GB2324545A

GB2324545A - Panels for e.g. walls or floors

Info

Publication number: GB2324545A
Application number: GB9703304A
Authority: GB
Inventors: Adolf Imhoff
Original assignee: Individual
Current assignee: Individual
Priority date: 1996-05-21
Filing date: 1997-02-18
Publication date: 1998-10-28
Also published as: ATE246290T1; EP0808959B1; EP0808959A2; GB9703304D0; DE19620296C1; DE59710490D1; EP0808959A3

Abstract

A construction system employing self-supporting panels for walls, partitions and floors uses framed panels with different core materials for the different uses. These panels are interconnected at their edges by elongate connectors (14). Each panel has edge channels interconnected by parallel internal sections (4), of rectangular channel section, with undercut recesses on each side, and arranged in spaced opposed pairs. Core material, (7), (Fig.3, not shown), which extends between the opposed pairs of sections (4), may be light-weight concrete, the density being chosen according to the panel use. The spaces (8) between the backs of the sections (4) can also be filled with light-weight concrete, or they can be filled with structural concrete which can be pre-stressed.

Description

2324545 1 COMPOSITE CONSTRUCTION SYSTEM USING SELF-SUPPORTING PANEL

ELEMENTS The invention relates to composite construction systems comprising self- supporting panel elements for use, in particular, as pre-fabricated wall and ceiling elements for buildings, each panel element comprising continuous U-shaped frame profiles and being divided into individual segments by load-bearing structural sections which are each closed on three sides and are fixed at an angle to the frame profiles, each segment comprising a core layer located between a pair of load-bearing structural sections arranged with their open sides facing each other.

There is nothing new in the concept of forming entire walls and ceilings using pre-fabricated units for the fast erection of buildings. When they are produced in a factory, such prefabricated units are manufactured in accordance with parameters determined by the architecture of the building in question. The provision of additional features such as door and window openings in the pre-fabricated unit are also carried out in the factory. Although such units can be produced inexpensively in larger batches, any adjustment to the size and function of the respective element can result in costly modification.of the s, 2 production process.

A self-supporting panel element of the type referred to above is known from DE-GM 9016771.6. Although the panel element produced in this manner can be easily adapted to its respective purpose in relation to its size and function, practical experience has shown that panel elements of this kind are not ideally suited for use as wall or ceiling elements. This is because all the identically produced panel elements in this well known construction system have to be designed in such a way as to withstand the normal forces occurring in the walls of buildings, as well as the bending moments in ceilings.

depending upon whether the panel is used as a element, the panel elements may be stronger Furthermore, it has been shown that joining the elements is very time-consuming, and hence individual abutting ends or bearing areas have using bolts.

Consequently, wall or ceiling than need be. individual panel costly, as the to be connected The object of the invention is to create a composite system for construction purposes which uses self-supporting panel elements that can be produced simply and cheaply, even in small batches, and which allows the elements used to be individually designed 3 with respect to the relevant structural engineering requirements.

According to the invention there is provided a composite construction system comprising self-supporting panel elements for use, in particular, as pre-fabricated wall and ceiling elements for buildings, and connecting sections for location between panel elements which are to be joined together, each panel element comprising continuous U-shaped frame profiles and being divided into segments by load-bearing structural sections which are each closed on three sides and are fixed at an angle to the frame profiles, each segment comprising a core layer located between two load-bearing structural sections arranged so that their open sides face each other, the core layer comprising a material having a density and/or composition dependent on whether the panel element is to be used as an exterior building wall, interior partition wall or ceiling element, the load-bearing structural sections between each pair of adjacent segments being spaced apart so that the cross-pieces of the sections face each other to define therebetween a support area which is packed with filling material, the load-bearing structural sections each having undercut recesses in all three of its closed sides projecting into the space bounded by said three closed sides, and the connecting sections each being shaped depending on whether 4 it is to be used in joining two wall panel elements or a wall panel element and a ceiling panel element.

