ITUA20164792A1 - Double and simple construction net in pultruded fiber rods connected by composite connectors drilled to form nets or cages with known resistance to block insulating cladding panels, renovation of old walls or construction of new ones - Google Patents

Description

"Double and simple mesh for building in pultruded fiber rods linked by perforated composite connectors to form nets or cages with known resistance to block external insulation panels, renovation of old walls or construction of new ones"

TEXT OF THE DESCRIPTION

The present invention relates to a wall comprising one or more pillars and at least one core or infill wall comprising one or more insulating panels and / or a pre-existing wall to be consolidated.

It is known that glass or carbon fiber rods for building have a high mechanical strength / weight ratio, are resistant to corrosion, do not transmit thermally like iron, and are non-magnetic.

The purpose of this patent is the creation of composite connectors in the shape of bars with holes of the desired strength and position, to bind together glass fiber or carbon fiber rods or networks of rods placed inside and outside of walls, with the formation of cages designed to retain and consolidate the heavy components of walls to be restored with bricks, stones, concrete, or light ones such as insulating panels. The purpose of the patent is to create fiberglass connectors that can form networks of rods to block the insulation panels of the walls and prevent them from coming off over the years.

In construction it is necessary to create connectors to tie parallel or orthogonal rods and form brackets to replace the iron ones, to hold glass or carbon fiber rods to build concrete pillars and walls and form cages in the shape of cubes or parallelepipeds or other, of the precise dimension to 1-2 millimeters, of well calculated and desired resistance. The cages are useful for retaining blocks of insulating panels in single layer or in several layers and to form infill walls that can be tied to beams and load-bearing pillars, thus ensuring greater resistance to earthquakes and thermal insulation, even with external insulation, to the infill walls.

On the market there are already FRP (Fiber Reinforced Polymer) nets that can be laid on the interior and exterior of walls but are not connected to each other to form cages of high mechanical resistance on curtain walls. In fact, the external network is separated from the internal one and each is independent from the other and is simply fixed to the wall with glues that fix bars without holes, bent to L. On the market there are already products defined as connectors or fasteners: they are made up of bundles of fibers of carbon or glass that run parallel inside a dense mesh that holds the threads to form a rod of 3-8 mm in diameter: to use them, 7-10 cm of mesh is cut, freeing the threads that spread like a staple on the surface and glue the threads. Also this device cannot tie rod nets, it cannot form cages.

This technical problem is solved according to the invention with a wall as described at the beginning, in which the core or infill wall is held and supported within at least one cage formed by pultruded rods of composite material placed on the opposite faces of the core or wall and connected to each other by means of connectors of composite material, the connectors being made up of bars provided with holes for the passage and retention of the rods, and the pillars being provided with holes for the passage and retention of the rods or elements that have holes for the passage and retention of the rods .

In an executive example, a plurality of said cages formed by rods and connectors is provided, which cages are continuous, linked together and tied or rigidly fixed to said pillars or to other load-bearing structures of the buildings, as such pillars or structures they are equipped with holes from 3 to 50 mm in diameter to accommodate and hold the rods, or elements fixed or fastened to pillars or structures, which elements have holes from 3 to 50 mm in diameter for the passage and holding of the rods (4), which cages have the dimensions of the walls to be consolidated or of the pillars or walls to be built, or of the insulating panels to be retained to form the walls.

According to a further executive example, the ultimate tensile strength is as required by the project and therefore in margins between 3 and 300 KN, while the elastic modulus for highly seismic areas is 100-300 GPa, including rods and / or carbon fiber and / or glass fiber and / or basalt fiber connectors.

According to a further executive example, the said cage is installed for renovation and consolidation of old walls with a simultaneous increase in thermal insulation by adding insulating coats on the external surface of the wall, restructuring obtained by drilling through holes in the perimeter wall, inserting connectors in the holes with three holes, where these connectors have a length at least equal to the thickness of the wall and in addition the thickness of the insulating panel, where these three-hole connectors have a first hole on the internal surface of the wall, a second hole on the external surface of the wall, which two holes are designed to accommodate two rods with a diameter of 6-16 mm, preferably 10 mm to enclose the structure of the wall, while the third hole that protrudes outside accommodates a third row of rods with a diameter of 6-14 mm, preferably 8 mm, which must enclose the coat, where this three-hole connector is long enough to understand the thickness hours of the wall and insulating panels added to the external surface, to connect the triple network of external and internal rods to the wall forming the said cages, in the number necessary to treat the whole wall, where each component of the cage has a load resistance of breakage between 25 and 100 KN, in relation to the thickness and weight of the wall to be restored.

