EP3816364A1 - Panneau de revêtement préfabriqué modulaire résistant au feu - Google Patents

Panneau de revêtement préfabriqué modulaire résistant au feu Download PDF

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Publication number
EP3816364A1
EP3816364A1 EP19205846.9A EP19205846A EP3816364A1 EP 3816364 A1 EP3816364 A1 EP 3816364A1 EP 19205846 A EP19205846 A EP 19205846A EP 3816364 A1 EP3816364 A1 EP 3816364A1
Authority
EP
European Patent Office
Prior art keywords
panel
mortar
particles
mold
density
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.)
Pending
Application number
EP19205846.9A
Other languages
German (de)
English (en)
Inventor
Rainer Cool
Gregor Freches
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.)
WALL & FACADE SOLUTIONS SRL
Original Assignee
Isosystems AG
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 Isosystems AG filed Critical Isosystems AG
Priority to EP19205846.9A priority Critical patent/EP3816364A1/fr
Publication of EP3816364A1 publication Critical patent/EP3816364A1/fr
Pending 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
    • E04F13/0862—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 composed of a number of elements which are identical or not, e.g. carried by a common web, support plate or grid
    • 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
    • E04F13/0889—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 characterised by the joints between neighbouring elements, e.g. with joint fillings or with tongue and groove connections
    • E04F13/0894—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 characterised by the joints between neighbouring elements, e.g. with joint fillings or with tongue and groove connections with tongue and groove connections
    • 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
    • E04F13/12—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 of metal or with an outer layer of metal or enameled metal
    • E04F13/123—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 of metal or with an outer layer of metal or enameled metal with an outer layer imitating natural stone, brick work, tiled surface or the like
    • 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
    • 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
    • E04F13/147—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 imitating natural stone, brick work or the like
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F2290/00—Specially adapted covering, lining or flooring elements not otherwise provided for
    • E04F2290/04—Specially adapted covering, lining or flooring elements not otherwise provided for for insulation or surface protection, e.g. against noise, impact or fire
    • E04F2290/045—Specially adapted covering, lining or flooring elements not otherwise provided for for insulation or surface protection, e.g. against noise, impact or fire against fire

