EP2495374B1 - Construction for housing with bearing walls and floors made from prefabricated concrete panels - Google Patents

Description

FIELD OF THE INVENTION

The present invention relates to buildings for individual or collective housing whose load bearing walls and floors are made by means of prefabricated concrete panels.

BACKGROUND BACKGROUND

Such a construction, as described above, is defined in FR 2 931 496 A1 .

Generally the construction of the walls of individual dwellings is carried out by small elements of concrete or terracotta. Insulation is reported inside at the time of dubbing. The exterior finish is obtained by a coating.

The floors are obtained either by casting a solid ground or by prefabricated elements (beams and interjoists) in the case of a crawl space. The insulation is either integrated with the floor or placed under the tiles (floating slab). The finishing of the floor is obtained by the installation of a tiling or a rearrangement before soft coating. Such a design, has the disadvantages associated with manpower (quantity and specificity), the duration of construction, the manual realization of joints, finishes, insulation and exterior cladding.

• spécificités propres quant aux dimensions, à l'aspect et aux découpes ;
• sécurité à la pose car risque de basculement lors des manutentions ;
• besoin d'étaiement ;
• nécessité de joint vertical continu sur la hauteur d'étage et impossibilité de marier des aspects différents à chaque lit, nuisant à l'esthétique ;

A first achievement, able to respond more specifically to the needs of collective housing, was to use floor-level panels. Unfortunately, such a design has the following drawbacks:

• specific features as to dimensions, appearance and cut-outs;
• safety when laying because risk of tipping during handling;
• need shoring;
• need for continuous vertical joint on the floor height and impossibility to marry different aspects to each bed, detracting from the aesthetics;

SUMMARY OF THE INVENTION

• dont les murs porteurs sont réalisés au moyen de panneaux, préfabriqués, juxtaposés et superposés ;
• dont les planchers sont réalisés au moyen de panneaux, préfabriqués, juxtaposés. Selon une première caractéristique avantageuse de réalisation de l'invention :
  1. a) chaque panneaux, entrant dans la composition d'un mur porteur, est constitué de la superposition :
     • d'une première couche, en béton coulé ;
     • d'une deuxième couche, d'isolant en plaque, pourvue d'une pluralité de trous traversants ;
     • d'une troisième couche, en béton coulé, qui, lors de sa coulée, pénètre et traverse les trous de manière à constituer des moyens de liaison des deux couches extrêmes en béton et qui prennent en sandwich la plaque isolante ;
  2. b) lesdits panneaux sont disposés, sur chant, en position couchée, sur 3 niveaux superposés qui comportent, pour le premier niveau, des panneaux inférieurs, de type sous allège, juxtaposés, reposant sur le plancher, pour le deuxième niveau, des panneaux médians, de type tableau entre ouvertures, reposant sur lesdits panneaux inférieurs et, pour le troisième niveau, des panneaux supérieurs, de type linteau, juxtaposés, reposant sur lesdits panneaux médians.

The invention, as described by the technical features of claim 1, is intended to realize constructions for individual or collective housing:

• whose supporting walls are made by means of panels, prefabricated, juxtaposed and superimposed;
• whose floors are made using panels, prefabricated, juxtaposed. According to a first advantageous characteristic of embodiment of the invention:
  1. a) each panel, forming part of a load-bearing wall, consists of the superposition:
     • a first layer, cast concrete;
     • a second layer of plate insulation provided with a plurality of through holes;
     • a third layer, cast concrete, which, during its casting, penetrates and passes through the holes so as to constitute connecting means of the two outer layers of concrete and sandwiching the insulating plate;
  2. b) said panels are arranged, on edge, in supine position, on 3 superimposed levels which comprise, for the first level, lower panels, of type under lighter, juxtaposed, resting on the floor, for the second level, median panels , of array type between openings, resting on said lower panels and, for the third level, upper panels, type lintel, juxtaposed, resting on said median panels.

• réduction importante des spécificités de chaque panneau par rapport au mur à hauteur d'étage quant aux dimensions, à l'aspect et aux découpes spécifiques ;
• sécurité à la pose car moins de risque de basculement lors des manutentions ;
• pas besoin d'étaiement ;
• amélioration de l'esthétique car pas de joint vertical continu sur la hauteur d'étage et possibilité de marier des aspects différents à chaque lit.
• diminution des de temps de pose grâce aux qualités dimensionnelles et au système de guidage obtenu par feuillure et clavette ;
• pose facilitée et esthétique des points singuliers améliorée grâce à l'utilisation de pièces de recouvrement assurant la finition des angles et des ouvertures de la construction.

