ES2432823B1 - Insulating construction panel with easy adhesion and high mechanical resistance, and its application in new and rehabilitation works - Google Patents

Abstract

Insulating construction panel with easy adhesion and high mechanical resistance, consisting of an extruded polystyrene insulating core reinforced on both sides by two layers of an easily adhered cementitious mortar with a built-in fiberglass net, with the possibility of inserting a series of pultruded rods of mineral fiber-based material, or metal bars, that run longitudinally below both sides of the outer reinforcing faces, parallel to these. It allows to create systems of conditioning and finishing of floors, walls and roofs, especially those of fiber cement or metal plates, without the need now to have to be restored, and also, in its variant of armed panel, light roof structural systems.

Description

Insulating construction panel with easy adhesion and high mechanical resistance, and its application in new and rehabilitation works.

The object of the present invention is a construction panel that combines very good thermal insulating, waterproofing and mechanical resistance properties, with a great ease of adhesion to different materials, conceived to be used in the finishing or conditioning of floors, walls and roofs. lightweight, especially fiber cement or metal plates, which can now be preserved, and also, in its reinforced panel variant, forming a new structural support for said roofs. The different systems of application of the panel in the corresponding rehabilitation and new project works are also object of invention.

In its basic format, it is a lightweight sandwich structure with an insulated core of extruded polystyrene and with the possibility of presenting lateral recesses for the tongue and groove coupling between panels, having as a novelty the material that covers it on both sides exterior, which is a cementitious mortar of high adhesion reinforced with fiberglass, which makes it an excellent support for mortars, coatings and tiling of all kinds, being able to be placed practically on any surface, whether vertical, horizontal or inclined supports. Optionally the panel can be presented armed with a series of pultruded rods of suitable material that cross its core longitudinally, just below both sides of the outer reinforcing faces, conferring greater resistance and bearing capacity, which transforms it into a structural panel for sloping roofs.

A new construction panel is thus available with all the advantages of the sandwich panel with extruded polystyrene core, that is, a lightweight, insulating, water-resistant panel, high mechanical resistance and easy processing and handling, but with a novel exterior finish of reinforced cementitious adhesive that improves its insulating and waterproofing qualities, and gives it a high adhesion capacity, multiplying its applications, both in rehabilitation works, especially in the insulation of corrugated plate covers with the possibility of offering decorative finishes replacing roof tiles, according to the new application system, such as, in its format of reinforced panel, in new construction of light roofs, acting as a supporting structure, with the same possibilities of unique finishing.

The technical field of the invention is that of construction in general, both as regards the roof structures, as well as the structural elements for the finishing or rehabilitation of the different parts of the buildings.

STATE OF THE TECHNIQUE.-

An increasingly widespread practice in the construction sector is to use sandwich panels as structural elements for the finishing or rehabilitation of different parts of buildings, especially with regard to sloping roofs and light enclosures.

The sandwich panels respond to a prefabricated product consisting of an insulating core of polymeric material coated externally by sheets or plates of any resistant material, usually wood or wood agglomerate, but also plaster, fiber cement, asphalt layer or metallic coating, which usually has means of assembly or coupling between adjacent panels incorporated into its perimeter edges. Among them, a type of panel formed by a wooden structure or sandwich board with extruded polystyrene insulating core, with different finishes at the bottom to be visible on the ceiling of the space, are widely used in the construction of habitable roofs. inside of the cover.

The use of this type of insulating panels as a sustainable base for building roofs is a good constructive option for new and rehabilitation works, since being light panels, with a weight that ranges between 15 and 30 Kg per m2, which contributes to lighten the weight supported by the structure, have a high bearing capacity, which exceeds 1000 kg per m2, and also provide the thermal insulation necessary to dispense with additional insulating materials. However, wood is not a material to be exposed to the weather, so they require additional waterproofing structures once placed, such as corrugated plates between the panels and the roof.

Additionally, this type of panels has the disadvantage of being incompatible with the pre-existing roofs of corrugated fibrocement (uralite) or metal plates when it comes to performing rehabilitation and insulation works, since these plates do not support the weight or the means fixing the panels of the panels, so it is necessary to completely replace the roofs.

In any case, in these works of conditioning of light covers it is frequent to have to completely replace the cover plates, with the consequent cost, since it is necessary to introduce insulating elements below them.