Definitions

  • the present invention relates to a fire-resistant modular prefabricated cladding panel and its manufacturing process, as well as a building comprising said panel.
  • Cladding panels also known as cladding systems
  • cladding systems of the state of the art comprising a decorative part and a supporting part, generally elements of bricks or stones associated with thermosetting foams, have existed for years. These panels have been used in the construction of new buildings as well as in the renovation of old buildings. The panels encountered a commercial success because the thermosetting foams offered some insulation properties.
  • thermosetting foams are directly integrated in their structures.
  • additional insulation provided by said thermosetting foams is not anymore a key competitive advantage for these panels.
  • Cladding panels according to the state of the art use polymer-based foams, which are not fire resistant. However, after the Grenfell tower fire in London region in 2017, some countries change the construction regulations requiring that any construction element of a building, including the cladding plate, should be almost free of organic compound(s)(less than 5%, preferably less than 1%), for the 6 th floor and above.
  • the invention aims to provide a solution to at least one drawback of the teaching provided by the prior art.
  • the invention aims to provide a fire resistant panel with convenient rigidity.
  • the invention is directed to a substantially inorganic fire-resistant modular prefabricated cladding panel adapted, in use, to be fastened to a building by fastening means, said panel comprising one or more decorative cladding elements embedded in a structural support element of a mortar matrix, an openwork metal plate and dispersed particles, whose density is lower than the density of the mortar matrix of the structural support element.
  • the device comprises one or more of the following technical features, taken alone or any combination thereof:
  • the invention also relates to a method for producing the panel, comprising the following steps:
  • the method comprises a step of filling the mold with sand after arranging the one or more decorative cladding elements of the panel in the mold and before the filing of the mold with mortar preferably mixed with at least the particles, whose density is lower than the density of the mortar matrix.
  • the method comprises a compression step of the structural support element, via a plate with a pressure ranging from 10 to 100 kPa, preferably from 30 to 70kPa exerted on said plate for a predetermined amount of time ranging for 0.5 to 100 seconds, said step taking place before the drying of said mortar and after the filling of the mold with mortar mixed with said particles.
  • the invention also relates to a building comprising the panel according to the invention.
  • the present invention is advantageous since the deformation resulting from temperature change or humidity are considerably diminished because of the use of a metallic insert, i.e. the openwork metal plate.
  • the panel according to the invention is stable and is therefore easy to mount because it requires fewer "on-the-spot" adjustments to compensate changes in dimension.
  • the rigidity of the panel also depends on the selection of a suitable open area ratio.
  • This ratio is a compromise between an improved adherence between the openwork metal plate (e.g. perforated metallic plate) and the substantially mineral binding composition (i.e. mortar), and an enhanced stiffness of the openwork metal plate.
  • An excessively high open area ratio would increase the anchoring effect of the openwork metal plate within the mortar matrix while reducing the stiffness of the openwork metal plate.
  • an excessively low ratio would reduce the anchoring effect of the openwork metal plate within the mortar matrix while increasing the rigidity of the openwork metal plate.
  • an openwork metal plate with a 3D structure e.g. ribs, profile, and/or texture
  • a corragurated plate synergistically interacts with the mortar matrix because the overall resistance of the structural support element goes beyond the contribution of the inherent enhanced stiffness of a profiled and/or ribbed plate, thanks to an improved anchoring effect. This allows increasing further the proportion of low-density particulates, without adverse effects on the overall resistance of the panel.
  • the openings can be used for the fastening of the panel on the building. Indeed, a fastening screw can pass through one of the openings. The more openings are present, the easier it is to select an optimized position of the fastening means (e.g. mechanical fixation such as screws), simplifying the tasks of the construction workers.
  • the fastening means e.g. mechanical fixation such as screws
  • Aluminum presents a specific elastic modulus (i.e. ratio between Young modulus and density) similar to that of steel.
  • the present invention is highly customizable. Indeed, a joint-free brick wall or an apparent joint brick wall can be manufactured with several panels produced on the same production line.
  • one or more decorative cladding elements are voluntarily not embedded in the panel in order to free one or more portions of the external surface of the panel, where openings for allowing the insertion of the fastening means (e.g. screw(s)) are formed.
  • one or more fastening screw holes are arranged on one or more joints sandwiched between their respective adjacent decorative cladding elements (e.g. bricks).
  • each subject-matter of the invention is also applicable to the other subject-matters of the invention.
  • each subject-matter of the invention is combinable with other subject-matters.
  • the features of the invention are also combinable with the embodiments of the description, which in addition are combinable with each other.
  • Figure 1 shows a perspective view of a cladding panel according to the invention.
  • the panel can comprise rows of decorative cladding elements, e.g. bricks.
  • the bricks in figures 1 and 2 are staggered leaving empty footprints corresponding in shape to half of the reference pattern brick.
  • the footprints are aimed at being filled with bridging bricks on site as shown in figure 2 .
  • the embodiment in figures 1-4 and 6 are described with bricks and apparent/appearing joints/grouts.
  • the use of bricks and/or appearing grouts should not limit the scope of the invention, because other(s) decorative claddings element(s) such as tiles in combination with or without an appearing grout can be used.
  • applying grout we mean the panel surface sandwiched between the cladding elements. This term is also known as (apparent or appearing) joint. This sandwiched surface can be coated for instance with sand to bring a decorative aspect. For bricks, sand is generally used. When the gap between two decorative cladding elements is smaller than a value between 2 to 6 mm, the joint surface is not visible anymore because the gap is too narrow. In this case, it is considered that there is no significant apparent/appearing grout/joint.
  • an untrimmed (rectangular or square) panel has a height from 50 to 90 cm, preferably from 60 cm to 70 cm and a length from 70 to 150 cm, preferably from 90 to 120 cm. If needed, a panel can be trimmed to the right size using for instance a suitable circular saw. The thickness of the panel ranges from 15 to 35mm.
  • Figure 2 represents a perspective view of a facade comprising several decorative cladding panels. It should be noted that panels could be fixed on vertical beams and the bridging cladding elements (i.e. bricks) are mounted at vertically oriented junctions between panels. Generally, the bridging bricks can adhere with glue, mortar such as cement-based adhesive or any other suitable binding mineral material on the panels.
  • glue glue, mortar such as cement-based adhesive or any other suitable binding mineral material on the panels.
  • Figure 3 represents a perspective view of a panel with form fitting opposing edges according to the invention.
  • the panel comprises a coupling structure arranged in opposing side edges, said structure including recesses and tongues.
  • the tongues are formed by some of the decorative cladding elements that are arranged on both edges.
  • the recesses and tongues are alternatively arranged along respective side edges.