Such an arrangement has the following main advantages:

• significant reduction in the specificities of each panel relative to the floor-level wall in terms of dimensions, appearance and specific cuts;
• safety when laying because there is less risk of tipping during handling;
• no need for shoring;
• aesthetic improvement because no continuous vertical joint on the floor height and possibility of marrying different aspects to each bed.
• reduced laying time thanks to the dimensional qualities and the guiding system obtained by rabbet and key;
• easier and more aesthetic installation of singular points improved thanks to the use of covering parts ensuring the finishing of angles and openings of the construction.

In addition, such a design has the advantage of reducing on-site operations because large panels, according to the invention, have a finished appearance and integrate the insulation.

Additional insulation and interior finishing can be provided by the installation of a doubling.

Since all components of the structural work are prefabricated, the dimensional tolerances allow assembly by gluing and / or keying.

The weight of an element does not exceed 1200 kg which will allow an easy mechanized installation. The height of the wall panels is less than 1 m50 to avoid shoring. The construction of a building will be done in a time much inferior to the traditional methods and will allow innovative aesthetic solutions.

1. a) chaque panneau, entrant dans la composition d'un plancher, est constitué de la superposition d'une première couche en béton coulé et d'une deuxième couche d'isolant en plaque de largeur inférieure à celle de la première couche de manière à dégager, de chaque côté, un espace destiné à être comblé par une armature métallique et une deuxième coulée de béton qui se solidarise à la première couche et qui maintient ledit isolant et enrobe l'armature ;
2. b) lesdits panneaux possèdent une longueur égale à la portée du plancher à couvrir.

According to a second advantageous characteristic of embodiment of the invention:

1. (a) each panel forming part of a floor consists of the superposition of a first layer of poured concrete and a second layer insulating plate of width less than that of the first layer so as to clear, on each side, a space to be filled by a metal frame and a second concrete pour which is secured to the first layer and which maintains said insulating and coating the frame;
2. b) said panels have a length equal to the range of the floor to be covered.

Said caisson design, whose unit width can vary between 0.50 m and 1.50 m and whose length corresponds to the range, are carrying, insulating and may have a decorative face type tiles, wood or other material. Thus, in a single operation, the laying of the floor and the floor covering will be carried out.

Here again the advantage is important because there are not so far elements of floors having a decorative upper face.

A significant financial saving will be achieved.

A heating network system can be integrated during the manufacture of the box.

Additional insulation can be added under the box to improve thermal insulation. This supplement may be added at the factory or made during installation.

• dont les parois latérales en regard sont en dépouille ;
• dont le fond de la peau comporte, en relief, la finition ou, directement posés sur elle, les matériaux de finition que l'on souhaite intégrer à la face des panneaux qui lui est en regard ;
• dont les parois latérales internes de la peau possèdent la forme externe latérale des panneaux ;

et en ce que les couches de béton, d'isolant et de béton sont successivement mises en oeuvre dans ladite peau.Each panel used in the composition of a load-bearing wall may be made by means of a mold consisting of a skin made of elastomeric material and a concrete counter mold:

• whose side walls facing are undercut;
• whose bottom of the skin has, embossed, the finish or, directly placed on it, the finishing materials that it is desired to integrate with the face of the panels facing it;
• whose inner side walls of the skin have the lateral external shape of the panels;

and in that the layers of concrete, insulation and concrete are successively used in said skin.

• dont les parois latérales en regard sont en dépouille ;
• dont le fond de la peau comporte, en relief, la finition ou, directement posés sur elle, les matériaux de finition que l'on souhaite intégrer à la face du panneau qui lui est en regard ;
• dont les parois latérales internes de la peau possèdent la forme externe latérale des panneaux ;

et en ce que les couches de béton, d'isolant et de béton latéral sont successivement mises en oeuvre dans ladite peau.Each panel, or box, used in the composition of a floor, can be made by means of a mold consisting of a skin made of elastomeric material and a concrete counter mold:

• whose side walls facing are undercut;
• whose bottom of the skin has, embossed, the finish or, directly placed on it, the finishing materials that are to be integrated into the face of the panel which is facing it;
• whose inner side walls of the skin have the lateral external shape of the panels;

and in that the layers of concrete, insulation and lateral concrete are successively used in said skin.

