Classifications

• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
  • E04B5/00—Floors; Floor construction with regard to insulation; Connections specially adapted therefor
• • 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
  • B28B23/00—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
  • B28B23/0062—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects forcing the elements into the cast material, e.g. hooks into cast concrete
• • 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
  • B28B23/00—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
  • B28B23/0075—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects for decorative purposes
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
  • E04B5/00—Floors; Floor construction with regard to insulation; Connections specially adapted therefor
  • E04B5/02—Load-carrying floor structures formed substantially of prefabricated units
  • E04B5/04—Load-carrying floor structures formed substantially of prefabricated units with beams or slabs of concrete or other stone-like material, e.g. asbestos cement
• • 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

Definitions

• the invention relates to a method of manufacturing an insulated concrete element according to the preamble of Claim 1, and a concrete element manufactured according to said method, of the type disclosed in the preamble of Claim 9.
• Insulated concrete elements of conventional type for example for outer walls, supporting inner walls or floors, are normally made as sandwich elements consisting of two concrete layers interconnected by reinforcement ladders.
• the inner layer is a supporting layer and the outer layer serves as a wall covering.
• Sandwich elements are as a rule one storey high but are also made as spandrel elements or in even larger dimensions, e.g. for use in industrial structures. It is also possible to prehang the windows and doors at the factory, so that the climate shell of the building will be complete as soon as the wall elements are mounted in place. Experience has shown that damage to such premounted windows during transport and assembly is quite rare. The mounting of hardware can also be completed at the factory.
• the wall element can also be cast with spaces for plumbing, electrical and telephone installations.
• the connections between the different wall portions are easily done as is the sealing for fire and noise protection.
• the inside can be made smooth so that it can be painted with a minimum of preparation.
• the outside can be made with various structures and surface treatments.
• the manufacture of a conventional wall element comprises the following steps:
• Form oil is applied to a table form and stop ends are mounted in place to define the surfaces of the element.
• the reinforcement is then prepared and placed on the table form and a first casting of a first concrete layer is done.
• the reinforcement comprises a welded mesh in which reinforcement ladders are tied securely with a predetermined spacing.
• insulation in the form of hard mineral wool is supplied onto the first concrete layer between the ladders and a welded mesh is tied to the reinforcing ladders on top of the layer of insula ⁇ tion.
• the second concrete layer is cast directly on the mineral wall or, alternatively, the entire package, with the first concrete layer, the mineral wall and the second welded mesh, is lifted by a lifting means, is turned over and is emersed in wet concrete in the table form. Any wall surface treatment necessary is done thereon, and the element is then ready for delivery.
• the wall surface treatment can include rolling or raking or the form can be coated before casting with a so-called retarder to delay hardening of the surface layer itself, so that a portion of the material can be washed off to partially expose the aggregate.
• the conventional concrete or wall element thus has a number of major disadvantages, it being heavy and difficult to handle, and gives rise to unnecessarily thick walls in addition to being time-consuming and complicated in manufacture and thus costly.
• the purpose of the present invention is therefore to define a method of manufacturing a concrete element which has the good properties of the sandwich element but in which the above indicated disadvantages have been removed, and a concrete element manufactured according to said method.
• the prefabricated structure will have the appearance of a building built completely at the site. There are no external joints, which present both technical and aesthetic problems.
• the required profiling can be optimized with high precision, e.g. as regards the thickness of the insulation and the joints, and combined lifting eyes/anchoring means can be cast into each element with exact placement and orientation.
• the anchoring means can, for example, be cast into the adjacent floor structure, which is cast on site.
• Prefabricated concrete elements according to the invention are preferable for environmental reasons as wells, since spackling is eliminated which can induce allergies, as well as sanding dust which is created when the casting joints are sanded off on the outside concrete element. Compared with walls cast on site, no time- consuming plugging of form tie holes is required.
• Base plastering can be done at the factory, which provides uniform high quality.
• the manufacture of a concrete element according to the invention is done initially in the same manner as accord- ing to the conventional technology, up to the application of cement for casting the first concrete layer.
• some kind of fastening device must be used between the insulation and the concrete sheet.
• sheets of insulation as moulds for reinforcing ridges and pressing the sheets into a mould provided with reinforcement and filled with fresh concrete produces, when the concrete has hardened, a concrete element with a smooth concrete surface and insulation securely cast thereto.
• Each sheet of insulation is suitably cut out so that at least one recess with a shoulder is formed adjacent to each of two opposite edges of the sheet.
• each insulating sheet is made with tightly spaced grooves over the entire surface of the sheet, forming relatively shallow channels relative to the recesses.
• the concrete penetrates into the channels and is caused to fill them up completely by vibrating the concrete. . Any enclosed air will exit through the gaps between the sheets or through the insulation material itself.
