KR20010042467A - Pre-cast concrete walling system - Google Patents

Abstract

The present invention relates to a preformed concrete panel comprising two skins and a non-concrete spacer member disposed between the two skins. A series of ducts extends through the spacer member and a connector passes through the duct between the two skins. In addition, a series of channels are formed on two opposing surfaces of the spacer member, and concrete support ribs extend along the channels to support the skin. In some embodiments, concrete connectors and ribs may be unconnected in length at or near their centers, with the two halves of the connector joined by an insulating structural tie extending into the two connector halves. Is monolithically shaped, ie monolithic. The skin may comprise ducts or ribs or boards, either of which are preformed, while being molded into concrete. Also disclosed herein is a battery shaping method for shaping the building panels vertically.

Description

Preformed Concrete Wall System {PRE-CAST CONCRETE WALLING SYSTEM}

There are several types of lightweight concrete wall systems in use today. The term “light weight” used to describe concrete refers to concrete having a weight of 1,400 kg / m ³ or less, which is still very dense.

Lightweight concrete wall systems in use today are made of solid walls made of lightweight materials, or hollowed out, including "concrete void" moldings that reduce the overall density of the panel by reducing the concrete content. Wall, ie wall panels. As used herein, the term "concrete voids" means that there is no concrete in the space filled with either air or non-concrete fillers.

The present invention relates to an improvement in the "concrete voids" of lightweight concrete walls.

There are two types of "concrete void" wall systems. There are skins in which solid material often acts as an insulator, a hollow type supporting the wall panel surface and a hollow type molded with the missing or removed form work. .

Insulation is a major concern in societies that have responsible energy policies and try to be energy efficient. Therefore, most buildings now use insulation as concrete voids. However, it is common to be of substantial value only when used for building exterior walls in areas where the temperature outside the building is uncomfortable for life. Most of the walls of a house are inner walls that require little insulation, so using a large number of insulation panels as an inner wall wastes the cost of the insulation used. Materials commonly used as insulation include foamed polystyrene and polyurethane. The use of the material as concrete voids achieves a dual purpose of not only providing thermal insulation but also reducing the weight of the wall member. However, the material is very low in melting temperature and hardly resistant to high temperature heat requiring fire. In addition, in some cases the insulation may be more expensive than alternative materials, especially in developing countries where the raw materials required to make the insulation are very expensive compared to building materials.

Many current wall systems use hard insulation to support the walls of sandwiched structures where the skins of the walls are bonded to the insulation.

As is well understood, walls can perform two basic functions. The first function acts as the side of the room, also known as the wall function. Several internal unloaded walls only perform this function. Structural load walls support the ceiling and upper floor loads, and not only withstand the horizontal forces, which are structural functions, but also act as side surfaces (wall functions) of the room. There are many things to consider when trying to reduce the weight of a wall and save material costs. It is evident that it is desirable to make the skin thickness of the wall member as thin as possible and if the total thickness of the wall should be at least 100 mm, the two wall skins should be separated by the other member but still connected.

When fabricating thin concrete wall sections by reinforcing steel mesh fabric, it is very difficult to reduce the wall sections below 25 mm because of the size of the wire mesh. The use of fiber reinforcement can further reduce the thickness of the wall sections, but thin wall sections (thickness between 8 and 45 mm, most preferably 12 to 35 mm) are produced by any other member during and after the manufacturing, curing treatment. I need support. The distance that the wall skin can effectively span between the support members depends on the skin thickness and is very limited without any additional support. This factor is further emphasized when using prefabricated cement boards, where the wall section thickness can be 4 mm.

Another problem is that the two wall skins must be connected to each other to provide sufficient strength to perform the wall function. However, at the point where the two skins are connected, a high stress zone occurs depending on the width between the connection supports. In most cases, the problem is solved by joining the wall skin to a "concrete void" and then connecting the two skins with a series of vertical studs or very thin vertical columns.

