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
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
  • B32B13/02—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material with fibres or particles being present as additives in the layer
• • 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
  • B28B1/52—Producing shaped prefabricated articles from the material specially adapted for producing articles from mixtures containing fibres, e.g. asbestos cement
• • 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
  • B28B13/00—Feeding the unshaped material to moulds or apparatus for producing shaped articles; Discharging shaped articles from such moulds or apparatus
  • B28B13/02—Feeding the unshaped material to moulds or apparatus for producing shaped 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
  • B28B19/00—Machines or methods for applying the material to surfaces to form a permanent layer thereon
  • B28B19/0015—Machines or methods for applying the material to surfaces to form a permanent layer thereon on multilayered 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
  • 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
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
  • B32B13/04—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material comprising such water setting substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
• • 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
  • E04C2/10—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 wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
  • E04C2/24—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 wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products laminated and composed of materials covered by two or more of groups E04C2/12, E04C2/16, E04C2/20
  • E04C2/246—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 wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products laminated and composed of materials covered by two or more of groups E04C2/12, E04C2/16, E04C2/20 combinations of materials fully covered by E04C2/16 and E04C2/20
• • 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
• • 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
  • E04C2/296—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 non-metallic or unspecified sheet-material
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2307/00—Properties of the layers or laminate
  • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
  • B32B2307/558—Impact strength, toughness
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2307/00—Properties of the layers or laminate
  • B32B2307/70—Other properties
  • B32B2307/718—Weight, e.g. weight per square meter
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2315/00—Other materials containing non-metallic inorganic compounds not provided for in groups B32B2311/00 - B32B2313/04
  • B32B2315/14—Mineral wool
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2607/00—Walls, panels

