ES2380857B1 - MANUFACTURING PROCEDURE OF PREFABRICATED BIDIRECTIONAL FORGED ELEMENTS OF REINFORCED CONCRETE AND STRUCTURE OF BIDIRECTIONAL FORGED OBTAINED WITH SUCH ELEMENTS - Google Patents

Abstract

Manufacturing process of prefabricated reinforced concrete bidirectional forging elements and bidirectional forged structure obtained with said elements. # Manufacturing procedure of prefabricated bidirectional forged elements (1) of reinforced concrete (H) (A) and provided with thermal insulation, comprising the steps of horizontally arranging a part (2) with thermal insulation properties at the bottom of a formwork (E), this part (2) being a matrix (M) of parallelepipeds (3) on a rectangular plate (4) , thus configuring a network of channels (5) perpendicular to each other for the reception of concrete (H), arranging the reinforcement (A) in the channels (5), pouring the concrete (H), jointly removing the part (2) and the set concrete (H), so that a lightened two-way forged element (1) is obtained insulating (2), and in which the formwork piece subsequently fulfills the function of thermal insulation. The invention also relates to a floor made of these elements.

Description

Manufacturing process of prefabricated reinforced concrete bidirectional slab elements and bidirectional slab structure obtained with said elements.

The present invention relates to a method of manufacturing lightened and thermally insulated bidirectional forging elements. The invention also refers to a bidirectional forging structure obtained with said elements.

Background of the invention

The prefabricated reinforced concrete and industrial insulated bi-directional forged elements are known, industrially obtained and whose objective is to increase the quality control of the finished element and decrease the installation time, minimizing the remaining actions coincidence of the work.

Examples of these elements are those described in documents FR1509229 and US3918222.

In the first one, prefabricated reinforced concrete bidirectional slab elements and provided with thermal insulation are described.

Likewise, the procedure for obtaining these is described, which is carried out by positioning the formwork, placing the reinforcement and subsequent filling with concrete. Optionally, the formwork can be lost in the concrete, and can have thermal insulation properties.

However, this procedure has the disadvantage of the complexity of manufacturing the element, especially due to the need to manage the formwork individually, especially to position them together.

On the other hand, in this document, the joining of the forged element obtained to the japan is also complicated, and is based on the use of screws that work at shear. In addition, the union obtained requires a later stage of finishing.

The second document also proposes prefabricated bidirectional forging elements in which the support on the jácenas is made on perimetral concrete tabs.

However, the described system has the disadvantage of specifying a specially adapted structure, in what refers to the shape of the supports, for the prefabricated elements. Nor does it solve the problem of thermal insulation.

Therefore, the inventors consider that the solutions related to lightened bidirectional forging elements of the prior art do not solve drawbacks linked to ease and speed of construction, quality and completeness of the finished element and thermal insulation properties of these.

Description of the invention

For this, the present invention proposes a manufacturing process for prefabricated reinforced concrete bidirectional slab elements and provided with thermal insulation, comprising the steps of:

a) Horizontally arrange a piece with thermal insulation properties at the bottom of a formwork, said piece being a matrix of parallelepipeds on a rectangular plate, so that a network of channels perpendicular to each other is con fi gured for concrete reception.

b) Arrange the reinforcement in said channels.

c) Pour the concrete into said channels.

d) Remove the piece and the set concrete together.

So that a lightened bidirectional forging element that incorporates an insulation is obtained.

The procedure allows to obtain in a smaller number of stages an element of prefabricated reinforced slab that already incorporates the insulation.

The element obtained has a high level of thermal insulation, avoiding thermal bridges in the vertical direction, especially thanks to the plate structure provided with parallelepipeds.

The procedure allows the use of large-size monobloc formwork / insulation pieces, so that the positioning tasks mentioned in the background are minimized, increasing manufacturing speed and precision in the dimensions of the element obtained.

Preferably, the process according to the invention previously comprises step c) a step consisting of arranging at the ends of some channels some support elements provided with a support flange that protrudes laterally from the element by the upper edges thereof.

