EP1292742B1 - Building panel, in particular for floors, walls or ceilings, with a reinforcing mesh embedded in a concrete slab and method of forming the same - Google Patents

Building panel, in particular for floors, walls or ceilings, with a reinforcing mesh embedded in a concrete slab and method of forming the same Download PDF

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Publication number
EP1292742B1
EP1292742B1 EP01945467A EP01945467A EP1292742B1 EP 1292742 B1 EP1292742 B1 EP 1292742B1 EP 01945467 A EP01945467 A EP 01945467A EP 01945467 A EP01945467 A EP 01945467A EP 1292742 B1 EP1292742 B1 EP 1292742B1
Authority
EP
European Patent Office
Prior art keywords
concrete
panel
reinforcing mesh
slab
wire rods
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.)
Expired - Lifetime
Application number
EP01945467A
Other languages
German (de)
French (fr)
Other versions
EP1292742A1 (en
Inventor
Michael Barrie Kemp
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 EP1292742A1 publication Critical patent/EP1292742A1/en
Application granted granted Critical
Publication of EP1292742B1 publication Critical patent/EP1292742B1/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E04F13/14—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements stone or stone-like materials, e.g. ceramics concrete; of glass or with an outer layer of stone or stone-like materials or glass
    • E04F13/141—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements stone or stone-like materials, e.g. ceramics concrete; of glass or with an outer layer of stone or stone-like materials or glass with an outer layer of concrete
    • E—FIXED CONSTRUCTIONS
    • E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
    • E01C—CONSTRUCTION OF, OR SURFACES FOR, ROADS, SPORTS GROUNDS, OR THE LIKE; MACHINES OR AUXILIARY TOOLS FOR CONSTRUCTION OR REPAIR
    • E01C5/00—Pavings made of prefabricated single units
    • E01C5/06—Pavings made of prefabricated single units made of units with cement or like binders
    • E01C5/08—Reinforced units with steel frames
    • 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
    • E04C2/06—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 reinforced
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C5/00—Reinforcing elements, e.g. for concrete; Auxiliary elements therefor
    • E04C5/01—Reinforcing elements of metal, e.g. with non-structural coatings
    • E04C5/02—Reinforcing elements of metal, e.g. with non-structural coatings of low bending resistance
    • E04C5/04—Mats
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/024—Sectional false floors, e.g. computer floors
    • E04F15/02405—Floor panels
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/08—Flooring or floor layers composed of a number of similar elements only of stone or stone-like material, e.g. ceramics, concrete; of glass or with a top layer of stone or stone-like material, e.g. ceramics, concrete or glass