It is known to mold two wall skins separately so that the two shaping skins are later joined to one another. However, wall panel skins assembled with particularly large structures, which may be 8 to 3 m in length and 10-25 mm thick and may include windows and doorways, are fragile thin preformed skin members that require considerable care before handling. Since it is necessary, the process is very difficult. In addition, since the connector / spacer is not homogeneous with the skin, it may break into thin pieces in the long run and create a high stress band near the connector. The stress may cause invisible cracking. Thus, this type of system is only suitable for very small modular unstructured panels. Another problem with the system is that separately molded skins use mold space very inefficiently and the system requires twice as much mold space that a monolithic molding system would need to produce panels of the same dimensions. Is the point.

The present invention solves the problems of the prior art and provides a preformed lightweight wall system that can weigh less than 800 kg / m ^{3 for the} wall volume.

The present invention relates to a preformed concrete wall system. In particular, the present invention relates to lightweight large sized prefabricated concrete panels and methods of making such panels. The panels of the present invention may be load bearing or non load bearing panels and are suitable for low cost single or double storey applications.

1 is a front view of a non-concrete spacer member, ie a void former;

2 is a cross-sectional view taken along the line II-II of FIG.

FIG. 2A is an enlarged cross-sectional view taken along the line IIa-IIa of FIG. 1. FIG.

Figure 2b is an enlarged cross-sectional view of the center of the duct.

3 is a rear view of a hollow void member half with an inner support.

4 is a cross-sectional view taken along line VI of FIG. 3;

5 is a cross-sectional view taken along the line V of FIG. 3.

6 is a front view of the wall spacer.

FIG. 7 is a plan view of the wall spacer shown in FIG. 6. FIG.

8 is a front view of a load panel according to the present invention.

9 is a side view of the load panel shown in FIG. 8;

10 is a front view of a battery shaping assembly according to the invention.

11 is an overall plan view of a battery shaping assembly work area.

12 is a front view of a mold battery according to the present invention.

FIG. 13 is a cross-sectional view taken along the line XIII-XIII of FIG. 12.

14 is a cross-sectional view taken along the line XIV-XIV of FIG. 12.

15 is a side view of the first bottom cell divider locator.

16 is a side view of a second bottom cell divider locator.

17 is a view of the bottom plate;

18 is a side view of the cell divider.

FIG. 19 illustrates a bottom surface of the cell divider illustrated in FIG. 18; FIG.

20 illustrates a spacer member coupled to a panel base board with a restraining strap.

21 is a view of an edgeboard.

FIG. 22 is an enlarged sectional view taken along the line XXII-XXII in FIG. 21;

23 is a front view of the cell frame of the panel.

24 is a view of an edgeboard seal.

25 is a diagram of a top cell divider locator.

In one embodiment of the present invention,

Two skins, including a concrete surface, or a board;

At least one lightweight non-concrete spacer member disposed within the building panel between the two faces, wherein the lightweight spacer member includes a plurality of spaced ducts extending therethrough and a series of distant extensions extending from an end of the duct to an adjacent duct; Forming a channel;

A concrete connector projecting through the duct connecting the skin; And

Concrete support ribs formed in the channel, wherein the ribs and the connector form two support structures for the skin;

It provides a concrete building panel having a.

The support structure is very strong, strong and monolithic in all directions, i.e. the components are molded simultaneously. The grid pattern and dimensions of the ribs and connectors depend on the shape of the spacer member and can be changed by changing the pattern and dimensions of the channels formed by the spacer member. The pattern can be square, rectangular or triangular. The ribs may extend in at least two co-planar directions, such as vertical and horizontal, preferably extending in three or four directions. In some structures, most of the intersection between the ribs occurs at the connector, that is, most of it occurs at the connector.

The ribs are dimensioned for various applications, including structures, and may differ in dimensions to the same spacer member. Ribs can be reinforced with fibers, fiber rods, or steel rods and are often reinforced with both rods and fibers.

Looking at the horizontally oriented panel, the channels formed in the spacer member extend outwards towards the other duct and upwards from the center of the duct towards the skin such that the tangent with the ribs intersects the plane of the skin at an angle of 30 to 60 degrees. It is preferable.

The core shape of the duct is preferably a shape or a bell-shape in which the end where the duct and the skin meet is extended radially.