More preferably, the support elements comprise a metal plate, said support flange being constituted by the protruding section of said plate, extending from the lower surface of the plate two anchors intended to be embedded in the concrete, a first one perpendicular to said plate, and the second forming an angle of 45 ° with the first.

The arrangement of the elements in the anchoring element makes it possible to place the prefabricated elements supported by the beams, so that the beams and the elements occupy the same space in vertical projection.

In the state of the art procedures, the joining of the elements to the structure is complicated during their placement in the structure, for example in the bolting phase described in the French patent, or in the preparation of taps adapted from the second mentioned patent.

On the other hand, the elements of the invention include the support element or flange in the prefabricated phase, which can be controlled much better, being necessary only during the placement to support the elements.

According to optional features of the support elements:

-

The first anchor is a pin in the form of the second anchor are two pins.

-

the pins are extended by two parallel sections to the plate, so that the second anchor is bent at an angle of 135 °.

-

the metal plate has a length between 240 and 260 mm, preferably 250 mm, the first anchor has a length between 250 and 280 mm, preferably 265 mm, the first section of the second anchor has a length between 330 and 370 mm , preferably 350 mm, and the second section a length between 240 and 260 mm, preferably 250 mm.

Advantageously, the process according to the invention comprises a subsequent step of joining a layer of pavement to the upper surface of the element.

According to various options of this stage:

-

the pavement is self-supporting, that is to say that it is supported by the edges in the nerves of the floor.

-

The pavement is made of calcium sulfate (put characteristics in memory).

-

The joint between the floor and the floor element is flexible so that it does not transmit the vibrations.

-

the thickness of the pavement is between 2.5 and 3.5 cm (preferably 30 mm memory).

-

The joints have a thickness between 4 and 6mm.

More advantageously, the process according to the invention comprises a step of adhering a ceiling finish layer with fire retardant properties.

According to various procedure options:

-

The ceiling finish comprises a substructure of steel profiles adhered to the concrete of the element and a cover plate adhered to said substructure, so that an air chamber is con fi gured.

-

The cover plate is non-reactive against fire with a minimum of 30 minutes.

-

The cover plate is made of plaster, fire retarded synthetic fibers or fireproof wood.

According to other general options of the invention:

-

The mold / insulation part is made of expanded polystyrene or other lightweight insulating materials and / or has been previously obtained by emptying by wire cutting.

-

The armor is a prefabricated armor.

-

The concrete is self-compacting, and its pouring into the mold / formwork is done with vibrating.

According to several options of the procedure with regard to the specific dimensions of the different components:

-

the parallelepipeds have a edge between 240 and 360 mm, preferably between 290 and 310 mm.

-

The rectangular plate has a thickness between 25 and 35 mm, preferably between 28 and 32 mm.

-

The air chamber has a height between 25 and 30 mm.

-

The cover plate (false ceiling) has a thickness between 40 and 50 mm, preferably 45 mm.

-

the channels have a width between 90 and 110 mm, preferably 100 mm.

-

The parallelepipeds have a square planar section between 600 and 800 mm, preferably between 690 and 710 mm, and more preferably 700 mm.

-

The elements obtained are rectangular with one side between 6.8 and 7.6 m and the other side between 2.2 and 2.6 m, preferably 7.2 X 2.4 m2.

Finally, and more advantageously, the piece with thermal insulation properties is a monobloc piece or two monobloc pieces.

The invention also refers to a bidirectional forging structure, which comprises a plurality of prefabricated bidirectional forging elements according to any of the preceding claims supported on the upper surface of some jaws by said support elements.

Brief description of the drawings

To better understand how much has been exposed, some drawings are attached in which, schematically and only by way of non-limiting example, a practical case of realization is represented.

Figures 1-5 represent schematically the different stages of obtaining the prefabricated element.

Figure 6a is a schematic perspective view of the part used as a mold for obtaining the prefabricated element and as an insulation thereof, according to a first preferred embodiment.