Definitions

  • the present invention relates to a building panel having a reinforcing mesh formed of wire rods welded together, the reinforcing mesh being embedded in a concrete slab and a method of forming such building panel.
  • Examples of building panels having a reinforcing mesh formed of wire rods welded together bedded in a concrete slab are to be found in, for example, DE 3113469A and EP A0145247 .
  • a building panel having a reinforcing mesh formed of feat plates welded together bedded in a concrete slab describes in CH356574A .
  • Type (a) when type (a) is cut, this can result in the filling falling out thus reducing its load bearing capability.
  • Type (b) suffers from the effects of moisture on the chipboard core and requires dry site conditions for installation. Further, the edges of the panels have to be covered after they are cut to comply with fire ratings. The metal on both panels can also be affected by moisture which causes corrosion. If corrosion goes undetected, the panels may become unsafe, being susceptible to collapse.
  • An objective of the invention is to overcome these disadvantages. Another objective is to improve the strength of the aforementionned buildingpanelasknown from EP 0 145 247 A .
  • the invention provides a panel as defined in claim 1.
  • the concrete slab is formed by pressing a mix including particles of a range of sizes under high pressure so that the resulting slab is dense and generally homogenous.
  • the wire mesh used in the invention is of the kind described, for instance, in GB 2299100 .
  • the invention provides a method of forming such a building panel as defined in claim 8, using a mix including particles of a range of sizes to make the concrete and forming the reinforcing mesh and concrete into a slab by pressing under high pressure, so that the resulting slab is dense and generally homogenous.
  • the panel of the invention is particularly strong and no other reinforced concrete panel currently available can be manufactured to be as thin as that of the invention, while giving the same structural strength.
  • the strength of the finished panel can be chosen to suit the particular application for which it is intended.
  • the panel of the invention is not affected by moisture or corrosion because, once formed it is of similar material to the fabric of the building construction in which it is installed. As it is not affected by moisture or corrosion, the panel can be installed in any climate or in buildings subject to all kinds of inclement weather conditions.
  • the panel of the invention is also advantageous in that there is no need for a separate bonding finish to be applied to the panels; the finish is, in effect, part of the manufacturing process. Further, a number of different finishes giving differing aesthetic effects are possible. For example, the panels may be finished so as to mimic granite, marble, stone or a terrazzo finish.
  • the panel of the invention is suited to flooring applications and is particularly useful in place of some known floor constructions.
  • block and beam floors use precast beams and lightweight blocks which are then reinforced by means of an overlaid cement screed.
  • the panel of the invention can be used in place of the lightweight blocks to provide a finished floor without the need for separate reinforcement or a cement screed and, hence, without the need for wet works on site.
  • a heavier grade of panel in accordance with the invention can be used in open concourse areas in railway stations and airport terminals and in shopping malls and superstores. In all of these locations, traditionally flooring has been in the form of large amounts of terrazzo set in a cement bed to provide a hard-wearing surface.
  • hard-wearing floors can be provided using the panel of the invention but with the added advantage that panels can easily be lifted to provide access to service conduits and the like below the floor.
  • the panel of the invention is particularly suited to use in flooring applications, it can also be used for curtain walling or partitioning where a robust, versatile finish is required, for example in railway stations or in other similar public-use locations.
  • the panel comprises a steel reinforcement mesh core, embedded in a concrete mixture.
  • the mesh and concrete are placed in a mould and then placed in a multistage press.
  • the steel reinforcement mesh core is formed of a lattice of wire rods which are welded together.
  • the wire rods each have at least one flat face and the rods are welded together with the flat faces of the rods abutting one another, so that contact between the wire rods occurs over an area.
  • Wire mesh of this kind which is described in, for example, published United Kingdom patent application GB 2299100 , has considerably enhanced weld shear strength.
  • the concrete mixture in which the mesh is embedded is specially formulated to be homogeneous. It is made using a range of particles from sizes from 10mm down to Fines so that the resulting concrete is very dense and of very high strength when cured.
  • the concrete mix is placed in a high pressure press and the reinforcing mesh is then laid over it. Pressure is applied using the press to force the mesh into the concrete mix and to drive out water. Under pressure the component parts are driven together and the chemical reaction within the concrete mix bonds the concrete into a solid slab which grips the reinforcing mesh.
  • the pressure applied is generally greater than 450 tons per square inch, producing a concrete of more than 70 Newtons.
  • the dimensions of the panel may, typically, be 600x600 mm square by 20mm to 50mm in depth depending on the required loading.
  • the panel can be supplied unfinished or can have a number of aggregates applied into the top surface during the production process, for example, marble chippings which may then polished to give a terrazzo finish.
  • the panels will be supported on each corner by either steel pedestals or on concrete blocks.
  • the panels are sufficiently strong and rigid to support the necessary loading when supported in this way.
  • the panel of the invention can also be supported on a pre-cast concrete beam for many uses.
  • the high structural strength of the panel makes it ideal for use in constructing block and beam foundation over sites of buildings by replacing the slab with prefabricated panels in accordance with the invention. This eliminates the need for large quantities of wet concrete and aggregates used to consolidate the base of a building.
  • the panel can also be used to replace the large areas of terrazzo floors which have to be set in a cement bed.
  • the panel described above can be suspended to give a working area for services in the void below the floor. Because individual panels can easily be lifted, the need for costly removal of traditional terrazzo floor when modifications are required can be avoided, saving a considerable amount of time and money. Further if an area of floor is damaged, individual panels can easily be replaced.
  • the panel of the invention is easily cut and shaped, providing flexibility as to floor and wall shapes and is not susceptible to harsh conditions, enabling it to last as long as solid stone or marble products.