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Well, it has been thinking of solving this problem as the panel that gives rise to the present invention has emerged, which is a sandwich panel with extruded polystyrene core, which is already known, but replacing the wood coating or wood agglomerate of its two outer faces, which is how this class of panels is normally used, by two layers of a cementitious mortar of high adhesion reinforced with fiberglass fabric, thus obtaining a perfect base for adhesives, mortars, coatings and tiling of mole type, which not only makes it possible to use the new panel in the insulation and waterproofing of light roofs without having to remove the corrugated plates, being a very light and resistant panel, which it can be fixed to said plates by mainly chemical means, and in turn be able to receive, for those same means, a tile-like finish layer for example, or a decorative substitution coating. tutive of the tile, but it opens a whole range of constructive possibilities, being able to be used equally in the insulation and finishing of other structural supports, such as pavements, walls and walls, according to different rehabilitation systems that are also claimed for invention.

In addition, from this simple or standard panel, a reinforced panel version has been created, by inserting reinforcement rods into its polystyrene core, which cross it longitudinally below both sides of the reinforcing faces, with in order to be able to be used as a supporting base of cover, replacing the usual corrugated plates, and to be able to offer an exterior termination similar to that of the standard panels.

The panel in question, both in its simple form and in its armed version, is considered an invention, at least at the national level, because although sandwich panels with polystyrene core are already known in various construction applications, In this case, the fiberglass reinforced cementitious coating on both sides of the panel and the built-in reinforcement create a new structure to be applied advantageously in the works.

In fact, a search for patents published with effect in Spain carried out in the SPTO's Young database reveals the absence of panels of these characteristics applied as constructive elements. Several patents are known for insulating panels for walls and roofs of a sandwich structure with a core of polymeric material, in particular extruded polystyrene, most of them utility models focused on the fixing mechanisms to the support structure or joint between panels to achieve greater impermeability and avoid the breakage of thermal bridges, as is the case of utility models with publication number ES1062413U "Insulating panel for light roofs and enclosures with thermal bridge breakage system", ES1035852U " Waterproof hot board ”, or ES1048024U“ Insulating and waterproofing coating plate applicable on roofs ”, but none of the patented panels foresee that the reinforcement layers are made of cementitious material, and even less with reinforcement reinforcements, which are singular elements of The present invention.

THE INVENTION.-

As already indicated, the insulating construction panel, of easy adhesion and mechanical resistance that serves as the basis for the present invention, is a sandwich panel consisting of an extruded polystyrene core of varying thickness depending on its application, reinforced on both sides by different layers of different materials, usually boards or agglomerates of wood, sheet metal, and with the possibility of presenting stepped and complementary recesses on its lateral sides to allow the tongue and groove coupling between panels, characterized in this case because the two outer layers of said polystyrene core are constituted by a high adhesion cementitious mortar with a built-in fiberglass net.

This reinforced adhesive material created on both sides of the panel covering, provides an adhesion capacity that adds to the good physical properties of its extruded polystyrene core, low weight (light panel), very low thermal conductivity (heat insulating) , very low water absorption (insulating) and high resistance to bending and compression stress (resistant), now being able to receive any plaster or tiling, such as sealing putties, plasters, paints, ceramic tiles, tiles, etc., and be able to be placed on all types of surfaces without practically the need for mechanical means, which allows its use in the rehabilitation or conditioning of light roofs of corrugated sheets of fiber cement or metal, which are structures that until now could not be preserved in these works , because due to their low weight it is supported without problem by these fragile covers and can be strongly adhered to them by Glued putties, without abusing aggressive mechanical fasteners that could break them apart, creating a base that sustains any roof finish, well the traditional tile, which is also secured on the panel by foams and glued putties, as waterproof coatings with decorative finishes especially developed for this purpose.

This adherent quality of the panel means that it can also be used in the regularization, insulation and waterproofing of walls and floors, according to appropriate methods described below.

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It should also be said that the cementitious layer on both sides of the panel, with its bonding on other construction supports, improves its insulating and waterproofing characteristics.

In particular, the advantages of this simple panel are the following:

•

It can be applied on any type of surface, and allows to receive any type of plaster or tiling material.