According to a further executive example, said cage is installed for renovation of old walls with two-hole connectors, with a diameter of 4-30 mm, with resistance between 3 and 100 KN at the ultimate breaking load, where said connectors have the length equal to the thickness of the wall, they penetrate through the wall to be restored, have on the external and internal surface of the wall the two holes through which rods of the desired length are placed, the rods being covered by plaster.

According to a further executive example, the wall itself is a new wall and in which the core or infill wall is made up of insulating panels, 40-400 mm thick, preferably 220 mm, to form infill walls between beams and pillars of load-bearing structures, where the cages form a cube or parallelepiped and have at least two rods on the same side of the cube or parallelepiped, which penetrate holes made in beams and pillars in the number established by the building project, to structurally tie the cages to beams and pillars, preventing the easy detachment and fall to the ground of the curtain walls in the event of seismic shocks, thus also obtaining perimeter walls with a stable thermal insulation over the years, of U = 0.100 - 0.280, preferably U = 0.120, where all the panels also external cladding are fixed in a stable and resistant way in the structure.

According to a further executive example, the pillars are made of concrete and are made of pultruded fiberglass or carbon rods held by composite brackets which brackets are equipped with holes with a diameter of 40 to 40 mm, or with bends similar to holes. open circular bars, with a diameter from 4 to 40 mm, to facilitate the insertion and blocking of rods for the formation of long walls and large surfaces, where the rods are blocked by glue or by iron wires within the open circular curve that is sized corresponding to the diameter of the rod.

The object of the invention is also a wall comprising a structural core or infill wall and a covering coat, which wall comprises one or more connectors consisting of composite bars or reinforced rigid plastic material, with resistance to the ultimate breaking load of 1 at 100 KN, preferably 30 KN, suitable for fixing the insulation, since the insulation consists of one or more insulating panels leaning against the surface of the wall or structural core, which insulation has a thickness of 30-300 mm, preferably 120 mm, in which the connectors have a length of 50-500 mm, preferably 200 mm, and a diameter of 5-20 mm, preferably 9 mm, and are equipped with one or two holes, with a diameter of 3-30 mm and placed at one end of the bar , where this bar is placed in a special cavity made in the structural core or infill wall in such a way that the hole or two holes of the bar are positioned outside the outer edge of the panel, the bar being fixed in the cavity by means of resin or glue, rods having a diameter of 3-16 mm, preferably 8 mm, of composite material comprising glass or carbon fiber or other, being provided, which pass into the holes of the connectors that protrude above the insulation, being the insulation and the rods covered with a 10-30 mm thick plaster.

The subject of the invention is also a method of manufacturing a connector consisting of a bar of composite material provided with one or more holes for the passage and retention of rods, which method involves the following steps:

a) strands of fiberglass, glass, E, S, basalt or carbon fiber are joined together and pre-wetted with epoxy or vinylester or other composite resins to form cords of 3-30 mm in diameter, preferably 10 mm ;

b) the ropes are wound around pins in the number of 2-30, in the desired number, with a diameter of 4-40 mm, which pins are fixed on steel plates at the desired distances between them;

c) after solidification of the resins around the pins, the ropes are extracted which therefore have holes with a diameter from 4 to 40 mm of the size as per the project and in the position as per the project with a maximum error of 1-3 mm, which size of the holes is suitable for accepting or connecting glass or carbon fiber rods with a diameter between 3 -30 mm, with an error plus or minus 1 mm, and resistance to the ultimate breaking load in relation to the type of fiber chosen between 30 and 300 KN, modulus elastic between 4-300 Gpa depending on the type of fiber used.