A construction system comprising self-supporting panel elements constructed in this manner can easily be produced to comply with any requirements relating to its size and function. This makes it particularly well suited to the production of small batches and individual designs. Particularly advantageous in terms of cost, is the fact that the density and the composition of the core layer of the panel elements can be individually adjusted, depending on whether the panels are being used as exterior building walls, interior partition walls or ceiling elements. A further costreducing advantage is that the individual panel elements can be joined together quickly and easily using the special connecting sections incorporated in the composite system of the invention.

Dividing the panel elements into several segments using structural sections provides an overall frame or truss-type structure that can be adapted to differing requirements by selecting the number and size of the segments accordingly. The individual segments can serve different functions within a panel element. Normally, the segments fulfil their primary function as wall or ceiling sections. In this case, the core layer of the segments consists of lightweight concrete, the core layer of a panel element used in an exterior building wall having the lowest density and that of a panel used for an interior partition wall having the highest density. At the same time, any openings for doors, windows and similar features can be included in the segments as required.

In a preferred form of the invention, the connecting sections for joining wall and ceiling elements together are U-shaped sections with bent-out limbs, whereby the gap between the limbs is greater than the width of the frame profiles bordering the long edges of the panel elements. Permanent fixing of these ceiling connector sections to the ceiling elements enables the ceiling and wall elements to be joined together simply and securely. The ceiling connector section that is joined to the ceiling element may be positioned on top of a wall element so that it overlaps the wall element frame profile, or it may be positioned below a wall element so that the frame profile at the bottom of the wall element is received in the U-shaped ceiling connector section.

To guarantee a secure and permanent joint between the respective ceiling connector section and the wall element frame profile 6 fixed into it, a layer of mortar is preferably applied between the ceiling connector section and the frame profile. This mortar layer ensures that the frame profile of the wall element and the ceiling connector section of the ceiling element cannot move relative to each other.

To adapt the panel elements used as a ceiling unit to withstand the bending moments that occur, the support areas of each panel element can be packed with standard concrete as the filling material and pre- stressable, reinforcing steel bars can be arranged in the support areas.

On the other hand, it is sufficient, when using the panel elements as wall elements, to fill the support areas of each panel element with a material that has an identical density and composition to that making up the core layer.

It is also proposed in this invention that the abutting faces of two wall elements that are to be joined together at right-angles may be linked using an open load-bearing structural section provided on each abutting face facing the opposing abutting face. In a preferred form of the invention, the free limbs of the facing open load-bearing structural sections are shortened in 7 such a way that the recesses formed in the limbs only have the undercut that is nearest to the cross-piece.

When two wall elements are to be joined together at right-angles, it is proposed that the facing open load-bearing structural sections at the abutting faces are positioned in such a way that they can be joined together using two clamps, each of which grips behind the undercuts in the limbs located nearest to the crosspieces, of the load-bearing structural sections.

Finally, the invention proposes that the area bounded by the facing open load-bearing structural sections and the clamping sections joining the structural sections together may be filled with a material corresponding to that making up the core layer.

An example of a composite construction system in accordance with the invention will now be described with reference to the accompanying drawings, in which:

Figure 1 is a view of a self-supporting panel element formed as a wall element, showing the top layer partly cut away; 8 Figure 2 is a cross-section along the line II-II in Figure 1; Figure 3 is a cross-section corresponding to Figure 2 through part of a self-supporting panel element constructed as a ceiling element; Figure 4 is a schematic view of the joint between a ceiling panel and two wall panels, one above and one below the ceiling panel; Figure 5 is a schematic view of a right-angled joint between two wall panels.

Figure 6a shows the cross-sectional shape of a load-bearing structural section; Figure 6b shows the cross-sectional shape of a frame profile; Figure 6c shows the cross-sectional shape of a ceiling connector section; and Figure 6d shows the cross-sectional shape of a clamping section.

The panel element 1 shown in Figure 1 is divided into a total of tw#b 9 six rectangular segments 2. The top and bottom edges of the panel element 1 are formed by frame profiles 3, which extend continuously over all six segments 2. As is clear from Figures 4 and 6b, the frame profiles 3 are in the form of U-shaped stringers, i.e. closed on three sides.

