articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/30—Producing shaped prefabricated articles from the material by applying the material on to a core or other moulding surface to form a layer thereon
    • B28B1/32—Producing shaped prefabricated articles from the material by applying the material on to a core or other moulding surface to form a layer thereon by projecting, e.g. spraying
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
    • B28B11/003—Apparatus or processes for treating or working the shaped or preshaped articles the shaping of preshaped articles, e.g. by bending
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B19/00—Machines or methods for applying the material to surfaces to form a permanent layer thereon
    • B28B19/003—Machines or methods for applying the material to surfaces to form a permanent layer thereon to insulating material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B7/00—Moulds; Cores; Mandrels
    • B28B7/0091—Transformable moulds allowing the change of shape of an initial moulded preform by preform deformation or the change of its size by moulding on the preform
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B7/00—Moulds; Cores; Mandrels
    • B28B7/06—Moulds with flexible parts
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/04—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
    • E04C2/044—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres of concrete

Definitions

  • An alternative panel to the monolithic panel has been the incorporation of a lightweight core between two layers of concrete. Where the core has been required to support a portion of the load an the panel it has been found that the density of the core has to be relatively high and the weight advantage is not significant. Where the core is hot intended to be of a load bearing nature the concrete layers which are reinforced by continuous reinforcing are required to have a total thickness at least equal to that of the monolithic panels.
  • the invention resides in a load bearing wall panel comprising a relatively lightweight non load bearing core and a layer of load bearing fibrous concrete material located on each face thereof, each layer being substantially impervious to moisture, the thickness of said layers being less than the thickness of the core.
  • At least one web is provided between the layers wherein said web provides resistance to shear forces exerted between said layers.
  • the panel is provided with webs at its top and bottom surfaces interconnecting said layers wherein said webs serve in distributing the loads thereon.
  • the embodiment is directed to a wall panel having a non-load bearing lightweight core with a relatively thin skin formed at each major face of the core, where the skins are formed of fibrous concrete and is load supporting.
  • Each skin of the panel is interconnected by a plurality of parallel webs interconnecting their inner faces and formed of the same material as the skins.
  • the core of the embodiment comprises a plurality of spaced parallel blocks of rigid polystyrene foam having a thickness determined by the nature of the application, and the degree of sound and thermal insulation required of the panel.
  • the skins are formed of a fibrous concrete which is formed from a mixture of sand and portland cement having a preferred ratio of between 1.5:1 and 2.5:1.
  • a quantity of pozzolanic material is added to the mixture to increase the strength of the final product and decrease its susceptibility to permeability.
  • the water to cement ratio is preferably 0.29:1 and should not exceed 0.4:1 in order that the final mixture has a final slump of between 60 and 120 mm.
  • the steel fibres are incorporated with the concrete mixture in a ratio of fibres to concrete of between 0.02:1 to 0.06:1.
  • the steel fibres are formed from mild steel wire although corrosion resistant metals can be used if such is desired.
  • the fibres of the embodiment have enlarged ends and a length of between 14 mm and 25 mm and a thickness of betweenO.3mm and 0.5mm.
  • the fibres may be incorporated with the concrete mixture at the time of mixing of the sand, cement and water. Alt- . ernatively if the concrete mixture is to be applied by spraying or like methods the fibres can be blown onto the surface with the concrete.
  • Each skin is interconnected by parallel webs formed of fibrous concrete which extend the full height of the panel.
  • the webs are formed by spacing the blocks of foam forming the core to provide moulding space between the blocks. Such webs serve in tying the skins together and resisting shear forces which may be exerted on the panel between the skins.
  • the dimensions of the panel are limited by the transportation limitations in moving the panels-from the factory to the site. At present the maximum limitations are a length 13 metres and a breadth of 5 metres. It is envisaged however that panels can be fabricated which are to extend the full length of the side of a house.
  • the thickness of the panel can vary to suit the application and similarly the thickness of each skin is determined by the proposed loading for the panel. In the case of a single storey building the thickness of each skin could be as low as 5 mm for light duty panels and 10 mm for the load bearing walls of a single storey building.
  • the engineering principle of the panel resides in the fact that the two skins share the compressive load and are separated to achieve a high modulus of section to resist buckling.
  • the webs interconnecting the skins serve to ensure that the two skins act as a single structural member.
  • the degree of separation of the skins will depend on the ratio of transverse to vertical loading proposed for the panel and the degree of sound and thermal properties desired for the panel and may vary between 9 mm to 300 mm. However for normal building structures a separation of 30 mm would be adequate for internal walls and 50 mm for external walls.
  • a panel was constructed according to the embodiment having a height of 2.7 metres and thickness of 71 mm with a skin thickness of 10 mm at each side of a core of rigid polystyrene foam core 51 mm thick.
  • the weight of such a panel was 58 kg/m 2 while the loading capacities were 10 KN/m 2 transverse pressure and a vertical loading of 50 KN/m of wall length.
  • the mould for the panel comprises a base plate 11 mounted to a frame 13 which is supported on a plurality of flexible pedestals 15.
  • the pedestals comprise a base 17 fixed to the factory floor and a resilient flexible mounting 19 fixed to the base 17.