These and other characteristics and advantages of the present invention will become clearer from the following description of some executive examples illustrated in the attached drawings in which:

Figures 1, 2 and 3 show various views of a diagram for using the connectors in a new perimeter wall;

Figure 4 illustrates a further executive example of the wall;

figures 5, 6, 7 show detail views of the wall of figures 1, 2 and 3;

Figures 8, 9, 10, 11 and 12 show different embodiments of connectors;

Figures 13, 14 and 15 show the brackets; Figure 16 shows the skeleton of a pillar;

Figures 17 and 18 illustrate executive examples of connectors for connecting rods.

You have the following possibilities of use: 1- If the wall is in excellent condition and you only want to fix the external insulation panels, use the connectors in fig. 8 or 9 respectively with one or two holes 10. Their length is 80 mm plus the thickness of the insulating panel between 50 and 180 mm. See example 1.

2 - If the conditions of the wall are still good, you want to partially isolate it and proceed as per example 1 or 2.

3 - If, on the other hand, the wall is decaying and you want to strongly consolidate the wall and at the same time also add the insulating panel, the connector 1 will be of the type in fig. 11 with three holes 10, where the distance between the holes will be determined by the building project. Of the three holes, two must be flush with the decaying wall, which constitutes the structural core, and rods of the diameter chosen by the designer will pass through the two holes based on the thickness and condition of the wall: the panels are glued on top of the wall. and in the third hole, which protrudes just above the panel, the fiber rods are passed and in this case the diameter of 8 mm is sufficient. Number of rods and diameters will be decided by the designer also in relation to the seismicity of the area.

4- To build new walls, the type of concrete or steel supporting structure is defined and chosen. After defining the structure, proceed as described in example 3 and in the new wall scheme of figures 1, 2 and 3.

5 - Another use of composite connectors is to form pillars of various shapes, circular, square, ellipse or other, see figures 13, 14, 15 and 16, or to form walls, fig. 16 or brackets 5 for pillars, figs. 14 and 15.

7- Another use are the connectors without bar, figs. 17 and 18 to form networks of the strength calculated on the basis of the diameters of connectors or networks, to join fiber or steel rods that cross, orthogonal or 45 degrees inclined in a lattice, fig.

18.

Nets or cages can be formed, with resistance as per project, such as to stably contain decaying and heavy walls or light walls in panels.

The insulating panels 3 both inside and outside the house are plastered.

The rods 4 and the connectors 1 with several holes are also used to reinforce prefabricated panels with fiber rods to form curtain walls for large industrial and commercial surfaces.

Example N ° 1 - pre-existing external wall insulation.

With reference to the hypothesis of use N ° 1, glass wool panels of the size of 1000 x 1200 x 120 mm were glued on the external surface proceeding as follows:

after having glued the first panel along the edge of 1000 mm, the other panels are brought together so that the edges contact each other well to avoid thermal bridges. When the row of panels has covered part or all of the façade, on each panel 1 meter wide and 120 cm high, three holes are made every meter to obtain a hole every 33 cm along the edges, 1 hole with a length of 12 cm corresponding to the thickness of the insulating panel plus 8 cm to penetrate the wall: insert the connector of the type in figure 8 or 9 with a length of 200 mm; enough resin to penetrate it to block it. Advantageously, the connector can be provided with one or more radial projections in the insertion area, so as to exercise a greater grip in the wall once the resin has been deposited. Before the resin or glue sets, the connector is pushed into the hole so that the 1 or 2 holes in the connector protrude 1-3 mm outside the outer surface of the insulation panel. The 8 mm diameter glass fiber rods are inserted into the holes of the connectors and plastered with mortar 20-30 mm thick on top.

Example N ° 2 - old wall to renovate, renovate, add insulating panels.