  • Figure 4 represents a perspective view of a facade made of a plurality of panels with form fitting opposing sides according to the invention. The vertical edges of two adjacent panels are arranged to fit together.
  • Figures 5a-5b represent two transversal sections of two (rectangular or square) panels according to the invention.
  • Figure 5a discloses straight side edges.
  • Figure 5b discloses side edges with a step.
  • the step(s) positioned on the side(s) of the panel allow(s) an overlapping with the neighboring plate(s) once they are mounted on a building.
  • the cladding panel can present bricks embedded in a structural support element comprising a mortar composition such as a cement-based adhesive.
  • the structural support element further comprises an openwork metal frame such as a perforated metallic plate. The perforated plate is anchored within the structural support element in an intermediate section thereof.
  • Figure 6 represents a transversal section of a portion of a panel with an appearing grout according to the invention.
  • Figure 6 shows that one of the openwork metal plate can be used for engaging with a fastening element such as a screw.
  • the dimensions of the thread/shank of the screw match those of the corresponding opening, in which the screw is fitted.
  • the fastening screw dimensions and the inradius of the opening(s) of the openwork metal plate can be selected such that the inradius of at least one or all openings is higher than the half of the major diameter of the fastening screw.
  • the inradius lies in a range from 2 to 8 mm, preferably in a range from 2 to 3 mm.
  • the inradius of said opening(s) and the fastening screw can be configured so that the head of the screw can be tightened against the external surface of the panel without weakening said surface.
  • the plate and the fastening means should be adapted in such a manner that traction stresses from the tightening of the screw and load are essentially borne by the metal perforated plate.
  • a difference ranging from 0.5 mm to 3.0 mm between the half of the diameter of the head and the inradius of the corresponding opening ensures that the head securely rests on the external surface of the structural support element. It is meant by major diameter, the largest diameter of the screw thread or shank.
  • the inradius is by definition the radius of the largest circle that fits inside any given geometric shape, especially inside a regular polygon.
  • Figure 7 represents a transversal section of a panel without an appearing grout according to the invention.
  • the opening engaging with a fastening screw is positioned directly underneath the corresponding decorative cladding.
  • This decorative cladding element is mounted once the panel is fixed on the building.
  • Figure 7 shows an embodiment, in which the openwork plate (e.g. perforated plate) separates a region with low-density particles from a region free of low-density particles.
  • This plate positioning with regard to the stratification of the low-density particles could be applied to any panel according to the invention with an appearing grout as for instance that in Figure 6 .
  • Figures 6 and 7 represent a transversal section of a portion of a panel with dispersed low-density particles according to the invention.
  • the use of dispersed low-density particles reduces the weight. It has been discovered that the overall rigidity of the panel is not or just slightly adversely influenced by the presence of low-density particles, which by nature introduces heterogeneity and weakens the structure. Synergistically, the combination of the openwork metal plate and the low-density particles present an overall resistance of the panel that is higher than what would normally be expected. Equally, it is preferred to stratify the reinforcing structure and to concentrate the dispersed low-density particles in the region wrapping the openwork metal plate. This stratified structure can comprise a support layer with dispersed low-density particles and an adhesive layer free of dispersed low-density particles.
  • the composition of the filling material (i.e. mortar composition) of both layers can be the same or different.
  • Figure 8 represents a magnified transverse section of a panel according to the invention.
  • the structural support element can comprise additional reinforcing particles such as fibers, granules or platelet particles.
  • the back face of the structural support element can comprise a woven or unwoven reinforcing fabric.
  • Figures 9A-9C represent usual formulas for assessing the open area ratio. These formulas are derived for the state in the art, for example a publication of the Industrial Perforators Association: Designers, Specifiers And Buyers Handbook For Perforated Metals, ⁇ 1993. The shapes of the perforated plate presented in figure 9A-9C should not be regarded as limiting the scope of the present invention.
  • the open area ratio of an openwork metal plate is the ratio between the cumulative surface of all openings area of the plate divided by the area delimited by the plate. It has been found that when the open area ratio of the openwork metal plate lies in the range from 30% to 70%, from 35% to 60%, more preferably from 35% to 49%, the stability is increased.
  • a method (not shown) for producing a panel comprises the steps of providing a mold with an appropriate shape; arranging the cladding elements of the panel in the mold; filling the mold with mortar, preferably mixed with at least the particles, whose density is lower than the density of the mortar matrix; placing the openwork metal plate in the mold; filling the mold with mortar mixed with said particles; optionally covering the back face of the structural support element with the woven or unwoven reinforcing fabric; and drying said mortar.
  • the openwork metal plate is displaced vertically in the mold to be positioned at a predefined height within the thickness of the support structure element.
  • the mold can therefore comprise one or more abutment surfaces to maintain in place the plate at the predefined height within the mold.
  • the plate can be pressed within the mold to reach its rest position on the abutment surface(s).
  • the displacement of the plate also ensures that the hydrated mortar passes though the openings of the openwork metal plate so as to optimize the anchoring effect and that the contact surface between the mortar and the openwork metal plate is maximized. This step also favors that air bubbles imprisoned in the mortar are released.
  • a step during, which the mold is filled with a coating element such as calibrated sand of the appearing joint/grout can be foreseen before the filling of the mold with the mortar, preferably mixed with low-density particles and after arranging the one or more decorative cladding elements of the panel in the mold.
  • the manufacturing process can comprise a step, during which a mortar composition free of low-density particles is filled in the mold before the step of the filling the mold with mortar mixed with low-density particles and prior to the placing of the plate. This step takes place after the filling of the mold with sand if applicable.
  • a woven or unwoven fabric can be applied on the uppermost layer of mortar (i.e. the back face of the panel) before the drying.
  • the use of the woven or unwoven fabric will increase the handling and stability during transport.
  • the complete layered preparation will be put under a complete surface pressure. This step place before the drying. This will increase the binding between the different layers and link all component together.
  • binding mixtures e.g. mortar mixed with low-density particles
  • Each binding mixture can be a-ready-to-use material or the result of a mix of several constituents, for instance a combination of at least a cement-based adhesive powder, water and optionally dispersed low-density particles.
  • substantially inorganic element is meant that the amount of mineral components represents at least 90%, more preferably 95%, in particular 99% in weight of the element.
EP19205846.9A 2019-10-29 2019-10-29 Panneau de revêtement préfabriqué modulaire résistant au feu Pending EP3816364A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP19205846.9A EP3816364A1 (fr) 2019-10-29 2019-10-29 Panneau de revêtement préfabriqué modulaire résistant au feu