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Floor Finish (AREA)
  • Panels For Use In Building Construction (AREA)
  • Reinforcement Elements For Buildings (AREA)
  • Manufacturing Of Tubular Articles Or Embedded Moulded Articles (AREA)

Abstract

A building panel has a reinforcing mesh embedded in a concrete slab formed by pressing. The reinforcing mesh is formed of wire rods each of which has at least one flat face. The rods are welded together with the flat faces of the rods abutting one another so that contact between the wire rods occurs over an area. Wire mesh of this kind has considerably enhanced weld shear strength. The panels are formed by pressing so that the concrete mix becomes dense and generally homogeneous. The high structural strength of such panels makes them ideal for use in constructing block and beam foundations and for use in walls, ceilings and flooring.

Description

  • The present invention relates to a building panel having a reinforcing mesh formed of wire rods welded together, the reinforcing mesh being embedded in a concrete slab and a method of forming such building panel. Examples of building panels having a reinforcing mesh formed of wire rods welded together bedded in a concrete slab are to be found in, for example, DE 3113469A and EP A0145247 .
  • A building panel having a reinforcing mesh formed of feat plates welded together bedded in a concrete slab describes in CH356574A .
  • In modern buildings, it is frequently the case that services, electrical cabling, data cabling, and the like, have to be provided over a wide area of the building without trailing cables forming a health hazard when power, data or the like are to be provided to points in the middle of floor areas. One preferred way of dealing with these needs is to provide a raised floor with a cavity below, in which services can be concealed. Either the entire floor area may be composed of panels which can be lifted at will to provide access to the cavity below or removable panels may be provided at intervals in a more permanent floor construction.
  • At present, the only types of flooring panels currently on the market suitable for use in the kind of raised floor construction described above are as follows:-
    1. a) a plain or edge-profiled steel tray welded to a flat steel top plate with the interior space filled with either concrete slurry or gypsum
    2. b) a plain steel stray with a slab of chipboard inside and either a plate or a tin-tray on the top.
  • The products currently available have a number of disadvantages. For example, when type (a) is cut, this can result in the filling falling out thus reducing its load bearing capability. Type (b) suffers from the effects of moisture on the chipboard core and requires dry site conditions for installation. Further, the edges of the panels have to be covered after they are cut to comply with fire ratings. The metal on both panels can also be affected by moisture which causes corrosion. If corrosion goes undetected, the panels may become unsafe, being susceptible to collapse.
  • An objective of the invention is to overcome these disadvantages. Another objective is to improve the strength of the aforementionned buildingpanelasknown from EP 0 145 247 A .
  • In a first aspect, the invention provides a panel as defined in claim 1.
  • In the panel of the invention the concrete slab is formed by pressing a mix including particles of a range of sizes under high pressure so that the resulting slab is dense and generally homogenous. The wire mesh used in the invention is of the kind described, for instance, in GB 2299100 . In a further aspect, the invention provides a method of forming such a building panel as defined in claim 8, using a mix including particles of a range of sizes to make the concrete and forming the reinforcing mesh and concrete into a slab by pressing under high pressure, so that the resulting slab is dense and generally homogenous.
  • The panel of the invention is particularly strong and no other reinforced concrete panel currently available can be manufactured to be as thin as that of the invention, while giving the same structural strength. The strength of the finished panel can be chosen to suit the particular application for which it is intended.
  • The panel of the invention is not affected by moisture or corrosion because, once formed it is of similar material to the fabric of the building construction in which it is installed. As it is not affected by moisture or corrosion, the panel can be installed in any climate or in buildings subject to all kinds of inclement weather conditions.
  • The panel of the invention is also advantageous in that there is no need for a separate bonding finish to be applied to the panels; the finish is, in effect, part of the manufacturing process. Further, a number of different finishes giving differing aesthetic effects are possible. For example, the panels may be finished so as to mimic granite, marble, stone or a terrazzo finish.
  • As mentioned above, the panel of the invention is suited to flooring applications and is particularly useful in place of some known floor constructions. For example, block and beam floors use precast beams and lightweight blocks which are then reinforced by means of an overlaid cement screed. The panel of the invention can be used in place of the lightweight blocks to provide a finished floor without the need for separate reinforcement or a cement screed and, hence, without the need for wet works on site.
  • A heavier grade of panel in accordance with the invention can be used in open concourse areas in railway stations and airport terminals and in shopping malls and superstores. In all of these locations, traditionally flooring has been in the form of large amounts of terrazzo set in a cement bed to provide a hard-wearing surface.
  • Similarly hard-wearing floors can be provided using the panel of the invention but with the added advantage that panels can easily be lifted to provide access to service conduits and the like below the floor.
  • Although the panel of the invention is particularly suited to use in flooring applications, it can also be used for curtain walling or partitioning where a robust, versatile finish is required, for example in railway stations or in other similar public-use locations.
  • An example of a panel in accordance with the invention will now be described in detail, by way of example.
  • The panel comprises a steel reinforcement mesh core, embedded in a concrete mixture. The mesh and concrete are placed in a mould and then placed in a multistage press.
  • The steel reinforcement mesh core, is formed of a lattice of wire rods which are welded together. The wire rods each have at least one flat face and the rods are welded together with the flat faces of the rods abutting one another, so that contact between the wire rods occurs over an area. Wire mesh of this kind, which is described in, for example, published United Kingdom patent application GB 2299100 , has considerably enhanced weld shear strength.
  • The concrete mixture in which the mesh is embedded is specially formulated to be homogeneous. It is made using a range of particles from sizes from 10mm down to Fines so that the resulting concrete is very dense and of very high strength when cured.
  • The concrete mix is placed in a high pressure press and the reinforcing mesh is then laid over it. Pressure is applied using the press to force the mesh into the concrete mix and to drive out water. Under pressure the component parts are driven together and the chemical reaction within the concrete mix bonds the concrete into a solid slab which grips the reinforcing mesh.
  • The pressure applied is generally greater than 450 tons per square inch, producing a concrete of more than 70 Newtons.
  • The dimensions of the panel may, typically, be 600x600 mm square by 20mm to 50mm in depth depending on the required loading.
  • The panel can be supplied unfinished or can have a number of aggregates applied into the top surface during the production process, for example, marble chippings which may then polished to give a terrazzo finish.
  • Typically, in a floor construction, the panels will be supported on each corner by either steel pedestals or on concrete blocks. The panels are sufficiently strong and rigid to support the necessary loading when supported in this way.
  • As mentioned above, the panel of the invention can also be supported on a pre-cast concrete beam for many uses. The high structural strength of the panel makes it ideal for use in constructing block and beam foundation over sites of buildings by replacing the slab with prefabricated panels in accordance with the invention. This eliminates the need for large quantities of wet concrete and aggregates used to consolidate the base of a building.
  • The panel can also be used to replace the large areas of terrazzo floors which have to be set in a cement bed. The panel described above can be suspended to give a working area for services in the void below the floor. Because individual panels can easily be lifted, the need for costly removal of traditional terrazzo floor when modifications are required can be avoided, saving a considerable amount of time and money. Further if an area of floor is damaged, individual panels can easily be replaced.
  • The panel of the invention is easily cut and shaped, providing flexibility as to floor and wall shapes and is not susceptible to harsh conditions, enabling it to last as long as solid stone or marble products.

