EP1801303A2

EP1801303A2 - Improved building component and method for manufacturing such a building component

Info

Publication number: EP1801303A2
Application number: EP06077116A
Authority: EP
Inventors: Paul Elsa Liekens
Original assignee: Individual
Current assignee: Individual
Priority date: 2005-12-01
Filing date: 2006-11-28
Publication date: 2007-06-27
Also published as: BE1016868A3; EP1801303A3

Abstract

Improved building component in the form of a composed panel, characterised in that the above-mentioned composed panel is made in the form of a prefab panel which consists at least of a profiled metal plate (2) onto which is fixed at least a gypsum board (4) or a sheet of calcium silicate on one side and onto which is provided a layer of concrete (7) on the other side.

Description

The present invention concerns an improved building component in the form of a composed panel to apply as a floor or wall element in building constructions.
Composed constructions consisting of a profiled steelplate are already known, upon which is cast a layer of concrete on the building site.
A disadvantage of such known constructions is that they are manufactured on the building site, i.e. mostly in open air, subject to all types of weather conditions, as a result of which parameters such as dampness, temperature and the like cannot be controlled.
Another disadvantage of such known constructions is that their manufacturing on the building site is relatively time-consuming, among others due to varying weather conditions, and that it is not possible to guarantee much precision and dimensional stability; moreover, the duration of the building activities is considerably extended.
Another additional disadvantage of such known constructions is that, also after they have been put in place, they require considerable finishing operations, since they must be plastered, which is very time-consuming, especially when these constructions serve as a floor element which also forms the ceiling of an underlying storey.
The present invention aims to remedy one or several of the above-mentioned and other disadvantages.
To this end, the present invention concerns an improved building component in the form of a composed panel, whereby the above-mentioned composed panel is made in the form of a prefab panel which consists at least of a profiled metal plate onto which is fixed at least a gypsum board or a sheet of calcium silicate on one side and onto which is provided a layer of concrete on the other side.
According to a preferred embodiment, the above-mentioned layer of concrete can be made of lightweight concrete if necessary.
If necessary, the above-mentioned profiled metal plate can be provided, for example, with systematic indentations which make sure that the metal plate can serve as a reinforcement, such that this metal plate can absorb tensile forces.
An advantage of such an improved building component according to the invention is that it can be prefabricated under ideal conditions, whereby weather influences such as rain, hail, snow, wind and the like have no effect whatsoever on the quality, and that the production can take place in a fast, accurate manner.
Another advantage of such an improved building component is that the above-mentioned gypsum board or sheet of calcium silicate, apart from its function related to fire resistance, can serve as a finished cladding for a wall or ceiling which only needs some finishing at the circumferential edges, which makes the plasterer's work considerably easier and less time-consuming.
A major additional advantage of such an improved building component is that the element, compared to the (most advanced) conventional construction methods, saves at least 15% on self-weight, which may even increase to 25 or 30% in case of small spans of 3 to 6 meter and with average loads (500-800 kN/m²), which makes such an improved building component very easy to handle on a building site or the like.
The present invention also concerns a method for manufacturing a building component in the form of a prefab composed panel according to the invention which consists at least of a metal plate onto which is fixed at least a gypsum board or a sheet of calcium silicate on one side and onto which is cast a layer of either or not lightweight concrete on the other side, whereby this method comprises the following steps:

providing a gypsum board or a sheet of calcium silicate and a profiled metal plate in a mould;
connecting the above-mentioned gypsum board or sheet of calcium silicate to said profiled metal plate;
casting a layer of either or not lightweight concrete on the above-mentioned profiled metal plate; and
if necessary, providing a reinforcement and/or one or several crane hooks in the above-mentioned layer of concrete.

In order to better explain the characteristics of the present invention, the following preferred embodiments of an improved building component, as well as a preferred method according to the invention, are described with reference to the accompanying drawings, in which:

figure 1 schematically represents a section of an improved building component according to the invention, seen in perspective;
figure 2 represents a section in detail according to line II-II in figure 1;
figures 3 to 5 represent a method according to the invention for manufacturing an improved building component step by step;
figure 6 represents a variant according to figure 5.