The panel element 1 is divided into the individual segments 2 by means of load-bearing structural sections 4 which are arranged at right-angles to the frame profiles 3 and are firmly attached to them. Each of the loadbearing structural sections 4 has an essentially U-shaped cross-sectional profile, closed on three sides, and, as Figure 6a shows, the section 4 consists of two lateral limbs 5 and a cross-piece 6 connecting them. Each segment 2 comprises a pair of load-bearing structural sections 4 arranged with the limbs 5 of one facing the limbs of the other, and between the two sections 4 there is a core layer 7, having a thickness which corresponds to the gap between the two limbs 5 of each section 4. Particularly good heat and sound insulation, together with sufficient natural stability of the panel elements 1 formed by the individual segments 2, is achieved by using open-pore lightweight concrete as the material of the core layer 7. The density and/or composition of this lightweight concrete used for the core layer 7 of the segments 2 is adjusted according to the use envisaged for the individual panel elements. The use of the panel elements 1 as exterior building walls, interior partition walls or ceiling elements makes different demands on the forces and moments to be withstood, and also with respect to the required heat and sound insulation. The lowest density core material is used for exterior building walls because these need to have good heat insulation. The low density, brought about by the particularly large-pore nature of the lightweight concrete, provides for particularly good heat insulation. Sound insulation, which is especially important inside buildings, is attained by means of a large mass, and hence a high density core layer 7 material is used. The density of the material in the core layer 7 of panel elements used as ceiling elements lies between the core layer density of the exterior building wall elements and the core layer density of the partition wall elements.

Figure 2 also shows that the neighbouring load-bearing structural sections 4 of adjacent segments 2 have their cross-pieces 6 facing each other with a gap between them. In this way, a support area 8 is formed between the facing cross-pieces 6 of the load-bearing structural section 4. In the case of panel elements 1 serving particularly as wall elements and subjected only to normal forces, the material used for filling the support areas 8 is the same as that making up the core layer 7.

Furthermore, it can be seen from Figures 1 and 2 that both sides of the panel element 1 have a covering layer 9 which is not only capable of providing fire protection, but also has an additional insulating effect.

Figure 3 shows a longitudinal section of part of a panel element 1 constructed as a ceiling element. As ceiling elements are particularly exposed to bending stress and, thus, moment loading, the required stability of these panel elements 1 when using lightweight concrete as the material for the core layer 7 can be achieved by filling the support areas 8 with normal concrete containing pre-stressed reinforcing steel bars 10. Otherwise, the structure of the panel element 1 used as a ceiling element corresponds to that of the panel element 1 described with reference to Figure 2, for use as a wall element.

The design of the load-bearing structural sections 4 is shown clearly in Figure 6a. As mentioned earlier, the section 4 has a U-shaped profile closed on three sides and defining two limbs 5 joined by a cross-piece 6. The limbs 5 and the cross-piece 6 12 each have a recess recess 11 projecting into the area bounded by the three sides, and each side of each recess 11 defines a devetailed undercut 12.

Individual panel elements 1 may be linked together in a wall-to ceiling joint or a wall-to-wall joint via connecting sections 13, 14, as shown in Figures 4 and 5.

Figure 4 shows a schematic diagram of a wall-ceiling-wall joint in which U-shaped sections as shown in Figure 6c are used as connecting devices 13. The limbs 13a of the connecting device 13 are bent outwards with a gap between them that is greater than the width of the frame profiles 3 bordering the long edges of the panel elements 1. Figure 4 shows that a ceiling element is joined to two wall elements by fixing two connecting sections 13 on opposite sides of the ceiling element in such a way that the free limbs 13a of each section point away from the ceiling element. The connecting sections 13, which are open at the top and bottom, receive the wall elements enclosed by the frame profiles 3. The limbs 13a form a lateral guide for the frame profiles 3 of the wall elements, enabling easy alignment of the wall elements in relation to the ceiling element. To connect the wall elements to the ceiling element and to prevent any movement 13 of the frame profiles 3 in relation to the connecting section 13, a mortar layer 15 is deposited between the connecting sections 13 and the frame profiles 3.