  • the interconnection between the mounting and the frame comprises a hinge arrangement.
  • the underneath of the frame is connected to at least one eccentric vibrator 21 which impart an oscillatory action on the frame 13 on the pedestals 15. Such vibrations permit compaction of the concrete as it is introduced into the mould.
  • a moulded liner 23 is laid on the base plate.
  • the moulding surface of the liner can be formed to any suitable texture (eg. a brick wall).
  • shuttering 27 is fixed around the perimeter of the proposed panel. Such shuttering may be textured to conform with the liner 23 or may be covered with a corresponding liner.
  • the liner has laid over it by spraying or screeding (as shown in Figure 2A) a layer 25 of a finishing mixture in order that an attractive finish is produced on the resultant panel.
  • the layer need only be slightly thicker than the depth of the deepest indentation of the liner.
  • the layer can be formed from a high quality white or pigmented cement. Compaction of the layer is achieved by vibrating the base plate 11 by means of the eccentric vibrators 2 1 . The layer is also trowelled onto the shutter at the edges of the panel.
  • the first skin of fibrous concrete 29 is introduced onto the mould from a hopper mounted above the mould and intend- ded to traverse the length of the mould (see figure 2B).
  • the hopper is constructed such that the width of the opening can be adjusted according to the width of the proposed panel.
  • the fibrous concrete 29 onto mould it is compacted by the action of the eccentric vibrators 21 (which can also be mounted to the hopper delivering the fibrous concrete).
  • the blocks of rigid foamed polystyrene Prior to the setting of the first layer 29 of fibrous concrete, the blocks of rigid foamed polystyrene are placed on the layer in spaced relation to provide for transverse parallel spaces between the blocks. In the case of the embodiment the spacings are 20 mm.
  • the heavy plate 31 is removed and a further layer 33 is deposited from the hopper into the mould and is screeded and compacted over the foam blocks and into the spaces between the blocks (see Fig . 2D).
  • the top layer can be smooth trowelled ready for painting or may be treated to provide a textured surface.
  • tie bars 34 are pressed into the upper face of the panel around the edges to facilitate fixing the panel to the foundations or to adjoining walls.
  • the panel is removed from the mould and is transferred to a curing chamber.
  • one side of the frame 13 supporting the base plate 11 is raised while the other side hinges on the pedestals 15 supporting that side and the panel is transferred to a trolley which supports the panel upright.
  • the raising of the one side of the mould can be achieved by neans of a crane or suitable hydraulic jacks.
  • the top and bottom of the panel may be forme with a continuous web 35 interconnecting the two skins (see Figs. 4).
  • the web 35 has located within it a length f continuous reinforcing 37 such as reinforcing mesh loated throughout the length.
  • the web has cast therein a series of spaced attachment means 39 such as thr aded sockets.
  • the attachment means facilitate the lifting of the panel on completion of the setting process, when transporting the panels to the building site and locating the panel in position on the foundations.
  • the web 35 serves in distributing the loads exerted on the panel in position by the roof structure of the building.
  • a blanking piece 41 Prior to the formation of the initial layer 25 of finishing material and the first layer 29 of fibrous concrete a blanking piece 41 is located in the mould on top of the liner 23 at the desired position of the window or accessway. The sides of the blanking piece may be textured in conformity with the texture of the liner 23 in order that on the completed panel there is some continuity of the panel finish.
  • a deeper blanking piece 41A or box with a closed top is located in the window space and the further layer is screeded around the blanking piece to the height thereof.
  • the blanking pieces may be suitably contoured at their edges to support and locate a window frame.
  • Figures 5A to 5E illustrate a method of forming panels of the embodiment into a curved configuration.
  • the mould comprises a flexible base plate 43 having rigid vertical shuttering 44 at either end and flexible vertical shuttering 47 at each side.
  • the base plate is supported at each end as is the base plate of the mould of figure 1 upon resilient pedestals 45 via hinge pins pivotally received on the pedestals.
  • the mounting of at least one of the hinge pins to the base plate is such as to permit longitudinal sliding movement of the hinge pin on the base plate.
  • the portion of the base plate is supported by a series of spaced transverse pins 49 mounted in side plates 48 which are located at each side of the base plate.
  • the vertical location of each pin in the side plates is variable due to the existence of a plurality of vertically spaced apertures in the side plates.
  • An inflatable bag 55 is located under neath the base plate between each pedestal such that on pedestal inflation the bag supports the base plate 43 in the horizontal position. By further inflation of the bag the base plate can be curved upwardly and the pins relocated to accept some of the loading on the bag. Alternatively by deflation of the bag 55 and relocation of the pins 49 the base plate can be caused to curve downwardly.
  • the base plate In forming the panel the base plate is initially positioned such that it is horizontal and the initial finishing layer and first layer 52 of fibrous concrete is applied to it to form a thin skin. Blocks of core material 55 are positioned on the layer while still wet and are pressed into place by a heavy plate. The layer is then compacted by means of vibrators 46 and allowed to set.
  • the second layer of fibrous concrete is applied between and over the blocks of core material and it is compacted by vibration. While the second layer is still fluid the weight of the base plate is taken by the inflatable bag, the pins 49 are withdrawn and the bag is inflated or deflated to give the desired curvature of the panel. On reaching the desired curvature the pins are reinserted.
  • the first layer flexes because it has not fully cured and because it is maintained thin enough to flex and the second layer conforms to the curvature because it is still wet.
  • the panel remains in the mould until it has cured sufficiently to be removed.
  • the light weight non load bearing core may be formed of any one of the following:-
  • the web may be formed of the following:-