•

It is heat insulating and waterproof.

•

It has a high mechanical resistance against bending and compression efforts.

•

 It is light and stable.

•

Easy processing and handling

Optionally, the standard panel described can be assembled, by inserting into its core of extruded polystyrene a series of pultruded rods that cross it longitudinally below both sides of the outer reinforcing faces, parallel to them. These rods are made of a mineral fiber based material, such as a combination of polyester and fiberglass, but they can also be replaced by small diameter bars of carbon steel or stainless steel.

This reinforcement considerably increases its mechanical resistance, in terms of bearing capacity, making it a structural panel for the construction of light roofs, being able to act as a support base on the roof slab in advantageous substitution, mainly due to its handling in the installation and its insulating-waterproofing capacity in service, of the usual floorboards or fibrocement or metal plates used for that purpose, and with the same finishing means as the covers of plates with standard panels, particularly in regard to decorative coatings raincoats used to replace traditional roof tiles.

The systems of application of the standard panel are also claimed for invention in works of conditioning of corrugated roofs, walls and pavements, and in its variant of armed panel, in construction works of light roofs, since all of them include techniques and products novel for this purpose.

These construction systems based on the panels in question are the following:

a) Light roofs conditioning system with standard panels.-

The component panels are fixed to the wave or channel ridges of the corrugated or corrugated plates of this type of roof, usually fiber cement (uralite) or metal plates, by gluing by means of special elastomeric putty cords and mechanical anchoring by Expansion screws of adequate length, formed a network of panels as a covering of the supporting plate of the roof.

In the case of a tile termination, the joints of the panel framework are sealed in both directions with fiberglass felt tapes fixed by means of a special elastomeric putty in order to form a watertight support base for foam bonding. of polyurethane of the different types of tiles.

This traditional tile roof can be replaced by an innovative decorative waterproofing coating termination, in which case the sealing of the joint junction is no longer necessary, because a layer of approximately 1 mm thick of a layer is applied on the panel framework Elastic waterproofing reinforced with an agglomerate of fiberglass threads bonded together by a binder, in order to seal all the interstices of the joint joints between panels and form a cover finish layer in the chosen waterproofing color. As a preferred embodiment, this waterproofing layer is an aqueous emulsion based on acrylic polymers or elastomeric resins, with high strength additives and pigments that give it a certain color, such as red tile.

b) Conditioning system of walls and walls with standard panels.

The component panels are fixed to the wall or wall by bonding by means of a mortar of powder adhesive kneaded with water and mechanical fixation by means of perforating screws or rivets, forming a network of panels whose joints are sealed with self-adhesive and plastered tapes, in order to form a base waterproof for the application of different finishes, such as paint or tiling.

c) Pavement conditioning system with standard panels.

The component panels are fixed to the pavement by glued by means of a mortar made of adhesive powder mixed with water and mechanically fixed by means of perforating screws or rivets, forming a network of panels on which a layer of mixed cement glue cement is applied as a glue base. a

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Ceramic tile termination, or a self-leveling paste layer reinforced with mineral fiber fabric for a termination of carpet or vinyl coverings.

d) Roof construction system with reinforced panels.-

The component panels are mechanically fixed on the structural slab of the sloping roof of the building, by hooks for the case of metal profiles or concrete beams, or by perforating screws for the case of wooden beams, through between adjacent panels along the tongue-and-groove coupling edge until the wooden beam is perforated, forming a network of panels as the base of the roof.

On this base of reinforced panels the same finishing layers can be applied as in the case of standard panels for conditioning of corrugated roofs; in particular, a tile termination, which requires the sealing of the joints between panels with fiberglass felt tapes, adhered by elastomeric putties or a decorative waterproofing coating termination, according to the technique and products already described.

As we see, there are now new techniques for finishing and conditioning floors, walls and light roofs of buildings based on a new construction panel of very good physical performance, being light, insulating, waterproof and resistant, and high capacity adherent to be able to integrate easily and safely in all these construction elements, which can optionally be armed with pultruded rods to have a greater bearing capacity and also have application as a structural base of light roofs, replacing traditional corrugated plates or similar.