The cross-sectional shape of the duct is preferably a flower shape with a " petal " formed at a position where the end of the channel crosses the duct.

In a preferred embodiment, the concrete perimeter beam extends around all or part of the outer circumference of the panel.

In one embodiment, the concrete connectors are not connected at or near the center of their length. Half of the connector extends therein towards the half of the connector and extends therein towards the concrete rib or is joined at or near the center by an insulated structural tie connected to the concrete rib.

In one embodiment, the skin is generally cementitious formed by a board comprising a fiber reinforced sheet material.

However, the strength of the support structure is strengthened several times by forming the structure integrally with the concrete surface skin.

Accordingly, the present invention provides a related embodiment

Providing a mold having a base and a side for placing a lightweight non-concrete spacer member on a concrete layer located within the mold, the lightweight non-concrete spacer member forming a plurality of spaced ducts within the mold;

Vibrating or stirring and pushing the spacer member into the concrete such that any air trapped under the spacer is discharged around the space or through the duct to the concrete surface and the concrete is forced into the duct and channel;

Injecting additional concrete over the spacer member to fill the mold;

Finishing the concrete surface with a texture suitable for wall use; And

Curing panel

It provides a building panel manufacturing method comprising a.

It is desirable to cover when curing the panel.

Stirring / vibration rates are generally very slow, preferably from 1/2 to 5 Hz, with 1 Hz being most preferred. The vibration amplitude of the panel may be on the order of 5 to 20 mm, with about 10 mm being preferred.

Of course, the panel may be formed of one or more non-concrete spacer members, the mold may form a space such as a door, window, etc., and all structural members may be reinforced if necessary during the molding process.

Alternatively, the panel side can be molded vertically upright. The spacer member may be filled or, if hollow, may have an internal support to prevent collapse due to hydraulic pressure and vibration. The angle of the inner support can be adjusted to suit the relative value of the hydraulic pressure which varies in the vertical shaping method.

In addition, the present invention is directed to a side and two opposite surfaces, at least one duct which preferably extends radially extending from one side of the panel to the other, and a series of runs away from the duct along each panel face. Provided is a non-concrete spacer member for use in making a building panel of the present invention that forms a channel.

Generally, the spacer member comprises a plurality of ducts in which channels extend between adjacent ducts.

As used herein, "non-concrete" includes high air content cementite products.

The spacer members are hollow and preferably made of two generally identical halves and then joined and sealed together to form the spacers.

Suitable materials for non-concrete spacers include gypsum and plaster, wood pulp and wood products, high impact styrene, foamed polystyrene, and any suitable porous material that is sealed on the outside to prevent concrete from seeping during molding. Any wastes combined together with any suitable plastic or cementite material.

When the voids are made of a material with good fire resistance, glass-reinforced gypsum plaster and foamed plaster plaster or foamed Pittland cement are preferred.

The minimum cross-sectional area at the center of the duct middle is about 125 mm ² , with a cross-sectional area of about 1250 mm ² being preferred. The ducts are preferably spaced in a square grid pattern between 100 and 500 mm.

Next, specific embodiments of the present invention will be described by way of example only with reference to the accompanying drawings.

1 and 2 illustrate a solid non-concrete element 10, namely a concrete void former 10. As shown, the spacer element may be rectangular, but a square is generally seen in plan view. A series of ducts 12 extend from one side 10A of the former to the other side 10B. The ends of the ducts are radially expanded or bell-shaped. A series of channels, including the vertical channel 14, the horizontal channel 16, and the diagonal channel 18, is formed on the faces 10A and 10B of the spacer member.

The cross-sectional area of the narrowest portion of the duct is substantially 1250mm ^2, but the channel is approximately 600mm ² is approximately 25mm depth and round cross-section, the depth can be the cross-sectional area changes in a range from 8mm to 40mm 65mm ² to 1600mm ^2.