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Architecture (AREA)
  • Manufacturing & Machinery (AREA)
  • Structural Engineering (AREA)
  • Civil Engineering (AREA)
  • Forms Removed On Construction Sites Or Auxiliary Members Thereof (AREA)
EP7878300249A 1977-08-15 1978-08-15 Panneaux muraux portants et procédé pour leur fabrication Withdrawn EP0000837A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
AUPD122977 1977-08-15
AU1229/77 1977-08-15

Publications (1)

Publication Number Publication Date
EP0000837A1 true EP0000837A1 (fr) 1979-02-21

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Application Number Title Priority Date Filing Date
EP7878300249A Withdrawn EP0000837A1 (fr) 1977-08-15 1978-08-15 Panneaux muraux portants et procédé pour leur fabrication

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AU (1) AU520177B2 (fr)

Cited By (14)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2223520A (en) * 1988-08-15 1990-04-11 Pan Lei Pan Insulated roofing panel
EP0392610A2 (fr) * 1989-04-10 1990-10-17 Bruce Harrington Unités de mur pour la construction de bâtiments
EP0473383A2 (fr) * 1990-08-27 1992-03-04 Cca Inc. Méthode pour la fabrication d'objets moulés avec motifs
EP0479512A2 (fr) * 1990-10-01 1992-04-08 Cca Inc. Procédé de fabrication d'un élément moulé comportant un motif
FR2698392A1 (fr) * 1992-11-23 1994-05-27 Saret Procédé et installation de fixation d'une plaque isolante sur un élément préfabriqué en béton et élément isolé obtenu par ce procédé.
WO1994015037A1 (fr) * 1992-12-18 1994-07-07 Thor Joergen Element de plancher et son procede de fabrication
US5445772A (en) * 1991-05-23 1995-08-29 Cca Inc. Method of producing patterned shaped article
FR2722223A1 (fr) * 1994-07-06 1996-01-12 Daussan & Co Article moule pour la protection anti-feu
WO2011082501A1 (fr) * 2010-01-05 2011-07-14 Beuchat, Barros & Pfenniger Procédé de fabrication de panneaux de cloison de type sandwich, panneau ainsi obtenu selon ledit procédé, ainsi que son montage dans un système de construction
FR2962462A1 (fr) * 2010-07-09 2012-01-13 Lamoureux Ricciotti Ingenierie Panneau isolant pour l'execution de parois de batiment et son procede de fabrication
WO2013010545A1 (fr) * 2011-07-19 2013-01-24 Connovate Aps Procédé de fabrication d'un élément en béton de haute résistance isolé complet ayant une excellente surface, et élément en béton de haute résistance fabriqué par ledit procédé
WO2015121762A3 (fr) * 2014-02-14 2015-11-26 Moser Johann Eduard Panneaux de construction structuraux préfabriqués et assemblages associés
CN108372579A (zh) * 2017-11-28 2018-08-07 同济大学 一种装配式水泥混凝土铺面板模具
CN114045977A (zh) * 2021-10-21 2022-02-15 浙江省送变电工程有限公司 一种uhpc大模块集成外墙板及其安装结构和制造方法