We wanted to consolidate a 380 mm thick wall and add glass fiber insulation panels 1000 wide, 1200 high, 120 mm thick. The whole wall must be drilled with through holes to accommodate three-hole bars; the diameters, the strength of the holes and their position are decided by the designer, based on the state of the wall to be restored. The distance between the holes drilled in the old walls is also calculated by the designer. In our case of a 380 mm thick wall, the holes were drilled at a distance of 1000 mm between them to incorporate the 1000 mm wide insulators; 500 mm long connectors with three holes are chosen, a hole at the beginning of the connector, and this hole is intended to remain on the internal surface of the wall, a second hole 380 mm from the first, intended to be on the external surface of the wall to be consolidated, a third hole 500 mm from the first interior, the wall having to be contained by 380 mm added to 120 mm of insulation for a total of 500 mm. In the holes that are on the external and internal surface of the wall to be consolidated, glass fiber rods with a diameter of 10 mm as long as the span are inserted. After this operation, the 1000 mm wide insulating panels are glued so that the insulators come close to the connectors that protrude from the wall. In the third row of connector holes, 8 mm diameter rods as long as the span are passed on the surface of the insulating panels to make an external net that also covers the insulating panels. On the inner and outer surface of the wall a net is added and plastered.

Example N ° 3 - new wall, illustrated in figures 1, 2, 3, 5, 6 and 7.

We wanted to build a sample wall span, 3 x 3, to verify the dexterity and time needed to raise the wall. The iron span was purchased with two HEA pillars 2 with parallel wings, 160 mm and an IPE 330 beam. 3 fiberglass panels with a thickness of 100x120x16 and others of 100x120x10 thickness were purchased to make a wall in panels 26 cm thick. In the wing of the two pillars 2, in the part that is in the internal part of the house, a 13-16 mm hole 20 was drilled every 300 mm starting from the ground, up to a height of 3 meters. Holes were drilled with a diameter of 13 mm for ten rods with a diameter of 10 mm. A rod has been inserted into each hole in the internal part of the wall, taking care to first insert four connectors with two holes for each rod, in order to make the cage for the three insulation panels. In a preferred executive example, the holes must be suitably at least 3 mm wider than the rod and therefore the holes must be made bearing in mind the rod chosen by the designer. For example, if 12 mm diameter rods are used, the hole is at least 15 mm so that the rod does not have too much slack within the hole. If rods with a diameter of 14 mm are also used then the hole has a diameter of 17 mm. Alternatively or in combination with the holes drilled in the pillars, it is possible to provide elements that can be fixed or fixed to the pillars, whether in metal or concrete, which elements are provided with 13-16 mm holes. The fiber panels have been raised and four connectors have been raised with two holes which are kept horizontal with little glue between the mating internal walls of the panels. At the end of the elevation we will have four connectors that protrude forward. In each hole with a diameter of 11 mm, which protrudes out of the external wall, a rod diameter 8 is inserted, for a total of ten rods of 8 mm. Therefore, at the end of the operations, each insulating panel is inside a cage that has three 10 mm rear rods that pass through the pillars, three 8 mm rods that pass in front, and three side connectors with two holes, one of which is fixed in the 10 mm rod that enters the pillar and a hole protrudes outside the wall that will hold the 8 mm rods that are on the front of the wall.

The circled part A in figure 3 corresponds to what is illustrated in figure 5, in which the holes 20 drilled in the pillar 2 and crossed by the rod 4 are clearly visible. As an alternative to the 13-16 mm holes 20 drilled directly on the pillars 2 it is possible provide elements provided with corresponding holes and which can be fixed to the pillars 2.

The circled part B in figure 3 corresponds to what is illustrated in figure 6, in which a connector 1 passing through the insulating panels 3 is visible in detail so as to present the holes 10 on the opposite faces of the wall, which holes 10 hold the rods 4 that run horizontally along the opposite faces of the wall.

The circled part C in figure 1 corresponds to what is illustrated in figure 7, in which the contact line 30 between adjacent panels 3 is visible. The connector protruding sufficiently to make the hole 10 accessible to the passage of the rod 4.

The external and internal surfaces of the walls are plastered with a thickness of 30 mm. In this example we have chosen a simple wall without a cavity. To make the cavities, 4-hole connectors are required (Fig. 12).

In the executive example of figure 4, further holes are provided in the connectors 1, which further holes are placed in a direction perpendicular to the holes illustrated in the figure, for example in figure 5, in such a way that further rods 4 placed perpendicular to the first ones are retained rods, i.e. placed vertically in the example in the figure. This precaution guarantees high resistance to shear forces on the wall. Alternatively or in combination, placing frame posts such as windows or doors ensures similar strength.