Figure 6b is a schematic perspective view of the part used as a mold for obtaining the prefabricated element and as an insulation thereof, according to a second preferred embodiment.

Figure 7a is a perspective view of the slab element obtained, when the mold of the first embodiment is used.

Figure 7b is a perspective view of the slab element obtained, when the mold of the second embodiment is used.

Figure 8 is a perspective view of elements obtained according to the method of the invention prior to being placed in jácenas.

Figure 9 is a perspective view of a support element of the floor element of the invention.

Figure 10 is an elevation view of the support element.

Description of a preferred embodiment

As illustrated in Figures 1 to 5, the invention relates to a method of manufacturing prefabricated two-way forging elements 1 of reinforced concrete H A and provided with thermal insulation, comprising the steps of:

a-Horizontally arrange a part 2 with thermal insulation properties at the bottom of a formwork E, represented in section in Figure 2, where this part 2 is a matrix M of parallelepipeds 3 on a rectangular plate 4, so that it is con fi gured a network of channels 5 perpendicular to each other for concrete reception

H.

b-Arrange the reinforcement A in the channels 5 that are con fi gured between the parallelepipeds.

c-Pour concrete H into channels 5.

d-Remove part 2 and set concrete H.

In this way, a lightened bidirectional forging element 1 is obtained which incorporates an insulation 2 such as those illustrated in Figures 7a and 7b.

These two variants differ in that in the first of them the finished product has a concrete fence, while in the second, the concrete structure ends laterally at protruding ends.

Therefore, both differ in the concrete / insulation ratio, the lowest ratio being that of the second embodiment represented in Figure 7b, which constitutes the preferred option.

It should be noted that in Figures 1 to 5 the manufacture of the elements according to the first embodiment has been described, but it is obvious to extend it to elements according to the second embodiment.

Preferably, after stage c, a stage is provided consisting of arranging at the ends of some channels 5,

or preferably all, support elements 6 provided with a support flange 6a protruding laterally from the element 1 by its upper edges.

This tab, as illustrated in Figure 8, will support the element obtained on the j-jengs. Being arranged at the upper edges, the element will be disposed with its upper surface flush with the upper surface of the jácena, with which the occupation in the vertical direction will be the same both in the forging element and in the support structure, which will allow to obtain directly wide continuous flat surfaces.

The invention also provides an inventive embodiment of these support elements.

Specifically, as seen in Figures 9 and 10, the support elements 6 comprise a metal plate 6b, said support flange 6a being constituted by the protruding section of said plate 6b.

Extending from the lower surface of the plate 6 there are two anchors intended to be embedded in the concrete H, a first 6c perpendicular to the plate 6b, and the second 6d at an angle of 45 ° with the first 6c.

The first anchor has the function of guaranteeing the good ribbing of the nerve and increasing the solidarity between the support and the concrete.

The second anchor is preferably with weld seams and its 45º direction sews the theoretical cutting edge of the nerve in shear stress.

Preferably, as seen in Figures 9 and 10, the first anchor 6c is a U-shaped pin and the second anchor 6d is two pins, and more preferably, the pins are extended by sections 6e parallel to the plate, so that the second anchor 6d is folded at an angle of 135 °.

As can be seen in Figure 8, with the elements obtained by the process of the invention, a bidirectional forging structure can be constructed in a minimum time, where the modular prefabricated forging elements rest on the upper surface of jácenas J through these support elements

6.

When the elements integrate the pavement and the false ceiling, once the elements are arranged, the slab integrates all the layers, especially the thermal insulation, and is also at the same height as the jácenas that support it.

Claims (31)

1. Manufacturing procedure for prefabricated two-way forged concrete elements (1) of reinforced concrete (H) (A) and provided with thermal insulation, which includes the steps of: a) Horizontally arrange a part (2) with thermal insulation properties at the bottom of a formwork (E), said part (2) being a matrix (M) of parallelepipeds (3) on a rectangular plate (4), so that a network of channels (5) perpendicular to each other for the reception of concrete (H) is con fi gured. b) Arrange the reinforcement (A) in said channels (5). c) Pour the concrete (H) into said channels (5). d) Remove part (2) and set concrete (H) together. So that a lightened bidirectional forging element (1) is obtained that incorporates an insulation (2).