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1984001402A1 (fr) * 1982-10-05 1984-04-12 Pool Fabrications Singapore Pt Organes structuraux
DE3901937A1 (de) * 1989-01-24 1990-07-26 Hoechst Ag Selbsttragendes fassadenelement in sandwichbauweise

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR1048938A (fr) * 1950-11-23 1953-12-24 Structures ou éléments de construction porteurs exerçant un effet d'écran ou isolant
FR1440381A (fr) * 1965-06-29 1966-05-27 Nouveaux panneaux de construction préfabriqués en ciment armé
FR2294291A1 (fr) * 1974-12-09 1976-07-09 Piazza Matthez Module de construction composite

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR1048938A (fr) * 1950-11-23 1953-12-24 Structures ou éléments de construction porteurs exerçant un effet d'écran ou isolant
FR1440381A (fr) * 1965-06-29 1966-05-27 Nouveaux panneaux de construction préfabriqués en ciment armé
FR2294291A1 (fr) * 1974-12-09 1976-07-09 Piazza Matthez Module de construction composite

Cited By (21)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2223520B (en) * 1988-08-15 1993-07-21 Lei Pan A roofing product
GB2223520A (en) * 1988-08-15 1990-04-11 Pan Lei Pan Insulated roofing panel
EP0392610A2 (fr) * 1989-04-10 1990-10-17 Bruce Harrington Unités de mur pour la construction de bâtiments
EP0392610A3 (fr) * 1989-04-10 1991-09-04 Bruce Harrington Unités de mur pour la construction de bâtiments
EP0473383A2 (fr) * 1990-08-27 1992-03-04 Cca Inc. Méthode pour la fabrication d'objets moulés avec motifs
US5376321A (en) * 1990-08-27 1994-12-27 Cca Inc. Method of producing patterned shaped article
EP0473383A3 (en) * 1990-08-27 1992-08-26 Cca Inc. Method of producing patterned shaped article
US5368791A (en) * 1990-10-01 1994-11-29 Cca Inc. Method of producing patterned shaped article
EP0479512A3 (en) * 1990-10-01 1992-09-02 Cca Inc. Method of producing patterned shaped article
EP0479512A2 (fr) * 1990-10-01 1992-04-08 Cca Inc. Procédé de fabrication d'un élément moulé comportant un motif
US5445772A (en) * 1991-05-23 1995-08-29 Cca Inc. Method of producing patterned shaped article
FR2698392A1 (fr) * 1992-11-23 1994-05-27 Saret Procédé et installation de fixation d'une plaque isolante sur un élément préfabriqué en béton et élément isolé obtenu par ce procédé.
WO1994015037A1 (fr) * 1992-12-18 1994-07-07 Thor Joergen Element de plancher et son procede de fabrication
WO1996001347A1 (fr) * 1994-07-06 1996-01-18 Daussan Et Compagnie Article moule pour la protection anti-feu
FR2722223A1 (fr) * 1994-07-06 1996-01-12 Daussan & Co Article moule pour la protection anti-feu
WO2011082501A1 (fr) * 2010-01-05 2011-07-14 Beuchat, Barros & Pfenniger Procédé de fabrication de panneaux de cloison de type sandwich, panneau ainsi obtenu selon ledit procédé, ainsi que son montage dans un système de construction
FR2962462A1 (fr) * 2010-07-09 2012-01-13 Lamoureux Ricciotti Ingenierie Panneau isolant pour l'execution de parois de batiment et son procede de fabrication
WO2013010545A1 (fr) * 2011-07-19 2013-01-24 Connovate Aps Procédé de fabrication d'un élément en béton de haute résistance isolé complet ayant une excellente surface, et élément en béton de haute résistance fabriqué par ledit procédé
WO2015121762A3 (fr) * 2014-02-14 2015-11-26 Moser Johann Eduard Panneaux de construction structuraux préfabriqués et assemblages associés
CN108372579A (zh) * 2017-11-28 2018-08-07 同济大学 一种装配式水泥混凝土铺面板模具
CN114045977A (zh) * 2021-10-21 2022-02-15 浙江省送变电工程有限公司 一种uhpc大模块集成外墙板及其安装结构和制造方法

Also Published As

Publication number Publication date
AU520177B2 (en) 1982-01-21
AU3881978A (en) 1980-02-14

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