Said mold design has the advantage of allowing the production of parts against undercut without having to open the mold resulting in a significant time saving production.

The mold is made by casting the elastomeric skin on the mother piece and then pouring the concrete against the mold on the elastomeric skin.

This method makes it possible to perfectly respect the dimensional dimensions of the mother piece even if it has parts against undercut.

This process greatly facilitates the production of the concrete elements mentioned above and makes it possible to obtain dimensional and aesthetic quality parts at a cost compatible with the market.

The construction of a building will require a calpinage. Thus, each element can be manufactured specifically (dimensions, reservations, etc.).

PRESENTATION OF FIGURES

The features and advantages of the invention will appear more clearly on reading the detailed description which follows of at least one preferred embodiment thereof given by way of non-limiting example and shown in the accompanying drawings.

• la figure 1 est une vue, en coupe transversale, d'un panneau de mur porteur ;
• la figure 2 est une vue de dessus de l'isolant en plaque entrant dans la constitution d'un panneau de mur ;
• la figure 3 est une vue, en coupe transversale, d'un panneau de plancher et de la jonction de deux panneaux consécutifs ;
• la figure 4 est une vue, en coupe transversale, d'un panneau de mur porteur et d'un moule ayant servi à le fabriquer ;
• la figure 5 est une vue, en coupe transversale, d'un panneau de plancher et d'un moule ayant servi à le fabriquer ;
• la figure 6 est une vue en élévation d'une des faces d'une construction pourvue de deux fenêtres ;
• la figure 7 est une vue en élévation d'une des faces d'une construction pourvue d'une porte ;
• la figure 8 est une vue en coupe, selon DD, de la face de la construction pourvue de deux fenêtres ;
• la figure 9 est une vue en coupe horizontale d'une liaison d'angle de deux panneaux de murs.

On these drawings:

• the figure 1 is a cross-sectional view of a load-bearing wall panel;
• the figure 2 is a top view of the plate insulation forming part of a wall panel;
• the figure 3 is a cross-sectional view of a floorboard and the junction of two consecutive panels;
• the figure 4 is a cross-sectional view of a load-bearing wall panel and a mold used to make it;
• the figure 5 is a cross-sectional view of a floorboard and mold used to make it;
• the figure 6 is an elevational view of one side of a building with two windows;
• the figure 7 is an elevational view of one of the faces of a construction with a door;
• the figure 8 is a sectional view, according to DD, of the face of the construction provided with two windows;
• the figure 9 is a horizontal sectional view of a corner connection of two wall panels.

DETAILED DESCRIPTION OF THE INVENTION

The construction, the panels and the molds represented in the figures constitute all the elements of the invention.

• dont les murs porteurs sont réalisés au moyen de panneaux (1,2,3), préfabriqués, juxtaposés et superposés ;
• dont les planchers sont réalisés au moyen de panneaux (12), préfabriqués, juxtaposés.

This is generally a construction for individual or collective housing:

• whose load-bearing walls are made by means of panels (1,2,3), prefabricated, juxtaposed and superimposed;
• whose floors are made by means of panels (12), prefabricated, juxtaposed.

• d'une première couche (4), en béton coulé ;
• d'une deuxième couche (5), d'isolant en plaque, pourvue d'une pluralité de trous traversants (6) ;
• d'une troisième couche, en béton coulé (7), qui, lors de sa coulée, pénètre et traverse les trous (6) de manière à constituer des moyens de liaison des deux couches extrêmes en béton (4) et (7) qui prennent en sandwich la plaque isolante (5).

Each panel (1,2,3), used in the composition of a load-bearing wall, consists of the superposition ( Figures 1 and 2 ):

• a first layer (4) of cast concrete;
• a second layer (5) of plate insulation provided with a plurality of through holes (6);
• a third layer of poured concrete (7) which, during its pouring, penetrates and passes through the holes (6) so as to constitute connecting means of the two extreme concrete layers (4) and (7) which sandwich the insulating plate (5).