Figures 1 and 2 represent an improved building component 1 according to the invention, whereby this building component 1 is what is called a 'composite building component', which consists of a composed panel which is made in the form of a prefab panel according to the invention, provided with at least one profiled metal plate 2 which in this case is made in the form of a galvanized steel plate.
In the given example, this metal plate 2 is profiled such that it has a corrugated structure over its entire length with a trapezoidal profiling 3.
In a special embodiment of a building component 1 according to the invention, the above-mentioned metal plate 2 can be further provided with one or several systematic indentations, not represented in the figures, which make sure that the metal plate 2 can serve as a reinforcement for the improved building component 1, such that this metal plate can absorb tensile forces.
Onto one side of the above-mentioned metal plate 2 is provided at least one gypsum board or a sheet of calcium silicate 4 according to the invention, in this case by means of screws 5.
For clarity's sake, we will hereafter only mention a gypsum board 4 in the description, on the understanding that also a sheet of calcium silicate could each time be applied.
It is clear that this gypsum board 4, which is preferably but not necessarily fire-resistant and/or waterproof, can also be fixed to the above-mentioned metal plate 2 in many other ways, for example by means of rivets, gluing or the like.
Thanks to the presence of the above-mentioned profilings 3 in the metal plate 2, parallel ducts 6 are formed between this metal plate 2 and the gypsum board 4.
Finally, the improved building component 1 according to the invention is also provided with a layer of concrete 7, applied on the above-mentioned metal plate 2 according to a method which will be further discussed in detail.
Preferably, but not necessarily, the above-mentioned layer of concrete 7 is made of a lightweight concrete.
As such an improved building component 1 according to the invention usually makes it possible to save at least 15% on weight compared to existing analogous constructions, it will be easy to handle on a building site or the like so as to be applied as a finished floor or wall panel.
When such a building component 1 is applied as a floor element in a building construction, the above-mentioned gypsum board 4 will form an almost entirely finished ceiling of the underlying storey of this building.
An advantage thereof is that there is a considerable gain of time, since the plasterer's work is restricted to touching up the edges of said element.
If required, the above-mentioned ducts 6 can be used to apply lines for the supply of water, gas, electricity and the like.
Moreover, places of assembly are created thanks to the presence of said ducts 6 for applying built-in spotlights in recesses in the above-mentioned gypsum board 4.
If required, after the above-mentioned building components 1 have been placed as floor panels, a compression layer can be further provided on these building components in the form of a layer of reinforced concrete which is provided on the above-mentioned layer 7 of the building component 1 on the building site, and which can possibly be anchored, for example by means of lattice girders, so as to obtain a self-supporting panel for larger spans.
A method according to the invention for manufacturing an improved building component 1 is represented step by step in figures 3 to 5.
A first step of the production process, which is represented in figure 3, consists in providing a gypsum board 4 in a mould 8 which is schematically and rudimentarily represented.
As is represented in figure 5, a profiled metal plate 2 is provided on the above-mentioned gypsum board 4.
It is clear that the above-mentioned metal plate 2 according to the invention must not be made in one piece, but that it can also be made in the shape of a number of composing metal plate parts which are provided next to each other on the gypsum board 4.
A subsequent step in the production process for manufacturing a building component 1 consists, according to the invention, in connecting the above-mentioned metal plate 2 and the gypsum board 4, which is done in this case by means of screws 5, but which can be done in many other ways according to the invention, for example by means of gluing, rivets or the like.
It is clear that, in the course of a method according to the invention, the above-mentioned gypsum board 4 and the above-mentioned metal plate 2 can also be connected to each other beforehand and can then be provided in the mould 8 together.
Finally, as represented in figure 5, a layer of concrete 7 is poured on the above-mentioned metal plate 2 in the mould 8, which is preferably, but not necessarily made of lightweight concrete.
The metal plate 2 hereby forms a partition between the wet concrete 7 and the gypsum board 4, such that any contact between the gypsum board 4 and the wet concrete 7 is avoided.
Figure 6 represents a variant according to figure 6 whereby, while the above-mentioned layer of concrete 7 is being poured, a reinforcement 9 is provided in this layer 7 which in this case is made in the shape of a steel mesh, but which can also be formed in other shapes, such as for example in the shape of a longitudinal reinforcement and/or lattice girders.
An advantage of such an embodiment of a building component 1 according to figure 6 is that the element 1 is more resistant to load and consequently less liable to shrinkage cracks.
The building component 1 can also be provided with one or several crane hooks 10 by providing these crane hooks 10, before applying the layer of concrete 7, in the mould so as to be partly cast in the concrete 7 as well.
It is clear that a building component can be provided with any random number of such crane hooks, as well as that the shape of these crane hooks can be realised in all sorts of possible existing variants.
Another advantage of such an embodiment of a building component 1 is that, thanks to the presence of crane hooks, it can be very easily handled on the building site by means of a crane or the like.
According to an embodiment which is not represented in the figures, while carrying out the method according to the invention for manufacturing an improved building component 1, a floor covering can be provided on the above-mentioned layer of concrete 7.
If this building component 1 is to serve as a two-sided visible wall element, an additional gypsum board 4 can be provided on this layer of concrete 7, such that the building component 1 is covered with a gypsum board 4 on either side which practically does not require any further finishing.
The present invention is by no means restricted to the embodiments given as an example and represented in the accompanying drawings; on the contrary, an improved building component according to the invention and a method for manufacturing it can be realised according to many variants while still remaining within the scope of the invention.