Example 4 - industrial warehouse wall

For industrial and commercial warehouses, the solution of a wall without a cavity with an insulating panel of thickness as requested by the buyer is chosen. In the vertical pillars, a series of holes with a diameter of 13 mm were made on the internal wings, every 30 cm from the ground. For the rest, proceed as in example 3.

Results

1 - The two-hole connectors used to consolidate old walls produced with vinyl ester resin and glass fibers type E rowing Owens Corning 2400 tex, have demonstrated the following breaking loads with official tests:

model: 6-9: 26500 N;

mod. 9-15: 33000 N;

mod. 7-13 39000 N.

For connectors normally supplied, the resistance is between 20,000 and 35,000 N. For connectors with carbon fiber it is between 35 and 150 KN

2 - The typical mechanical resistance of the plaster and the infill wall is improved by the number of rods that cross the plaster itself. The rods have a resistance to the ultimate breaking load, for a diameter of 8 mm of 60 KN, for those with a diameter of 10 mm of 90 KN.

3 - The new wall has a U value = 0.120 with a thickness of 26 cm of the insulating panels in glass wool or 20 cm of polyurethane foam, and two plasters of 3 + 3 cm. The weight of the curtain wall, excluding structures and plasters, is 30 kg per square meter. The rods are held by the two pillars by connecting connectors that hold at least 30 KN. For plasters, an increase in the number of rods or a reduction in the size of the mesh improves the resistance to earthquakes. The scheme of the possible new wall is in Fig. 4.1.

The elevation speed of the insulating panels inserted in rod cages is about 6 hours for a 6 meter wall. Therefore the cost of the perimeter wall is of the order of magnitude of € 110 per square meter, excluding fixtures and foundations.

Claims (9)