2.

Method according to the preceding claim, which comprises prior to step c) a step consisting of arranging at the ends of some channels (5) support elements (6) provided with a support flange (6a) protruding laterally from the element ( 1) by its upper edges.

3.

Method according to the preceding claim, wherein the support elements (6) comprise a metal plate (6b), said support flange (6a) being constituted by the protruding section of said plate (6b), extending from the lower surface of the plate (6) two anchors destined to be embedded in the concrete (H), a first one (6c) perpendicular to said plate (6b), and the second one (6d) forming an angle of 45º with the first one (6c) .

Four.

Method according to the preceding claim, wherein the first anchor (6c) is a U-shaped pin and the second anchor (6d) is two pins.

5.

Method according to the preceding claim, in which the pins are extended by two sections (6e) parallel to the plate, so that the second anchor (6d) is bent at an angle of 135 °.

6.

Method according to any of the preceding claims, which comprises a step of joining a layer of pavement to the upper surface of the element.

7. Method according to the preceding claim, wherein the floor is self-supporting.

8.

Method according to any of the two preceding claims, wherein the floor is calcium sulfate.

9.

A method according to any of the three preceding claims, wherein the joint between the pavement and the slab element is flexible such that it does not transmit the vibrations.

10.

Method according to any of the four preceding claims, wherein the thickness of the pavement is between 2.5 and 3.5 cm.

eleven.

Method according to any of the two preceding claims, wherein said joints have a thickness between 4 and 6 mm.

12.

Method according to any of the preceding claims, which comprises a step of adhering a ceiling finish layer with fire retardant properties.

13.

Method according to the preceding claim, wherein said ceiling finish comprises a substructure of steel profiles adhered to the concrete of the element and a cover plate adhered to said substructure, so that an air chamber is con fi gured.

14.

Method according to the preceding claim, wherein said cover plate is non-reactive against fire with a minimum of 30 minutes.

fifteen.

Method according to the preceding claim, in which the cover plate is made of plaster, fire retarded synthetic fibers or fire retarded wood.

16.

Process according to any of the preceding claims, wherein the part (2) is made of expanded polystyrene or other lightweight insulating materials.

17.

Method according to any of the preceding claims, in which the part (2) has been previously obtained by emptying by cutting with thread.

18.

Method according to any of the preceding claims, wherein the reinforcement (A) is a prefabricated reinforcement.

19.

Method according to any of the preceding claims, wherein the concrete (H) is of the self-compacting type.

20. Method according to any of the preceding claims, wherein the c) stage of concrete pouring (H) is made with vibrated.

twenty-one.

Method according to any of the preceding claims, wherein the parallelepipeds have a edge between 240 and 360 mm, preferably between 290 and 310 mm.

22

Method according to any of the preceding claims, wherein the rectangular plate (4) has a thickness between 25 and 35 mm, preferably between 28 and 32 mm.

2. 3.

Method according to any of claims 12 to 15, wherein the air chamber has a height between 25 and 30 mm.

24.

Method according to any of claims 12 to 15 or 23, wherein the cover plate (false ceiling) has a thickness between 40 and 50 mm, preferably 45 mm.

25.

Method according to any of the preceding claims, wherein the channels have a width between 90 and 110 mm, preferably 100 mm.

26.

Method according to any of the preceding claims, in which the parallelepipeds have a square planar section between 600 and 800 mm, preferably between 690 and 710 mm, and more preferably 700 mm.

27.

Method according to any of the preceding claims, wherein the elements obtained are rectangular with one side between 6.8 and 7.6 m and the other side between 2.2 and 2.6 m, preferably 7.2 X 2.4 m2

28.

Method according to any of the preceding claims, wherein the part with thermal insulation properties is a monobloc part or two monobloc parts.

29.