Claims

Improved building component in the form of a composed panel, characterised in that the above-mentioned composed panel is made in the form of a prefab panel which consists at least of a profiled metal plate (2) onto which is fixed at least a gypsum board (4) or a sheet of calcium silicate on one side and onto which is provided a layer of concrete (7) on the other side.
Improved building component according to claim 1, characterised in that the above-mentioned gypsum board (4) or sheet of calcium silicate is fixed to the above-mentioned metal plate (2) by means of screws (5).
Improved building component according to claim 1, characterised in that the above-mentioned gypsum board (4) or sheet of calcium silicate is made waterproof.
Improved building component according to claim 1, characterised in that the above-mentioned gypsum board (4) or sheet of calcium silicate is made fire-resistant.
Improved building component according to claim 1, characterised in that the above-mentioned metal plate (2) is provided with one or several systematic indentations which provide the metal plate (2) with the function of a reinforcement of the building component (1).
Improved building component according to claim 1, characterised in that the above-mentioned metal plate (2) is made in the form of a galvanised steelplate.
Improved building component according to claim 1, characterised in that the above-mentioned layer of concrete (7) is made of lightweight concrete.
Improved building component according to claim 1, characterised in that it is provided with one or several crane hooks (10) which are cast in the above-mentioned layer of concrete (7).
Improved building component according to claim 1, characterised in that a reinforcement (9) is provided in the above-mentioned layer of concrete (7).
Improved building component according to claim 9, characterised in that the above-mentioned reinforcement (9) is made in the form of a longitudinal reinforcement, lattice girders and/or a mesh reinforcement.
Method for manufacturing a building component in the form of a prefab composed panel according to any one of the preceding claims, characterised in that this method comprises the following steps:
- providing a gypsum board (4) or a sheet of calcium silicate and a profiled metal plate (2) in a mould (8);

- connecting the above-mentioned gypsum board (4) or sheet of calcium silicate to said profiled metal plate (2);

- casting a layer of either or not lightweight concrete (7) on the above-mentioned profiled metal plate (2); and

- if necessary, providing a reinforcement (9) and/or one or several crane hooks (10) in the above-mentioned layer of concrete (7).
Method according to claim 11, characterised in that on the above-mentioned layer of concrete (7) is provided an additional gypsum board (4).