CLAIMS 1. Wall comprising one or more pillars (2) and at least one core or infill wall comprising one or more insulating panels (3) and / or a pre-existing wall, characterized by the fact that the core or infill wall is held and supported within at least a cage formed by rods (4) pultruded of composite material placed on the opposite faces of the core or infill wall and connected together by connectors (1) of composite material, the connectors being (1) consisting of bars provided with holes (10) for the passage and retention of the rods (4), and being the pillars (2) provided with holes (20) for the passage and retention of the rods (4) or elements that have holes of passage and holding of the rods (4). 2. Wall according to claim 1, wherein a plurality of said cages formed by rods (4) and connectors (1) is provided, which cages are continuous, linked together and tied or rigidly fixed to said pillars (2) o to other load-bearing structures of buildings, as these pillars (2) or such structures are provided with holes from 3 to 50 mm in diameter to accommodate and hold the rods (4), or with elements fixed or fastened to the pillars or structures , which elements have holes from 3 to 50 mm in diameter for the passage and retention of the rods (4), which cages have the dimensions of the walls to be consolidated or of the pillars or walls to be built, or of the insulating panels (3) to be held back to form the walls. 3. Wall according to one or more of the preceding claims, in which the resistance to ultimate breaking loads is as required by the project and therefore in margins between 3 and 300 KN, while the elastic modulus for highly seismic areas is 100-300 GPa , including the rods (4) and / or connectors (1) carbon fibers and / or glass fibers and / or basalt fibers. 4. Wall according to one or more of the preceding claims, in which said cage is installed for renovation and consolidation of old walls with a simultaneous increase in thermal insulation by adding insulating coats on the external surface of the wall, restructuring obtained by drilling through holes in the perimeter wall, inserting in the holes connectors (1) with three holes (10), where these connectors (1) are at least equal to the thickness of the wall and in addition the thickness of the insulating panel, where these connectors (1) with three holes have a first hole (10) on the internal surface of the wall, a second hole (10) on the external surface of the wall, which two holes (10) are suitable for accommodating two rods (4) with a diameter of 6-16 mm, preferably 10 mm, to enclose the wall structure, while the third hole (10) that protrudes outside houses a third row of rods (4) with a diameter of 6-14 mm, preferably 8 mm, which enclose the coat, where this connector and (1) with three holes has sufficient length to understand the thickness of the wall and insulating panels added to the external surface, to connect the triple network of external and internal rods to the wall forming the said cages, in the number necessary to treat everything the wall, where each component of the cage has a breaking load resistance of between 25 and 100 KN, in relation to the thickness and weight of the wall to be restored. 5. Wall according to one or more of the preceding claims, in which said cage is installed for renovation of old walls with two-hole connectors, with a diameter of 4-30 mm, with a resistance between 3 and 100 KN at the ultimate breaking load , where said connectors (1) have a length equal to the thickness of the wall, penetrate through the wall to be restored, have two holes (10) on the external and internal surface of the wall through which rods (4) of the desired length are placed, the rods (4) being covered by plaster. 6. Wall according to one or more of the preceding claims, in which the wall itself is a new wall and in which the core or infill wall is made up of insulating panels (3), 40-400 mm thick, preferably 220 mm, to form curtain walls between beams and pillars (2) of load-bearing structures, where the cages form a cube or parallelepiped and have at least two rods (4) on the same side of the cube or parallelepiped, which rods (4) penetrate into holes made in beams and pillars (2) in the number established by the building project, to structurally tie the cages to beams and pillars (2), preventing the easy detachment and fall to the ground of the curtain walls in the event of seismic tremors, thus also obtaining perimeter walls with a stable thermal insulation over the years, of U = 0.100 - 0.280, preferably of U = 0.120, where all the external cladding panels are fixed in a stable and resistant way in the structure. 7. Wall according to one or more of the preceding claims, in which the pillars are made of concrete and are formed by pultruded fiberglass or carbon rods held by composite brackets (5), which brackets (5) are provided with holes in the diameter from 4 to 40 mm, or curves similar to open circular holes, with a diameter from 4 to 40 mm, to facilitate the insertion and blocking of rods (4) for the formation of long walls and large surfaces, where the rods are locked by means of glues or by means of iron wires within the open circular curve which is dimensioned corresponding to the diameter of the rod. 8. Wall comprising a structural core or infill wall and a cladding coat, characterized in that comprises one or more connectors (1) made up of composite bars or reinforced rigid plastic material, with resistance to the ultimate breaking load from 1 to 100 KN, preferably 30 KN, suitable for fixing the insulation, since the insulation consists of one or more insulating panels leaning against the surface of the structural core or infill wall, which cladding has a thickness of 30-300 mm, preferably 120 mm, in which the connectors have a length of 50-500 mm, preferably 200 mm, and a diameter of 5-20 mm , preferably 9 mm, and are equipped with one or two holes, with a diameter of 3-30 mm and placed at one end of the bar, where this bar is placed in a special cavity made in the structural core or infill wall so that such that the hole or the two holes of the bar are positioned outside the outer edge of the panel, the bar being fixed in the cavity by means of resin or glue, rods with a diameter of 3-16 mm, preferably 8 mm, of material being provided composite comprising fiberglass or carbon or other, which pass through the holes of the connectors that protrude above the cladding, being the cladding and the rods covered with a plaster of 10-30 mm thickness. 9. Method of manufacturing a connector (1) consisting of a bar of composite material provided with one or more holes for the passage and retention of rods, characterized by the fact that involves the following steps: a) fiberglass, glass, E, S, basalt or carbon fiber strands are joined and pre-wetted with epoxy or vinylester resins or other composites to form cords of 3-30 mm in diameter, preferably 10 mm; b) the ropes are wound around pins in the number of 2-30, in the desired number, with a diameter of 4-40 mm, which pins are fixed on steel plates at the desired distances between them; c) after solidification of the resins around the pins, the ropes are extracted which therefore have holes with a diameter from 4 to 40 mm of the size as per the project and in the position as per the project with a maximum error of 1-3 mm, which size of the holes is suitable for accepting or connecting glass or carbon fiber rods with a diameter between 3 -30 mm, with an error plus or minus 1 mm, and resistance to the ultimate breaking load in relation to the type of fiber chosen between 30 and 300 KN, modulus elastic between 4-300 Gpa depending on the type of fiber used.