Plans and drawings.-

For a better understanding of the panel object of the invention and the way in which in its standard presentation or armed variant it is used in construction systems, the following figures are attached at the end of this specification:

Figure 1: Perspective view of the standard panel, where the outer layers of cementitious material with built-in fiberglass are appreciated.

Figure 2: Perspective view of the reinforced panel, with pultruded rods below both faces of coating.

Figure 3: Perspective view of the light roof conditioning system with tile termination using standard panels, where the means for fixing the panels to the corrugated plate are appreciated.

Figure 4: Perspective view of the light roof conditioning system with reinforced elastic lining termination based on standard panels, where the three component layers of the lining can be seen.

Figure 5: Detailed view of the mechanical fixing system of a standard panel to a corrugated roof plate.

Figure 6: Perspective view of the wall and wall conditioning system using standard panels, where the sealing strips between panels can be seen.

Figure 7: Perspective view of the pavement conditioning system using standard panels, where the intermediate position of the panels between the different system components can be seen.

Figure 8: Perspective view of the construction system of a building roof using reinforced panels, placed directly on a slab of trusses or metal profiles, with a reinforced elastic lining termination.

Figure 9: Detailed view of the mechanical fastening system using hooks of two coplanar reinforced panels to a metal profile or concrete beam

Figure 10: Detailed view of the mechanical fastening system by means of perforating screws from two coplanar reinforced panels to a wooden beam, where the passage of the screw through the tongue and groove of coupling between panels is appreciated.

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EXECUTION MODE.-

In the drawings of the aforementioned figures it can be seen that the described construction panel consists of a sandwich structure with an extruded polystyrene core (1) and outer faces (2) covered by a cementitious mortar reinforced with a fiberglass net, in such a way that on a first very fine layer of mortar (3) the fiberglass fabric (4) of grid weave is deposited around 5 mm of thread separation, which is in turn covered by a second end Capath layer of mortar.

The manufacture of this standard panel has no secret, starting from simple extruded polystyrene panels cut to size, on which the layers of mortar and fiberglass fabric are applied in a process train to the setting.

As a variant, the panel can be presented with a greater thickness and stepped recesses on its lateral sides for tongue and groove coupling, provided with a reinforcement of pultruded rods (5) of mineral fiber-based material, or even small-diameter steel bars, which gives it greater resistance to bending stresses and bearing capacity.

This reinforcement is implanted in the panel below both sides of the cementitious outer reinforcement layer, by opening longitudinal channels that once the rods are housed along them and retained with putty or cement, are closed with the same layer

The standard panel, of less thickness and without reinforcement, is intended for conditioning and finishing works of inclined roofs of corrugated plates (6), walls (12) and pavement floors (13), and the thicker reinforced panel, to new construction of light roofs, where supported by beams or floor slabs

(14) It must act as a supporting base for the roof or a decorative waterproof coating.

Starting from standard and prefabricated reinforced panels, the technical details of the building systems based on them created are described below in reference to the drawings.

a) Light roof conditioning system with standard panels (Figures 3, 4 and 5) .-

First of all it is advisable to clean the cover plate, and then waterproof the singular points of the cover, such as the gutter, using special waterproofing products. Next, the panels are placed, which are installed parallel to the ridge. The fixation can be done by gluing with a special elastomeric putty (7) on the wave crests or channels (6) of the cover plate, or by riveting, although in very exposed or covered areas of large dimensions the fixation can be made by gluing and riveting simultaneously. To adjust the size of the panels, they are cut using a saw.

For the riveting of panels to the cover plate, expansion screws (11) of suitable length are used, which is pierced by the screw.

One of the possible terminations of the paneled roof is the traditional tile placement. Once the joints between the panels are sealed with a fiberglass tape bonded with putty based on elastomers (8), the tiles are placed, which are adhered with polyurethane foam.

When the termination with reinforced elastic coating is chosen, the sealing of the joints is not necessary. In this case, the application of a hand approximately 1 mm thick is made of an elastic waterproofing (9) on which a glass fiber felt (10) is placed as a reinforcement as a reinforcement. It is well impregnated, ensuring that no bubbles remain and once dry, one or two hands of the elastic waterproofing (9) are applied, until a cover finish layer is formed in the color of the waterproofing chosen.