Said panels are arranged, on edge, in supine position, on 3 superimposed levels ( Figures 6 and 7 ) having, for the first level, lower panels (1), of type under lighter, juxtaposed, resting on the floor, for the second level, median panels (2), of array type between openings, resting on said panels lower (1) and, for the third level, upper panels (3), lintel type, juxtaposed, resting on said median panels (2). Each panel (12), used in the composition of a floor, consists of the superposition ( Figure 3 ) a first layer of cast concrete (13) and a second layer of plate insulation (14) of a width smaller than that of the first layer (13) so as to clear, on each side, a space to be filled by a metal reinforcement (15) and a second concrete pour (16) which solidifies with the first layer (13) and which holds said insulator (14) and coats the reinforcement (15).

Said panels have a length equal to the scope of the floor to be covered.

Each panel (1, 2, 3), forming part of a load-bearing wall, comprises, on each longitudinal side of the first layer (4), grooves (8) intended for guiding, positioning and keying of two joined panels. They are preferably recessed to avoid male parts likely to be damaged. Each panel (1, 2, 3), forming part of a load-bearing wall, comprises, in addition, a reinforcement metal reinforcement.

The panels (1,2,3) used in the composition of a load-bearing wall are intended to be connected at each corner of the building ( Figure 9 ), by erected poles (24) and poured concrete (25) inside a formwork delimited by the ends of said panels, an external decorative element (26) and a shuttering element (27).

Each panel (12), forming part of a floor, comprises, on the lateral edges of the decorative face of the poured concrete layer (13), rabbets (17) intended to house joint covers (18). and rebates (19) for casting keying concrete (20) therein.

Each panel (12), used in the composition of a floor, comprises, in addition, a reinforcing wire mesh.

Each panel (12), forming part of a floor, comprises, in addition, a heating network.

• dont les parois latérales en regard sont en dépouille ;
• dont le fond de la peau (9) comporte, en relief, la finition ou, directement posés sur elle, les matériaux de finition (11) que l'on souhaite intégrer à la face des panneaux (1,2,3) qui lui est en regard ;
• dont les parois latérales internes de la peau (9) possèdent la forme externe latérale des panneaux (1,2,3) ;

et en ce que les couches de béton (4), d'isolant (5) et de béton (7) sont successivement mises en oeuvre dans ladite peau (9).The mold for the manufacture of the panels used in the composition of a load-bearing wall not forming part of the present invention is constituted ( Figure 4 ) an elastomeric material skin (9) and a concrete counter mold (10):

• whose side walls facing are undercut;
• whose bottom of the skin (9) has, in relief, the finish or, directly placed on it, the finishing materials (11) that one wishes to integrate in the face of the panels (1, 2, 3) which is opposite;
• whose inner side walls of the skin (9) have the lateral external shape of the panels (1, 2, 3);

and in that the layers of concrete (4), insulation (5) and concrete (7) are successively used in said skin (9).

• dont les parois latérales en regard sont en dépouille ;
• dont le fond de la peau (21) comporte, en relief, la finition ou, directement posés sur elle, les matériaux de finition (23) que l'on souhaite intégrer à la face du panneau (12) qui lui est en regard ;
• dont les parois latérales internes de la peau (21) possèdent la forme externe latérale des panneaux (12) ;

et en ce que les couches de béton (13), d'isolant (14) et de béton latéral (16) sont successivement mises en oeuvre dans ladite peau (21).The mold for the manufacture of panels used in the composition of a floor, not forming part of the present invention is constituted ( Figure 5 ) an elastomeric material skin (21) and a concrete counter mold (22):

• whose side walls facing are undercut;
• the bottom of the skin (21) has, in relief, the finish or, directly placed on it, the finishing materials (23) that is to be integrated into the face of the panel (12) facing it;
• whose inner side walls of the skin (21) have the lateral external shape of the panels (12);

and in that the layers of concrete (13), insulation (14) and lateral concrete (16) are successively used in said skin (21).

The finishes may be imitations of wood, tiles or any other type of material or directly said integrated materials during the pouring of concrete.

The piece is removed by simple pulling force by acting on the deformation of the skin which takes its place once the piece extracted. Vents (33) have been arranged in the bottom wall of the counter mold.

In the preferred embodiment of the invention, the panels of the load-bearing walls have the following dimensions: length A = 4 m, width B = 1 m, thickness C = 0.20 m decomposing as follows: outer concrete layer = 5 cm, insulation board = 10 cm and inner concrete layer = 5 cm.

• longueur = portée, largeur = 1 m, épaisseur = 0,20 m se décomposant comme suit : couche de béton supérieur = 5 cm, plaque d'isolant = 15 cm ;
• largeur de ladite plaque = 0,75 cm dégageant ainsi un espace de chaque côté de 12,5 cm pour le béton latéral.