As will be described later herein, spacer members are used in the vertical shaping method of concrete building panels in which the channels 14 are erected vertically. In the embodiment shown in FIG. 1, the dimensions of all the channels 14, 16, 18 are the same, but the concrete flow is changed by changing the channel dimensions, for example, by making the vertical channels 14 larger to facilitate the molding process. It can be done easily. The selection channel, for example the vertical channel 14, can be enlarged to become a structural member when joined to the opposite side of the spacer member to bond and reinforce steel or fiber rods while the other channel can be kept smaller. In some cases, the enlarged reinforcing ribs may partially or completely replace the structural members 52, 54 shown in FIG. 8 described below.

As shown in FIG. 2A, the cross section of the channel is bell shaped so that the edge of the finished product panel described later smoothly harmonizes with the skin and prevents sharp edges from which stress can spread. As shown in FIG. 2, the ribs not only radiate outwardly in the plane of the spacer member surface from one duct to the other, but also are bent outwardly radiating from the central region of the duct, so that the ribs with the channel surface shown in FIG. Tangent T intersects the plane of the spacer member surface at an angle. In addition, the channel can penetrate through the spacer member, which is generally shown as a C-shaped connection in FIG. 2 formed by connecting the channel portions 16a, 16b and the central portion 16c, so that the cross section cut along the central region of the duct is Each of the channels resembles a flower head forming petals.

Hollow or partially hollow spacer members 10 shown in FIGS. 3 to 5 may also be used. 3 is a rear view of half 20 of hollow spacer element 10. The front view is the same as the front view of the spacer member shown in FIG. At the point where several channels 14, 16, 18 are formed, the material is extended to form a coplanar flat ridge 22. They are coplanar with the rear perimeter edge 24. Therefore, when the two halves 30 are coupled to the rear surface and the rear surface, the ridges 22 and 24 of each of the half portions come into contact with each other to be bonded together. The spacer member thus formed surrounds a series of hollows 26 which are generally triangular.

Since the ridges 24 abut internally, when the two halves of the spacer member are joined together, this increases the strength of the voids and can also cut the voids along horizontal or vertical channels where the material is solid.

Ridge is not essential except when it is necessary to make the spacer member stronger to withstand pressure. These ridges may not be connected so that they are only partially supported, which can be adjusted to suit the required degree of pressure. In some cases, the ridge can be eliminated, or the spacer member can be stepwise changed from the continuous ridge to the partial ridge or the ridge can be removed from the building panel.

If desired, with or without ridges, the hollows 26 and any other hollows can be partially or completely filled with waste to further reinforce the spacer member so that it does not collapse due to pressure.

6 and 7 illustrate the plastic wall spacer 30 used to separate the spacer member 10 from the mold wall when the surface skin is made of concrete. The wall spacer has four pins 32 on one side that can be pushed into the spacer member to secure the wall spacer to the spacer member and on the other side the member can vary between 8-45 mm in height "h" but here is 12 mm Or a plate on which protrusions 34 are formed.

8 and 9 illustrate a load panel 50 that may be formed using the spacer member 10. The panel has a perimeter beam 52 (reinforced with a rigid steel rod, not shown) that extends around the outer circumference of the panel. There is also a series of four steel reinforced columns 54 spaced 600 mm apart. Between the wall and the column 54 is arranged a series of spacer member assemblies, each made of three spacer members shown coupled to one another in FIG. 1. The face or skin 58 of the panel is 12 mm thick concrete and forms a wall surface internally interconnected by a series of small horizontal connectors 60 (formed by the spacer duct 12). A series of support ribs 62 interconnects the horizontal connector 60 and the ribs are formed by channels 14, 16, 18 in the spacer member.

Even if the panel comprises one spacer member assembly made of a plurality of bonded spacer members and forms part of an optional outer beam, non-loaded panels without load columns can also be produced. Semi-load bearing panels may also be provided, provided with only one load column.

10 and 11 illustrate an entirety of a vertical battery forming apparatus that can be used to form the panel shown in FIG. 8. Before describing the apparatus in detail, the principle of the vertical battery shaping system will be briefly outlined.