On this termination of elastic coating, once dry, the bonding of sheets or special mineraloplastic bands with slate appearance is carried out, then, once glued and dried, apply a protective varnish.

b) Wall and wall conditioning system with standard panels (Figure 6) .-

Standard panels can also be placed on walls or vertical walls (12) as a regularization layer. The placement is done by fixing the panels with specific mortars for bonding expanded polystyrene sheets to walls and partitions, ensuring that the surface is clean, free of dust, grease, oils and also be rough.

Once the mortar is dry, a mechanical fixation of the panels is done by means of perforating screws or rivets, to subsequently seal the joint joints with fiberglass tape placed with putty

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elastomeric (8). Once placed and mechanically fixed, the tape is placed in the joints of the panels. The joints between panels are plated and sanded, cleaning the dust and finally finishing with a suitable paint.

c) Pavement conditioning system with standard panels (Figure 7) .-

The standard panels also serve to regulate the surface and improve the thermal insulation in pavements (13). On the clean, dry and firm support, a layer of adhesive is applied with which the panels will be glued, then proceed to its mechanical fixation to the support, in order to obtain a firm, resistant and insulating base for the placement of any coating. It is convenient to leave about 10 mm around the perimeter, which will then be sealed with a polyurethane elastomeric putty-glue, before the installation of a skirting board.

Once the panels are installed, they can be finished by laying ceramic tiles that will be glued with a specific flexible glue cement. Another possibility is to regularize the surface with a layer of self-leveling paste, which can be reinforced with mineral fiber fabric, and on this layer proceed to the placement of carpet or vinyl type coverings.

d) Roof construction system with reinforced panels (Figures 8, 9 and 10) .-

Due to their characteristics, panels armed with pultruded rods can be used to replace roofs that need to be changed, or as a new construction enclosure, with the advantage that they are an excellent thermal insulation with a very low weight.

In the case of metal structures (14) that show signs of deterioration, they will be treated before placing the panels. To do this, first, the profiles are sanded well and cleaned to remove dust. Next, a primer layer is applied with an iron reconverting product in iron protection, or an anticorrosive primer for all kinds of iron surfaces and steels. Once the primer dries, two layers of synthetic enamel are applied. The structure is thus able to receive the enclosure and isolation plates, which are anchored to the trusses or metal profiles by suitable hooks (15).

The termination of the roof with tile or decorative waterproofing coating follows the same technique as for the standard panels, as shown in Figure 8 for the case of the synthetic coating.

The aforementioned structural panels are equally valid for concrete and wood structures, both in new construction and in the case of rehabilitation.

In rehabilitation of roofs with concrete slabs, once the existing roof is removed, a visual inspection of the state of the structure is carried out, mainly if there have been filtration problems. In this case it is very likely that the concrete that forms the structure may have signs of corrosion. The preparation will consist of cleaning, removal of deteriorated concrete, cleaning of the reinforcements with a steel brush and protecting them with an anticorrosive coating layer. Once dry, the section of the piece that is being repaired with specific mortar must be recomposed, and it is also advisable to protect the structure with paint.

Once the concrete structure has been rehabilitated, or in the case of new construction, the installation of the reinforced panels is carried out directly on the structure, using mechanical hook-type fasteners (15) as in the previous case.

In rehabilitation of roofs with forged wooden beams, once the existing roof is removed, a visual inspection of the state of the structure is carried out, mainly if there have been filtration problems, and if the wood is damaged or has a woodworm problem . If the wood is damaged and requires replacement in its section, epoxy resins are used to recompose them, available in liquid or pasty versions, depending on the type of application required. In general, for the replacement with this type of wood, fiberglass reinforcements are used, such as armament rods. Once the replacements have been made, it is convenient that the wooden beams are protected with special varnishes.

Once the wooden structure has been rehabilitated, or in the case of new construction, the installation of the reinforced panels is carried out directly on the beams, but in this case using screw-type mechanical fasteners (16), such as self-drilling screws or bolts, which cross adjoining panels by the tongue and groove coupling edge until the wooden beam is drilled.

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Claims (13)

one.

 Insulating construction panel with easy adhesion and high mechanical resistance, of the type of sandwich panels consisting of an insulated core made of extruded polystyrene (1), with the possibility of presenting stepped and complementary recesses on its lateral sides to allow tongue and groove coupling between panels, characterized in that the two outer layers (2) of the polystyrene core are constituted by a cementitious adhesion mortar (3) with a fiberglass net (4) incorporated.