Claims (10)

  1. A building panel having a reinforcing mesh formed of wire rods welded together, the reinforcing mesh being embedded in a concrete slab, characterised in that the wire rods which form the mesh each have at least one flat face and the rods being welded together with the flat faces of the rods abutting one another, so that contact between the wire rods occurs over an area; and in that the concrete slab is formed by pressing a concrete mix including particles of a range of sizes under high pressure so that the resulting slab is dense and generally homogenous.
  2. A panel according to claim 1 in which the particles range from 10mm diameter to Fines.
  3. A panel according to claim 1 or 2 in which at least one face of the concrete slab is formed with a decorative finish or coating.
  4. A floor comprising at least one panel in accordance with any of claims 1 to 3 and means for supporting the said panel at the edges and/or corners thereof.
  5. A floor according to claim 4 in which the means for supporting the panel includes at least one pre cast concrete beam.
  6. A wall comprising at least one panel according to any of claims 1 to 3.
  7. A ceiling comprising at least one panel according to any of claims 1 to 3.
  8. A method of forming a building panel comprising the steps of embedding a reinforcing mesh formed of wire rods welded together in concrete, the wire rods each having at least one flat face and being welded together with the flat faces abutting one another so that contact between the wire rods occurs over an area; using a mix including particles of a range of sizes to make the concrete and forming the reinforcing mesh and concrete into a slab by pressing under high pressure, so that the resulting slab is dense and generally homogenous.
  9. A method according to claim 8 in which the particles range in size from 10mm diameter to Fines.
  10. A method according to claim 8 or 9 further comprising forming a decorative finish or coating on at least one face of the slab.
EP01945467A 2000-06-23 2001-06-22 Building panel, in particular for floors, walls or ceilings, with a reinforcing mesh embedded in a concrete slab and method of forming the same Expired - Lifetime EP1292742B1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
GB0015491 2000-06-23
GB0015491A GB2363806B (en) 2000-06-23 2000-06-23 Improved building/flooring panel
PCT/GB2001/002798 WO2001098602A1 (en) 2000-06-23 2001-06-22 Improved building/flooring panel