Referring to FIG. 11, the system requires a flat concrete platform positioned at ground level that is at least 20 meters wide by approximately 12 meters long. Rails 102 and 104 are disposed in the concrete platform. A large expensive mobile crane 106 moves over the rail 102, and a small expensive mobile crane 108 moves over the rail 104. The panel is made from a mold battery 110 made of a number of components, including a side frame 112 and a cell divider 114, as described in detail below. The mold assembly includes a heavy steel base frame 116. The cell dividers face vertically, and the panels are battery-shaped between paired adjacent cell dividers 114. A concrete panel curing rack 118 is positioned adjacent the base plate 116.

The heavy steel base frame 116B is located on a concrete platform between the rails 104 approximately 8 m away from the frame 116A. The battery shaping operation of manufacturing panel 50 may be stationary, but it is desirable to follow the principle of moving the mold / molding position every two or four cycles. Thus, the battery forming mold is first assembled on the frame 116A and ready to be molded with the spacer member assembly located inside the series of molds formed between the cell dividers 114. Concrete is injected until it is filled into the cell, vibrating if necessary. The concrete panel can then be cured in the mold until it can be moved. A small expensive mobile crane 108 is used to remove one of the side frames 112 and place it on the second frame 116B. The cell dividers that were located adjacent to the side frames are transferred into the cell divider cleaning area 120 located between the frames 116A and 116B using small expensive cranes and repositioned on the base plate 116B after cleaning. The edge board, seal, and blockout are removed from around the exposed panel 50 so that the large expensive mobile crane 106 moves to the concrete panel curing rack 118. The process is repeated until the mold is completely reassembled on the base 116B and all of the concrete panels 50 are positioned on the rack 118.

While the concrete panel 50 is cured on the curing rack 118, the mold can be used to produce a second set of concrete panels. After the panels are cured, the panels are moved to a curing rack adjacent to the base 116B. In a two-cycle system, the base can be moved approximately 8 m in one direction along the rail by industrial roller skates (not shown) or other means when the two-cycle operation described above is repeated. Alternatively, it is possible to use a large expensive mobile crane and have concrete panel curing racks 118 on both sides of the base frame, in which case the mold can be reassembled on the base 116A and the concrete panels formed in the third forming operation. Is moved to the empty rack on the other side of the mold. The mold is reassembled on base 116B and a fourth set of panels is made and stored on the last empty rack. The base may then be moved to repeat the fourth cycle operation described above. After four different sets of panels are made, the base can be moved back to a new location or repositioned according to the required storage period of the concrete panels. If desired, it can be moved several times in one direction and then the mold can be moved sideways to start a new production line. Alternatively, the empty base frame 116 may be temporarily moved to load the panel 50 into the transport vehicle and then returned to reassemble the mold.

In a roadside project, if the roadway is fairly flat, the mold can continue to move along the roadway on one continuous production line, placing the panels adjacent to the area where the building will be built. Next, the product is lifted directly into the building by a mobile crane and does not need to be transported.

In the system described above, curing time of the panel is sufficient so that the panel can be moved directly from the manufactured position to the position to be installed. It is evident that this increases the efficiency of the process, especially in developing countries, where large concrete panels are difficult to handle and time consuming in the process, especially where sophisticated material handling devices and infrastructure are generally lacking. By moving the mold, the space remains close to the concrete curing rack 118, so that the panel 50 can be loaded in the vehicle. When the crane is not used to disassemble the mold, it can be loaded using the large expensive mobile crane 106.

Next, the mold assembly and concrete pouring method will be described in detail.

The mold batteries assembled in FIGS. 12-14 are illustrated, and the components of the mold batteries are illustrated in the figures of the following figures. Base frame 116 is located at the base of the mold battery. The frame is clearly shown in FIG. The frame is made of three small steel frames 150, 152, 154. Frame 154 is identical to frame 150. Each frame consists of two parallel heavy duty steel I-beam girders fixed on top of two similar parallel I-beam girders 158. A bracing beam 160 extends between two oppositely opposite edges that the beam intersects. Parallel beam 158 protrudes to only one side of frame members 150 and 154 and to both sides of frame member 152. Additional bracing 160 is installed between adjacent frame members to reinforce the frame.