Definitions

• the present invention relates to a composite wall panel with outer sides of concrete and with intermediate insulating material.
• Wall panels made of reinforced concrete, now in use usually consist of two, at least five centimetres thick reinforced concrete layers with intermediate insulating material. A layer thickness of at least five centimetres is required for the concrete to give sufficient protection of the reinforcement, since if the reinforcing steel starts to rust, it will expand and may break the concrete layers. Concrete panels with a thickness of five centimetres are comparatively heavy; the density is about 2.4, and the panels therefore have to be mechanically connected to each other.
• One object of the invention is to produce wall panels, which are less heavy and have better thermal and sound isolating properties than previously known wall panels. The wall panels according to the invention also become more easy to handle than the previously known panels.
• the wall panels are produced from two thin panels of concrete reinforced with oriented fibres and intermediate insulating material, preferably of mineral wool.
• the concrete sides are fixed by the steel fibres at the intermediate insulating material layer, forming a sandwich construction.
• the comparatively thin concrete sides and the intermediate, comparatively thick insulating material provide a very good sound-proofing and thermal insulation.
• the panels according to the invention thus consist of two thin fibre concrete panels with intermediate insulating material, such as mineral wool or cellular plastic.
• intermediate insulating material such as mineral wool or cellular plastic.
• the panels need not be structural elements, but instead the inherent strength of the thin concrete panels is quite sufficient, and the elements thus will be light.
• the bracing only are made of fibre concrete, which fact, however, need not increase the weight of the panels with more than 20 - 22 kg/m 2 .
• the invention is characterized in that very thin fibre concrete panels are cast together with intermediate insulating material into strengthwise cooperating and very light wall panels, and in that a mixture of steel fibres and plastic fibres in the concrete attach to the insulating layer, when the form is vibrated.
• the mixture of oriented steel fibres and plastic fibres enhances the resistance of the concrete panels against blows and gives a more ductile rupture.
• the plastic fibres preferably polypropylene, prevent micro cracks from forming in the panels and prevent the steel fibres from sedimentation when vibrating the casting form.
• the plastic fibres are the only reinforcement in the outmost 5 millimetres, which are kept free of steel fibres in order to prevent rust outbursts.
• the invention also comprises a new method of quick and economical orientation of the fibres in the desired directions without any slow manual processing.
• the strength of the final products can be varied within wide limits depending on the intended use by the fact that larger or smaller fibre amounts quickly can change into orientations in different directions so that the desired properties are best obtained.
• the properties can also be varied in different ways by using different blends of different kinds of fibres.
• the fibres are oriented in a concrete panel by vibrating the concrete material during the casting.
• the fibres are mixed into the concrete mass by stirring, and by performing the vibration according to the invention, during the casting the fibres will orient in the direction of the movement of the mass.
• the orientation so that e.g. 40 % of the fibres are brought to orient themselves in about the direction of movement of the mass, and part thereof, e.g. 20 %, in the cross direction, with the remaining fibres scattered in different directions, a high strength in all directions is obtained with the highest strength in the longitudinal direction, a good unity and a minium of crack formation, is obtained.
• suitable amounts of steel fibres are between 1 and 1.5 % by volume, and of plastic fibres, 0.1 - 1 % by volume, preferably between 0.2 and 0.5 % by volume.
• Suitable sizes of the steel fibres are a length of 25 - 40 millimetres and a diameter 0.3 - 0.4 millimetres, and suitable sizes of the plastic fibres are a length of 6 - 12 millimetres and a diameter of 35 - 200 microns. The sizes are approximate, and can be allowed to vary depending on the manufacture technique, and so can the form of the fibres.
• the plastic fibres may for example be square or ribbon formed.
• the fibre concrete advantageously contains 300 - 400 kg/m 3 of cement with a particle size ⁇ 5, preferably ⁇ 3 millimetres, and 1.2 - 1.5 % by volume of steel fibres and 0.2 - 1.0 % by volume of polypropylene fibres.
• a concrete mass was formed with a particle size ⁇ 3 millimetres and a cement content of 400 kg/m 3 and an addition of 1.2 % by volume of steel fibres having a length of 25 millimetres and a diameter of 0.3 millimetres, and 0.3 % by volume of polypropylene fibres having a length of 6 millimetres and a diameter of 35 - 200 microns.
• the flow over the output feeder 5 and the guide rails 8 orients the fibres, whereby the length of the output feeder also affects the degree of orientation.
• the flow velocity may be increased or reduced by changing the inclination angle of the output feeder, as is shown with the dashed lines of the output feeder 12 and the wiper 13, whereby the height of the casting table 7 can be changed correspondingly.
• the guide rails 8 control the flow along the output feeder plane the degree of orientation is increased.
• the flow velocity and the vibration effect are variable and are controlled with control means.
• the degree of orientation increases at lower flow velocity and higher vibration effect.
• the longitudinal movement of the laying-out carriage can be varied continuously from 0 to 17.4 m/min and its cross movement between 0.75 and 3.0 m/min.
• the cross movement is used in casting of concrete panels being wider than the output feeder in order to lay out an even layer over the whole surface of the casting table.
• the more coarse and heavy fibres such as steel fibres, are oriented more easy than the thinner and lighter plastic fibres, such as polypropylene fibres, which demand a longer orientation distance, i.e. a longer output feeder or smaller inclination of the output feeder.
• the most suitable degree of orientation has to be tested out empirically and is affected by the consistency of the concrete, the fibre concentration, the type of fibres used and the composition of said fibre mixtures.
• thin panels of concrete can be produced with as good properties as the earlier eternite panels, and also panels with better properties than those most frequently used today, that is the plaster panels which are fragile and sensitive to moisture. Further, thicker panels, 5 centimetres or more, can be produced for use as partition walls, alone, or for outer walls and structural wall elements.
• outer panels of the wall panel according to the invention are manufactured according to the above described method and with the means for the orientation of the fibres, and will be described more in detail with an example and with reference to Fig. 2.
• the intended inner panel 20 was cast with a thickness of 15 millimetres and with a reinforcement of 1.2 % by volume of steel fibres and 0.3 % by volume of polypropylene fibres.
• Insulating material 21 was place on the panel, consisting of 20 centimetres of mineral wool, and on the insulating material the outer panel 22, 23 was cast, with a thickness of 2 centimetres, whereby firstly, a 1.5 centimetres thick layer 22 was cast in the same way as the inner panel, and thereupon an upper, 5 millimetres thick layer 23 was cast, containing only polypropylene fibres as a reinforcement.
• a wall panel with the width of 2.4 meters and the height of 3.0 metres was loaded with a pressure force of 114 kN, corresponding to 3 times the normal load in an actual case. No important deformations could be observed under the influence of the load, and the break load thus lie substantially higher.
• the fibre reinforcement makes it suitable also to substitute conventional concrete for high strength concrete with a compressive strength of 80 to 120 MPa.
• the bending moment was 14.6 kNm/m. In comparison thereto, the bending moment at normal wind load is 0.36 kNm/m, i.e. 1/40 of the bending moment at the test.
• This stiffness of the element depends on that the outer panel and the inner panel cooperates through shear stresses in the insulating material.
• the maximum shear stress at the test load can be calculated to 158 kPa, which is substantially higher than the values obtained in clean shear tests according to the above. Fire and load tests have also been performed, and the panels were shown to have a separating and structural function for 120 minutes, corresponding to fire class 120 A.

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• Engineering & Computer Science (AREA)
• Architecture (AREA)
• Structural Engineering (AREA)
• Chemical & Material Sciences (AREA)
• Ceramic Engineering (AREA)
• Mechanical Engineering (AREA)
• Civil Engineering (AREA)
• Manufacturing & Machinery (AREA)
• Life Sciences & Earth Sciences (AREA)
• Wood Science & Technology (AREA)
• Curing Cements, Concrete, And Artificial Stone (AREA)
• Panels For Use In Building Construction (AREA)

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Publications (1)

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• 1993
  • 1993-06-10 EP EP93913747A patent/EP0648303A1/en not_active Withdrawn
  • 1993-06-10 AU AU43669/93A patent/AU4366993A/en not_active Abandoned
  • 1993-06-10 WO PCT/SE1993/000518 patent/WO1993025778A1/en not_active Application Discontinuation
  • 1993-06-10 CA CA002138375A patent/CA2138375A1/en not_active Abandoned
  • 1993-06-16 CN CN93109027A patent/CN1051351C/zh not_active Expired - Fee Related
• 1994
  • 1994-12-16 KR KR1019940704604A patent/KR950702267A/ko not_active Application Discontinuation

Non-Patent Citations (1)

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