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP19205846.9A EP3816364A1 (fr) 2019-10-29 2019-10-29 Panneau de revêtement préfabriqué modulaire résistant au feu

Publications (1)

Publication Number Publication Date
EP3816364A1 true EP3816364A1 (fr) 2021-05-05

Family

ID=68387229

Family Applications (1)

Application Number Title Priority Date Filing Date
EP19205846.9A Pending EP3816364A1 (fr) 2019-10-29 2019-10-29 Panneau de revêtement préfabriqué modulaire résistant au feu

Country Status (1)

Country Link
EP (1) EP3816364A1 (fr)

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
BE891963A (fr) 1981-01-30 1982-05-17 Genten Ernst Procede de production d'une plaque de parement isolante et plaque de parement ainsi obtenue
FR2706174A1 (fr) * 1993-06-08 1994-12-16 Pic Conseil Plaque de bardage absorbant acoustique.
US20100107531A1 (en) * 2008-11-06 2010-05-06 Garrick Hunsaker Thin brick matrix panel and related methods and systems
EP2392741A1 (fr) 2010-06-01 2011-12-07 Ge & Co. S.A. Plaque de parement isolante et son procédé de fabrication
US20140057075A1 (en) * 2012-08-23 2014-02-27 Chao-Lang Wang High-pressure fire-retardant material with metal layer and method for making the same
US20140083033A1 (en) * 2011-05-02 2014-03-27 Pacific Prebenched Ltd. Natural rock panel, natural rock veneer panel and panel support apparatus
CA3010868A1 (fr) * 2015-10-23 2017-04-27 Max Life, LLC Panneau mural

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
BE891963A (fr) 1981-01-30 1982-05-17 Genten Ernst Procede de production d'une plaque de parement isolante et plaque de parement ainsi obtenue
FR2706174A1 (fr) * 1993-06-08 1994-12-16 Pic Conseil Plaque de bardage absorbant acoustique.
US20100107531A1 (en) * 2008-11-06 2010-05-06 Garrick Hunsaker Thin brick matrix panel and related methods and systems
EP2392741A1 (fr) 2010-06-01 2011-12-07 Ge & Co. S.A. Plaque de parement isolante et son procédé de fabrication
US20140083033A1 (en) * 2011-05-02 2014-03-27 Pacific Prebenched Ltd. Natural rock panel, natural rock veneer panel and panel support apparatus
US20140057075A1 (en) * 2012-08-23 2014-02-27 Chao-Lang Wang High-pressure fire-retardant material with metal layer and method for making the same
CA3010868A1 (fr) * 2015-10-23 2017-04-27 Max Life, LLC Panneau mural

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