Next, cell divider locators 170 and 172 are secured to the steel base 116. The cell divider locator 170 (see FIG. 15) includes an elongated steel plate in which nine upwardly protruding blocks 174 are located. The block is generally rectangular in plan view, and the top of the block forms a sloped wall that extends to the flat rectangular top. A series of holes 176 are formed in the cell divider to bolt the cell divider to the base frame 116. Cell divider locator 172 is much shorter than cell divider locator 170 and forms only one block 174. In use, cell divider locator 170 is used to position nine cell dividers to form eight cells for panel shaping. When additional cell divider locators 172 are placed on both sides of cell divider locator 170, two panels may be further molded, as shown in FIG. 13. The lower cell divider locator is aligned with the member 156 of the base frame 116 and bolted. Thus, six locators 170 and twelve locators 172 are required.

Next, the bottom steel plate 180 shown in FIG. 22 is placed on top of the base frame 116 between the bottom cell divider locators. The width of the bottom plate is equal to the distance between the edges of the girders 156.

The side frame 112 is located on both sides of the base frame 156. The side frame is made of steel girders and must be strong enough to transfer the hydraulic pressure generated during molding to the base frame 116. When assembling the mold battery assembly, one of the two side frames is installed after positioning the bottom plate and the other at the end of the assembly process. Bolts 192 escape from the base of the side frame and fit into corresponding holes provided in the base plate. The upper end of the frame forms two trapezoidal plates 194 each comprising through holes 196 for lifting the side frame using an elevated mobile crane. The upper end of the frame also forms a series of six upstanding cylindrical protrusions 198 used to mount the upper cell divider locator 250, as described below.

After fixing the first side frame 112 to the base frame 116, the first cell divider 114 is attached to the side frame. As shown in FIG. 18, the cell divider includes two plates 202 welded to each side of the support frame. On each side of the cell divider is a straight hook 210. A series of horizontally oriented slots 212 are formed at the top of the cell divider. As shown in FIG. 19, the base of the cell divider forms six rectangular slots 214 configured to receive block 174 of the bottom cell divider locator.

Next, a bottom panel base board 220 is installed that includes an elongated metal plate with downward edges. Board 220 forms the base of the mold. As shown in FIG. 20, a restraining strap 222 extends between the board 220 and the bottom steel plate 180.

After installing the board 220, a sealant is applied to the bond to attach the edge board seal 240 to the edge board 230 (see FIG. 24). The edge board seal bends the tip 242. Because of the angle of the tip, the hydraulic pressure P acting on the seal can force the tip to contact the cell divider, whereby the greater the pressure, the better the seal.

An edge board is illustrated in FIGS. 21 and 22. Each edge board includes two elongated metal tubes 232 having an annular rectangular cross section joined together by a series of plates 234. An annular socket 236 is provided that receives a prop close to the middle of the edge board. An accompanying cylindrical plug 238 is provided at the base of the edge board. As shown in FIG. 23, the cell divider is fitted into the bottom panel base board 220 using a plug 238. FIG. 23 shows an arrangement in which two concrete panels are molded end to end rather than one concrete panel extending along the entire length of the mold. Next, blockouts are installed if windows and doorways are required.

A release agent is applied to the surface of the cell divider, base board 220 and edge board seal 240.

Next, the spacer member assembly is attached to the base board 220 with a restraining strap 222. During the molding process, after injecting the concrete into the mold, the lightweight spacer member may be raised if not restrained by each strap 222, which must lift a ton of force. The spacer member assembly includes a plurality of spacer members as shown in FIG. 1 or 4 coupled together in one block as shown in FIG. 9 or FIG. 10 for ease of handling. In general, the spacer member assembly is graded, that is, the spacer member located close to the top of the mold is hollowed out and the spacer member located towards the bottom is filled up to withstand greater hydraulic pressure. The spacer member facing the middle of the panel can be hollowed out but partially filled.

If the skins are made of fiber reinforced sheet material, they are attached to the spacer member and installed in the above step.

In the next step, if desired, reinforcing ribs are installed around the periphery, any space where column 54 is to be located, above the doorway or window, and, if necessary, along channels 14, 16, 18.