Figure 5 shows the right-angled joining of two panel elements constructed as wall elements. The abutting faces of the wall elements to be joined together at right-angles are each formed with an open load-bearing structural section 4 which faces that on the opposing abutting face. In the example shown in Figure 5, the free limbs 5 of the facing open loadbearing structural sections 4 are shortened in such a way that the recesses 11 in the limbs 5 possess only one undercut 12, namely the undercut 12 nearest to the cross-piece 6. Two wall elements can be joined together at right-angles in a particularly stable manner by having the facing load-bearing structural sections 4 joined together by two connecting sections 14 formed as clamping sections, and by having the volume bounded by the two open loadbearing structural sections 4 filled with lightweight concrete. The connecting sections 14 grip behind the undercuts 12 in the limbs 5 of the load-bearing structural sections 4. Executing a wall-to-wall joint in this manner provides a precise rightangled connection between two wall elements, and at the same time prevents any reciprocal shifting of the wall elements. The 14 design of the connecting section 14 is shown in Figure 6d.

A construction system as described above is designed for construction purposes using self-supporting panel elements 1 and facilitates the simple and inexpensive production of panel elements 1 tailored to their respective use. Besides allowing for adaptation of the size and function of the individual panel elements 1, the system also permits adjustment with regard to the mechanical stress that has to be withstood as well as heat and noise insulation.

Claims

1. A composite construction system comprising self-supporting panel elements for use, in particular, as pre-fabricated wall and ceiling elements for buildings, and connecting sections for location between panel elements which are to be joined together, each panel element comprising continuous U-shaped frame profiles and being divided into segments by load-bearing structural sections which are each closed on three sides and are fixed at an angle to the frame profiles, each segment comprising a core layer located between two load-bearing structural sections arranged so that their open sides face each other, the core layer comprising a material having a density and/or composition dependent on whether the panel element is to be used as an exterior building wall elemen interior partition wall or ceiling t, the load-bearing structural sections between each pair of adjacent segments being spaced apart so that the cross-pieces of the sections face each other to define therebetween a support area which is packed with filling material, the load-bearing structural sections each having undercut recesses in all three of its closed sides projecting into the space bounded by said three closed sides, and the connecting sections each being shaped depending on whether it is to be used in joining two wall panel 16 elements or a wall panel element and a ceiling panel element.

2. A construction system according to claim 1, in which the core layer material consists of lightweight concrete, the core layer material of a panel element used as an exterior building wall having the lowest density and the core layer of a panel element used as an interior partition wall having the highest density.

3. A construction system according to claim 1 or claim 2, in which at least one segment is provided with a window or a door.

4. A construction system according to any one of the preceding claims, in which the connecting sections used to join together wall elements and ceiling elements are U-shaped sections provided with limbs bent outwards, the gap between the limbs being greater than the width of the frame profiles bordering the long edges of the panel elements.

5. A construction system according to claim 4, in which the ceiling connector sections are permanently attached to the ceiling panel elements.

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6. A construction system according to claim 4 or claim 5, in which a mortar layer is applied between the ceiling connector sections and the frame profiles of the wall panels to be joined to the ceiling panel.

7. A construction system according to any one of the preceding claims, in which, in the case of a ceiling element, the support areas of the panel element are packed with standard concrete as a filling material and prestressed reinforcing steel bars are positioned in the support areas.

8. A construction system according to any one of the preceding claims, in which, in the case of a wall element, the support areas of the panel element are packed with lightweight concrete as the filling material, the density of this filling material corresponding to the density of the material used in the core layer.

9. A construction system according to any one of the preceding claims in which the abutting faces of two wall elements to be joined together at right-angles are each provided with an open load-bearing structural section facing the opposing abutting face.

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10. A construction system according to claim 9, in which the free limbs of the facing open load-bearing structural sections are shortened, such that the recesses formed in the limbs only have the undercut that is nearest to the cross-piece.

11. A construction system according to claim 9 or claim 10, in which the facing open load-bearing structural sections are 3oined together by two connecting sections formed as clamping sections, each connecting section gripping behind the undercuts located nearest the cross-pieces of the load-bearing structural sections.

12. A construction system according to any one of claims 9 - 11, in which the area formed between the facing open load-bearing structural sections is filled with lightweight concrete.

13. A construction system as hereinbefore described with reference to the accompanying drawings.