Method according to claim 5, wherein the metal plate (6b) has a length between 240 and 260 mm, preferably 250 mm, the first anchor has a length between 250 and 280 mm, preferably 265 mm, the first section The second anchor has a length between 330 and 370 mm, preferably 350 mm, and the second section a length between 240 and 260 mm, preferably 250 mm.

30

Bidirectional forging structure with thermal insulation, comprising a plurality of prefabricated bidirectional forging elements (1) according to any of the preceding claims supported on the upper surface of a few jaws (J) by said support elements (6).

SPANISH OFFICE OF THE PATENTS AND BRAND Application no .: 201030826 SPAIN Date of submission of the application: 31.05.2010 Priority Date: REPORT ON THE STATE OF THE TECHNIQUE 51 Int. Cl.: See Additional Sheet RELEVANT DOCUMENTS

Category

56 Documents cited Claims Affected

X

US 4942707 A (HUETTEMANN ERIK W) 07/24/1990, column 3, line 4 - column 4, line 6; column 5, line 53 - column 7, line 36; Figures 1, 2, 10, 11. 1, 6-28

Y

2, 30

Y

WO 2005108700 A1 (PLASTEDIL SA) 11/17/2005, page 18, line 14 -page 19, line 4; page 35, line 29 -page 36, line 17; Figures 1, 11 -13. 2, 30

X

EP 2146017 A1 (BELETTO AG) 01/20/2010, & Summary of the EPODOC database. 1, 6-11, 16, 18-22,

Recovered from EPOQUE; AN EP-09165535-A; Figures 1, 3, 11, 12.

25-27

X

US 5172532 A (GIBBAR JR JAMES H) 12/22/1992, column 4, line 4-column 6, line 57; 1, 6-11, 16-22,

Figures 1, 2.

25-28

TO

GB 110211 A (AVEY SAMSON) 10/18/1917, page 3, lines 3-20; Figures 4, 5. 2, 30

TO

NL 2001087 C1 (STADI ONTWIKKELING B V) 06/16/2009, & EPODOC database summary. Recovered from EPOQUE; AN NL-2001087-A; figures. 1, 30

TO

US 3579937 A (LUKENS EDWARD E) 05/25/1971 column 2, lines 59-62; Figures 4, 5. 2, 30

Category of the documents cited X: of particular relevance Y: of particular relevance combined with other / s of the same category A: reflects the state of the art O: refers to unwritten disclosure P: published between the priority date and the date of priority submission of the application E: previous document, but published after the date of submission of the application

This report has been prepared • for all claims • for claims no:

Date of realization of the report 03.05.2012

Examiner S. Fernández de Miguel Page 1/5

REPORT OF THE STATE OF THE TECHNIQUE Application number: 201030826 CLASSIFICATION OBJECT OF THE APPLICATION E04B5 / 04 (2006.01) E04B5 / 14 (2006.01) E04C2 / 288 (2006.01) Minimum documentation sought (classification system followed by classification symbols) E04B, E04C Electronic databases consulted during the search (name of the database and, if possible, terms of search used) INVENTIONS, EPODOC State of the Art Report Page 2/5  WRITTEN OPINION Application number: 201030826 Date of Written Opinion: 03.05.2012 Statement

Novelty (Art. 6.1 LP 11/1986)

Claims Claims 2-5, 7-11, 13-15, 21-27, 29, 30 1, 6, 12, 16-20, 28 IF NOT

Inventive activity (Art. 8.1 LP11 / 1986)

Claims Claims 3-5, 29 1, 2, 6-28, 30 IF NOT

The application is considered to comply with the industrial application requirement. This requirement was evaluated during the formal and technical examination phase of the application (Article 31.2 Law 11/1986).  Opinion Base.- This opinion has been made on the basis of the patent application as published. State of the Art Report Page 3/5  WRITTEN OPINION Application number: 201030826 1. Documents considered.- The documents belonging to the state of the art taken into consideration for the realization of this opinion are listed below.