Next, a release agent is applied to one surface of the second cell divider 114 to position the second cell divider over the next lower cell divider locator 170. The operation is repeated until the cell dividers, edge boards, edge board seals, suppression straps, spacer members, reinforcements, etc. are all in place.

Next, the top cell divider locator 250 shown in FIG. 25 is placed on top of the mold. Each of the top cell divider locators has eleven accessory protrusions 252 spaced along the base of the top cell divider locator. At each end of the cell divider locator is a plate 254 formed with a hole 256 for receiving one of the protrusions 198 on the side frame 112. All six top cell divider locators are used. The accessory protrusion 252 is sandwiched between the members 232 of the edge board 230. The spacer member assembly is coupled to the top cell divider locator and placed in the mold. When the mold is assembled, as shown in Figure 16, concrete is injected into the top of the mold. The concrete mix should be made of at least portland cement, fine aggregates such as sand, superplasticising high range water reducing agents and water. The mixture may include fibers or steel, such as polypropylene, and coarse mixtures to increase strength by reducing the water / cement ratio in some cases, but in some applications. The dimensions of the coarse mixture depend on the skin thickness of the panel surface (if the skin is concrete). In the case of using the wall spacer shown in Figs. 7 and 8, the thickness thereof may be 12 mm, and the diameter of the coarse mixture may be up to about 8 mm. When the thickness of the skin is 15 mm, a thick mixed material having a diameter of about 10 mm can be used. If a thin board is used as the skin and the channel is small, the coarse mixture may be omitted from the mix design.

The mold or concrete can be vibrated during filling if necessary.

Concrete panels can be cured early. After the concrete panel is sufficiently cured, the mold battery is disassembled and the components other than the steel base are moved as described above with reference to FIGS. 12-14. It is necessary to cut the strap 222 to separate the bottom panel base board 220 from the concrete panel.

In general, the above-described mold battery is composed of ten cells approximately 6m to 7m in length and 3m in height. One or more concrete panels can be manufactured in each cell. The thickness of the panel can vary between 50mm and 200mm, which reduces the cell divider required to complete the battery configuration. The 10 common cell configuration can vary from 6 to 20 cells in extreme cases.

The advantages of the above mentioned mobile vertical forming method compared to the fixed horizontal forming method are as follows:

The molding area is small;

• short travel distances for materials and operators;

No finishing skills are required and only a few skilled technicians are needed;

• It is not necessary to cover the product during initial curing to prevent water loss;

• heat of hydration is included to promote curing without loss of moisture;

• lower overall capital costs-less depreciation;

• No site cover or building is needed for site production;

• the facility can be relocated in one day;

A removable battery mold means that the product is stored and loaded on the vehicle immediately after dismantling, which means less product handling;

By using two bases, the speed of the battery mold assembly is improved.

The panel of the present invention is much more preferred for vertical molding but can also be produced by the horizontal molding method.

In horizontal forming, the panel manufacturing method first treats the flat mold surface with a release agent to easily detach the panel from the mold.

The edge boards form the perimeter and depth of the panel and are placed in place on the mold surface. In addition, the edge boards form any doorway or window extending through the panel.

Next, the concrete is poured into the mold and evenly distributed in the mold to approximately half the depth of the edge board.

Concrete is preferably made of portland cement, a small amount of coarse admixture, and sand. The mix must be plastic because it must flow into the channel on the spacer member 10. The water / cement ratio is important to prevent invisible cracking.

One or more spacer members 30 are placed on top of the leveled concrete and the voids are so light that the members must be pushed into the concrete until they are correctly positioned or vibrated and injected. Generally, the spacer member vibrates at approximately 1 Hz and amplitude 10 mm. This forces the concrete through the duct 12 and into the channel 18 while forcing any contained air around the former spacer or through the duct 12 to fill the channel 18 with concrete. The spacer member is pushed into the mold until it is positioned approximately 10 mm to 12 mm from the horizontal mold surface, depending on the exact location in the mold, ie the desired thickness of the skin, in particular the dimensions of the blend and the amount of reinforcing material used in the skin.