• a concrete slab is obtained with concrete ridges which are, as the case may be, dovetail-shaped, T-shaped or rectangular, said ridges fitting into corresponding dovetail-shaped, T-shaped or rectangular channels in the insulation material.
• Each of these concrete ridges serves as an anchoring means for the insulation.
• each shoulder is made so that the channel formed by two adjacent shoulders has in cross-section a greater width in its inner portion than in its outer portion. This assures secure anchoring of the insulation in the concrete.
• the cross-section of the channel can be either dovetailed or T-shaped.
• a dovetail channel is provided by sawing the recess out at a suitable angle.
• the T-shape is achieved by routing out a groove in the recess adjacent to and parallel to the shoulder forming the bottom of the channel.
• Fig. 1 shows insulation consisting of a group of sheets of insulation lying adjacent to each other
• Fig. 2 shows a mould provided with reinforcing ladders and filled with reinforced concrete
• Fig. 3 shows the mould according to Fig. 2 in cross- section along the line A-A
• Fig. 4 shows a hydraulic pressing means disposed on the mould
• Fig. 5 shows a finished concrete element
• Fig. 6 shows a concrete element covered with stone, said element having dovetailed channel
• Fig. 7 shows a concrete element covered with wood, which has channels with straight parallel lateral surfaces
• Fig. 8 shows a concrete element with a plaster front, said element having channels with T-shaped cross-section
• Fig. 9 shows a supporting inner wall in section, having a core of insulation with channels on alternating sides
• Fig. 10 shows in section the construction of outer wall elements at a joint between two elements and a concrete floor structure
• Fig. 11 shows a portion of an insulation sheet which has a channel with a U-shaped cross-section.
• a concrete element 2 is dimensioned according to applicable specifications as regards supporting function, insulation, fire protection, noise insulation and any specific functional requirements. Control plans and check lists for the product are established.
• the element 2 is built up essentially of an insulation block 4 and a reinforced concrete layer 6 which are joined together by openings 8 in the insulation block, said openings surrounding anchoring ridges 10.
• the insulation block is composed of insulation sheets 12, preferably of cellular plastic, provided at adjacent facing edges with recesses 14 and shoulders 16. When the insulation sheets are joined together into an insulation block along a joint line 18 located between adjacent sheets, the recesses and shoulders of the adjacent insulation sheets form channels 20.
• channels 20 with varying cross-sections can be formed, dove-tailed, T-shaped or U-shaped cross-sections being preferable.
• the channels 20 are suitably made by sawing out or routing out the recesses 14 and shoulders 16, the defining surfaces of the channels 20 being roughened up thereby and having a rough surface layer with many small projections 22. Ordinary sawing can provide a positive grip depending on the structure which is produced in the saw-cut.
• a casting mould 24 of steel is cleaned and oiled. Stop ends (not shown) are set in place to limit the outer dimensions of the element.
• the mould has a mould edge 26 at either end.
• a prefabricated mould for doors or windows is fixed as needed with magnets (not shown) .
• Electrical boxes and smaller com- ponents to be cast in the concrete are fixed with hot melt adhesive, for example.
• a prefabricated reinforcement cage comprising spacers and reinforcement ladders 28 which are known per se is placed in the mould and is fixed therein.
• the reinforcement ladders are oriented as shown in Figs. 2 and 3 with a spacing which is adapted to the corresponding spacing between the channels in the insulation sheets or which agrees with the outer dimen ⁇ sions of the sheets.
• the insulation sheets 12 are pre ⁇ pared as specified above and the mould 24 is filled with a calculated amount of fresh concrete which is prelimina ⁇ rily smoothed off.
• the insulation block 4 is placed above the concrete in the form with the aid of a lifting and
• the element is achieved.
• the concrete is vibrated by means of conventional vibrators arranged in the mould. This causes the concrete to penetrate into each groove or channel 20 and the vibration is terminated only when no further sinking of the insulation block is noticed and the intended thickness of the element has been achieved.
• the concrete should then have been pressed up along the outer edges and thus fill out the entire space under the insulation.
• the lifting and pressing means 30 are removed from the casting mould 24, which is transferred to a hardening chamber (not shown) , in which the concrete is quickly hardened by using the released heat of the reaction, which as a rule is sufficient to maintain a continuous temperature of about 40°C.
• the mould is removed from the hardening chamber and the finished element 2 is removed from the mould.
• a wall covering 50 is applied to the outside of the concrete element.
• Alternative wall coverings are brick, wood or plaster.
• a brick siding 50 is fixed to the concrete element by means of wall ties 52 cast into each anchoring ridge 10 and which anchor the brick siding in a known manner (Fig. 6).
• a wooden siding 50 is fixed to braces 54 cast in the concrete in a corresponding manner (Fig. 7).
• Plastering is done with the aid of a track-mounted plastering roller of conventional type which provides a good plaster undercoating. With the aid of a conventional vibrator beam, the plaster is vibrated in place in the right thickness.
• a mesh reinforcement may be pressed down to about half of the thickness of the plaster and the plaster 50 be smoothed off by means of an angled steel blade (Fig. 8).
• the element is inspected and then placed upright on a transport pallet.
• a surface finish which is ready for painting is obtained at the same time on the side of the concrete facing the inside of the structure, even including window reveals and the like.
• the plaster layer applied directly to the outside of the insulation sheet or onto a plaster carrying mesh is elastic and is able thereby to absorb stresses arising through temperature variations, thus making possible a plaster wall covering which is free from joints.