Document

Publication or Identification Number publication date

D01

US 4942707 A (HUETTEMANN ERIK W) 24.07.1990

D02

WO 2005108700 A1 (PLASTEDIL SA) 11/17/2005

D03

EP 2146017 A1 (BELETTO AG) 01/20/2010

D04

US 5172532 A (GIBBAR JR JAMES H) 22.12.1992

D05

GB 110211 A (AVEY SAMSON) 18.10.1917

D06

NL 2001087 C1 (STADI ONTWIKKELING B V) 06/16/2009

D07

US 3579937 A (LUKENS EDWARD E) 25.05.1971

2. Statement motivated according to articles 29.6 and 29.7 of the Regulations for the execution of Law 11/1986, of March 20, on Patents on novelty and inventive activity; quotes and explanations in support of this statement The present invention relates to a manufacturing process for prefabricated reinforced concrete bidirectional forging elements and a bidirectional forging structure obtained with said elements. Document D01 anticipates the features described in claim 1 referring to the manufacturing process. Said document discloses a method for making bidirectional reinforced concrete slabs provided with thermal insulation. The method comprises the step of horizontally arranging a piece (12) with thermal insulation properties in a formwork (36), the piece being a matrix of parallelepipeds on a rectangular plate, so that a network of perpendicular channels (14) is configured. each other for the reception of concrete (see figure 1). Likewise, it comprises the steps of arranging the reinforcement (24) in said channels, pouring the concrete (22) into said channels and jointly removing the piece and the set concrete. In view of the preceding document, claim 1 is comprised in the prior art and is therefore not new or imply inventive activity (Art. 6.1 and Art. 8.1 of LP 11/1986). Documents D03 and D04 have similar characteristics although the prefabricated elements described by the latter apply to the realization of walls. Claim 2 adds a step consisting in arranging at the ends of some channels some support elements that protrude laterally from the forging element at its upper edges. The previous documents do not have this characteristic, however, document D02 shows the realization of reinforced concrete slab elements provided with thermal insulation that have support elements (12) provided with protruding flanges at the ends of some channels (4). laterally of the slab element (2) (see figures 1, 12 and 13). This document differs only in that said support elements protrude at medium height and not from the top. The placement at one height or another of the support elements are considered obvious variants for a person skilled in the art. As an example, document D05 is cited (see figure 4). It is considered obvious for one skilled in the art to combine the technical characteristics of documents D01 and D02 and arrive at the invention as described in claim 2. Therefore, the invention defined in this claim derives from the state of the art of an obvious way for an expert in the field and does not imply inventive activity (Law 11/1986, Art. 8.1). Claim 6, relating to joining a pavement layer to the upper surface of the element, is anticipated by document D01 (see column 6, lines 36-38). Claims 7-11, refer to said pavement but are expressions of desire or refer to measures or material of known composition and lack inventive activity. Claims 12 and 15, which describe the possibility of adhering a ceiling finish layer with fire retardant properties, are likewise anticipated by document D01 (see column 6, lines 45-49). Claims 13 and 14, also related to the roof finishing layer, lack inventive activity as they are respectively configurations known in the state of the art and mere expressions of desire without specific technical characteristics. . State of the Art Report Page 4/5  WRITTEN OPINION Application number: 201030826 Claims 16-20, relating to the use of expanded polystyrene pieces or other light insulators, to obtain them by emptying by cutting with wire and the concrete used, are likewise anticipated by document D01. Claims 21-27, which detail the dimensions of the different elements used, lack inventive activity. Claim 28 expresses the possibility of realizing the thermal insulation element by a single piece or by two. This possibility is also contemplated in document D01 (see column 6, lines 50-64). In relation to independent claim 30, referring to the floor structure, document D01 describes a floor structure comprising a plurality of prefabricated two-way floor elements (10). Document D02 shows the support of forged elements (2) on the upper surface of some jaguars (60) by means of support elements (12). Consequently, it is considered that this claim lacks inventive activity (Law 11/1986, Art. 8.1). State of the Art Report Page 5/5