In the preferred embodiment of the invention, the floor panels have the following dimensions:

• length = span, width = 1 m, thickness = 0.20 m decomposing as follows: upper concrete layer = 5 cm, insulation board = 15 cm;
• width of said plate = 0.75 cm thus giving a space on each side of 12.5 cm for the lateral concrete.

Concrete used for the manufacture of wall and floor panels is self-placing concrete (BAP). It can be traditional, insulating or special.

The floor elements are intended ( Figures 6, 7 and 8 ) to rest, for a given construction, on beams (28) supported by foundation pads (29).

The figure 6 represents one of the faces of a construction provided with two windows.

The length of the panels (2) is obtained by partitioning the mold. The frames (30) of windows can be introduced into their housing by vertical translation. A mounting clearance (31) is provided at the corners;

The figure 7 represents one of the faces of a construction provided with a door. The height of the door frame (32) (2.20 m) exceeds 20 cm panels (1) and (2) thus requiring partitioning of the mold accordingly to achieve the panel (3). It is also possible to change the width of one of the panels (1) or (2) by 20 cm to compensate for this difference.

By using said molds, it is also possible to produce gables and roof panels with a face imitating tiles or other roofing material.

The concrete counter mold may contain heating means to reduce the setting time of the concrete.

Of course, those skilled in the art will be able to carry out the invention as described and represented by applying and adapting known means without it being necessary to describe them or to represent them.

It may also provide other variants without departing from the scope of the invention which is determined by the content of the claims.

Claims (8)

1. Construction for individual or collective housing:

   - of which the load-bearing walls are made using panels (1, 2, 3), that are pre-fabricated, juxtaposed and superimposed;

   - of which the floors are made using panels (12), that are pre-fabricated and juxtaposed;

   characterised in that each panel (1, 2, 3), entering into the composition of a load-bearing wall, is constituted by the superposition:

   - of a first poured concrete layer (4);

   - of a second board type insulation layer (5), provided with a plurality of through-holes (6);

   - of a third poured concrete layer (7) that, when it is poured, penetrates and passes through the holes (6) in such a way as to constitute means for connecting the two end concrete layers (4) and (7) which sandwich in the insulation board (5);

   and in that said panels are arranged, on edge, in laying down position, on 3 superimposed levels that comprise, for the first level, lower panels (1), of the skirting type, juxtaposed, resting on the floor, for the second level, medial panels (2), of the painting type between openings, resting on said lower panels (1) and, for the third level, upper panels (3), of the lintel type, juxtaposed, resting on said medial panels (2).
2. Construction, according to claim 1, characterised in that each panel (12), entering into the composition of a floor, is comprised of a the superposition of a first layer made from poured concrete (13) and of a second layer of an insulation board (14) with a width less than that of the first layer (13) in such a way as to release, on each side, a space intended to be filled by a metal reinforcement frame (15) and a second pouring of concrete (16) that attaches itself to the first layer (13) and that maintains said insulation (14) and coats the reinforcement frame (15);
   and in that said panels have a length equal to the surface of the floor to be covered.
3. Construction, according to claim 1, characterised in that each panel (1, 2, 3), entering into the composition of a load-bearing wall, comprises, on each longitudinal side of the first layer (4), rebates (8) intended for the guiding, positioning and keying of two sealed panels.
4. Construction, according to claim 1, characterised in that each panel (1, 2, 3), entering into the composition of a load-bearing wall, comprises, in addition, a reinforcing metal frame.
5. Construction, according to claim 1, characterised in that the panels (1, 2, 3) entering into the composition of a load-bearing wall, are intended to be connected, at each angle of the construction, by posts reinforced (24) and cast in concrete (25) inside a formwork delimited by the end of said panels, a decorative external element (26) and a formwork element (27).
6. Construction, according to claim 2, characterised in that each panel (12), entering into the composition of a floor, comprises, on the lateral edges of the decorative surface of the layer made from cast concrete (13), rebates (17) intended to house joint covers (18) and rebates (19) intended to cast therein keying concrete (20).
7. Construction, according to claim 2, characterised in that each panel (12), entering into the composition of a floor, comprises, in addition, a metal reinforcing mesh.
8. Construction, according to claim 2, characterised in that each panel (12), entering into the composition of a floor, comprises, in addition, a heating network.

Images