2.

Insulating construction panel of high adhesion and mechanical resistance, according to the first claim, characterized in that the extruded polystyrene core (1) of the panel has a series of pultruded rods (5) inserted longitudinally underneath both sides of the faces of external reinforcement (2), parallel to these.

3.

 Insulating construction panel of high adhesion and mechanical resistance, according to the second claim, characterized in that the rods (5) that assemble the extruded polystyrene core of the panel are made of a mineral fiber-based material, such as a combination of polyester and fiber of glass.

Four.

 Insulating construction panel of high adhesion and mechanical resistance, according to the second claim, characterized in that the rods (5) that assemble the extruded polystyrene core of the panel are carbon steel or stainless steel bars.

5.

 Light roof conditioning system using the standard panel object of the first claim, characterized in that the component panels are fixed to the wave or channel ridges (6) of the corrugated or corrugated plates of this type of roofs, whether they are fiber cement plates –Uralite- or metal, by gluing using polyurethane foam cords (7) and / or mechanical anchoring by means of expansion screws

(11) of suitable length, a network of panels formed as a covering of the cover plate.

6.

Light roof covering system, according to the fifth claim, characterized in that the joints of the panel framework are sealed in both directions with fiberglass tapes bonded with elastomeric putty (8) in order to form a watertight base for placement by gluing with polyurethane foam of the different types of tiles.

7.

 Light roofing conditioning system, according to the fifth claim, characterized in that a layer of approximately 1 mm thick of an elastic waterproofing (9) reinforced with an agglomerate of fiberglass threads (10) is applied on the panel framework In order to seal all the interstices of the joint joints between panels and form a cover finish layer in the chosen waterproofing color.

8.

 Light roofing conditioning system, according to the preceding claim, characterized in that the elastic waterproofing (9) is an aqueous emulsion based on acrylic polymers or elastomeric resins, with high strength additives and pigments that give it a certain color.

9.

 Conditioning system for walls and walls using the standard panel object of the first claim, characterized in that the component panels are fixed to the wall or wall (12) by gluing by means of a mortar of water-mixed powder adhesive and mechanical fixation by means of perforating screws or rivets , forming a network of panels whose joints are sealed with fiberglass tapes bonded with synthetic plaster that allows smooth (8) and plaster finishes, in order to form a watertight base for the application of different finishes, such as paint or tiling.

10.

Pavement conditioning system using the standard panel object of the first claim, characterized in that the component panels are fixed to the pavement (13) by glued by water-mixed powder adhesive mortar and mechanically fixed by means of perforating screws or rivets, forming a framework of panels on which a mixed cement glue cement layer is applied as a glue base for a ceramic tile termination, or a self-leveling paste layer reinforced with mineral fiber fabric for a carpet or vinyl finish .

eleven.

Roof construction system using the reinforced panel object of the second or third claim in its panel variant with lateral flattened recesses for tongue and groove coupling between panels, characterized in that the component panels are mechanically fixed on the structural slab

(14) of the sloping roof of the building, by hooks (15) in the case of metal profiles or concrete beams, or by drilling screws (16) in the case of wooden beams, through in between adjacent panels by the tongue-and-groove coupling edge until the wooden beam is perforated, forming a framework of panels as the base of the roof. ES 2 432 823 Al 12. Roof construction system, according to the eleventh claim, characterized in that the joints of the framework of reinforced panels are sealed in both directions with self-adhesive tapes (8) in order to form a watertight support base for placement by gluing with polyurethane foam The different types of tiles. 5 13. Roof construction system, according to the eleventh claim, characterized in that a layer of approximately 1 mm thick of an elastic waterproofing (9) reinforced with an agglomerate of fiberglass threads (10) is applied on the framework of reinforced panels. ), in order to seal all interstices of the joint joints between panels and form a cover finish layer in the chosen waterproofing color. 14. Roof construction system, according to the preceding claim, characterized in that the elastic waterproofing (3) is an aqueous emulsion based on acrylic polymers or elastomeric resins, with additives and high strength pigments that give it a certain color ES 2 432 823 Al ES 2 432 823 Al ES 2 432 823 Al