Publications (2)

Publication Number Publication Date
EP1292742A1 EP1292742A1 (en) 2003-03-19
EP1292742B1 true EP1292742B1 (en) 2009-06-10

Family

ID=9894321

Family Applications (1)

Application Number Title Priority Date Filing Date
EP01945467A Expired - Lifetime EP1292742B1 (en) 2000-06-23 2001-06-22 Building panel, in particular for floors, walls or ceilings, with a reinforcing mesh embedded in a concrete slab and method of forming the same

Country Status (8)

Country Link
US (1) US20040035072A1 (en)
EP (1) EP1292742B1 (en)
JP (1) JP2004501299A (en)
AT (1) ATE433526T1 (en)
AU (1) AU2001267682A1 (en)
DE (1) DE60138950D1 (en)
GB (1) GB2363806B (en)
WO (1) WO2001098602A1 (en)

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CH358574A (en) * 1958-07-25 1961-11-30 Stampfli Joseph Component
WO1986002969A1 (en) * 1984-11-06 1986-05-22 William John Matthews Slabs for false floors

Family Cites Families (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1809870A (en) * 1927-11-16 1931-06-16 Walter F Bossert Concrete reenforcement
US1707939A (en) * 1928-08-06 1929-04-02 Leon R Mackenzie Wear course for pavements
US2372042A (en) * 1941-10-24 1945-03-20 Ralph D Yankee Concrete construction
US3121825A (en) * 1959-10-14 1964-02-18 Moroni T Abegg Electrically conductive floor covering for use in explosive hazard areas
US3822979A (en) * 1968-06-17 1974-07-09 Davy & United Eng Co Ltd Apparatus for producing pressed concrete articles
US4067156A (en) * 1976-01-12 1978-01-10 Donn Products, Inc. Computer floor structure
US4169688A (en) * 1976-03-15 1979-10-02 Sato Toshio Artificial skating-rink floor
US4259824A (en) * 1976-08-16 1981-04-07 Lopez Fred T Precast concrete modular building panel
NL7901193A (en) * 1979-02-15 1980-08-19 Bruil Arnhem Wegenbouw ARMED ROAD COATING, FOR example ASPHALATIC COAT.
DE3113469A1 (en) * 1981-04-03 1982-10-21 Stelcon International B.V., 3500 Utrecht Prefabricated reinforced-concrete panel with rectangular outline
CA1206346A (en) * 1983-11-04 1986-06-24 Richard P. Morris Concrete floor panel and floor system
US4918891A (en) * 1987-05-12 1990-04-24 U.M.C., Inc. Precast concrete foundation elements and system and method of using same
US5106227A (en) * 1989-07-25 1992-04-21 Hifh Technologies, Inc. Reinforced asphalt concrete and structure for producing same
EP0815335A1 (en) * 1995-03-18 1998-01-07 Tinsley Wire (Sheffield) Limited Wire mesh
US6426029B1 (en) * 1995-10-10 2002-07-30 Donald R. Hiscock Lamination between plastic resins and cement

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CH358574A (en) * 1958-07-25 1961-11-30 Stampfli Joseph Component
WO1986002969A1 (en) * 1984-11-06 1986-05-22 William John Matthews Slabs for false floors

Also Published As

Publication number Publication date
WO2001098602A1 (en) 2001-12-27
DE60138950D1 (en) 2009-07-23
GB2363806B (en) 2003-05-14
US20040035072A1 (en) 2004-02-26
GB2363806A (en) 2002-01-09
EP1292742A1 (en) 2003-03-19
JP2004501299A (en) 2004-01-15
AU2001267682A1 (en) 2002-01-02
ATE433526T1 (en) 2009-06-15
GB0015491D0 (en) 2000-08-16

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