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• Engineering & Computer Science (AREA)
• Architecture (AREA)
• Structural Engineering (AREA)
• Civil Engineering (AREA)
• Physics & Mathematics (AREA)
• Mechanical Engineering (AREA)
• Ceramic Engineering (AREA)
• Chemical & Material Sciences (AREA)
• Manufacturing & Machinery (AREA)
• Electromagnetism (AREA)
• Building Environments (AREA)
• Manufacturing Of Tubular Articles Or Embedded Moulded Articles (AREA)
• Panels For Use In Building Construction (AREA)
• Adornments (AREA)
• Compositions Of Oxide Ceramics (AREA)
• Curing Cements, Concrete, And Artificial Stone (AREA)

Applications Claiming Priority (3)

Publications (1)

Family

ID=26661214

Family Applications (1)

Country Status (6)

Cited By (1)

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Family Cites Families (5)

• 1991
  • 1991-10-18 SE SE9103042A patent/SE9103042D0/ unknown
• 1992
  • 1992-10-15 SE SE9203033A patent/SE501752C2/sv not_active IP Right Cessation
• 1993
  • 1993-03-30 EP EP93910488A patent/EP0692050A1/de not_active Ceased
  • 1993-03-30 AU AU40959/93A patent/AU4095993A/en not_active Abandoned
  • 1993-03-30 WO PCT/SE1993/000268 patent/WO1994023143A1/en not_active Application Discontinuation
• 1995
  • 1995-09-28 NO NO19953848A patent/NO311773B1/no not_active IP Right Cessation
  • 1995-09-29 FI FI954633A patent/FI954633A0/fi unknown

Non-Patent Citations (1)

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