If a circumferential beam is needed and any other structural member of the panel needs to be reinforced, the reinforcing rod is placed on the mold circumference between the edge board and the former. Next, the remaining concrete is poured into the top of the former to fill the mold. The surface is scraped off of fine gravel and finished in a suitable configuration. The panel can be covered, cured and then lifted from the mold. Covering the panel prevents excessive evaporation of moisture and prevents cracking.

When additional structural members such as vertical studs / columns, horizontal beams or windows and doorways are needed, the spacer members are cut and assembled to fit the panel configuration.

Regardless of whether it is manufactured by vertical shaping or horizontal shaping, the overall shape of the building panel, the pattern of the ribs that joins the skin by means of a radially expanded bell-shape, performs the following functions:

1. A monolithically shaped concrete shape is formed by forming a series of ribs around the former inside the wall cavity around the duct where the two wall skins reinforce and reinforce the high stress areas joined together by the column.

2. The radially extended ends of the duct and ribs increase the skin depth of the rib sections to prevent cracks from spreading on the skin, so that the thinnest part of the skin is always bounded by deeper ribs in the cross section. Prevent and suppress progress.

3. The finished panel, when used, is vertically hollow except for the outer beam, small horizontal column and any other rigid structural member. This allows for easy access and service into the wall cavity through the thin concrete skin of the wall and the soft spacer member 30.

The spacer member may be formed of any suitable molding material such as gypsum, plaster, wood pulp, wood products, high impact styrene, expanded polystyrene, foamed cement, suitable plastics or waste moldable to the desired shape of the former.

If the fire resistance grade of the building panels is to be high, it is desirable to change the thickness of the glass reinforced gypsum plaster and the foamed gypsum plaster to the desired fire resistance grade.

The heat insulator may be inserted into the hollow of the spacer member 30. As an alternative, the member 30 may be made of an insulating material having a wall thickness that provides the desired insulation when combined with the hollow of the member 30.

In a variant, for countries with a single or tropical climate, the duct 12 is blocked approximately in the middle along the length of the insulation layer. Half of the connector must be separated by a thermal insulation layer and structurally joined by a structural tie member. The tie member is preferably made of low thermal conductivity, for example reinforced plastic. The tie member penetrates the heat insulation layer and protrudes in a bell shape to be fixed and embedded in concrete. The shape of the structural tie member can be changed from cylindrical tube to X-shape or star shape. When the member is star shaped, the number of points of the star relates to and corresponds to the number of channels or ribs crossing the connector as each point or protrusion on the star protrudes and is fixed within each rib. These protrusions are perforated or corrugated so that the protrusions can be properly joined within the ribs. In addition, the insulating layer shall not be sealed in the middle of the minimum cross-sectional area of the duct, ie the length of the connector, if the structural tie member is designed in a circular or tubular shape, and the duct, insulating layer or tube shall be in two, as in the case with all tie members. It shall be shaped to fit and seal in the smallest cross-sectional area of the divided duct. The portion of the tubular tie that protrudes into the bell shape of the connector also has a perforation through which a thin reinforcing rod can be inserted to structurally secure the connector and the rib to the tie. Structural ties should act approximately the same structural function as connectors are skinned to skin. Concrete is a good heat conductor, and solid concrete columns formed by ducts transfer cold temperatures through the walls to form cold spots. The thermal insulation layer prevents this.

It will be understood by those skilled in the art that the present invention may be variously modified and changed as shown in the specific embodiments without departing from the spirit and scope of the invention as broadly disclosed. Accordingly, embodiments of the present invention are merely illustrative in all respects and are not limiting.

Claims (15)

Two skins, including a concrete surface, or a board; At least one lightweight non-concrete spacer member disposed within the building panel between the two faces, wherein the lightweight spacer member comprises a plurality of spaced ducts extending therethrough and a series extending away from an end of the duct to an adjacent duct; Forming a channel of; A concrete connector projecting through the duct connecting the skin; And Concrete support ribs formed in the channel, where the ribs and connectors form a support structure for the two skins Containing Concrete building panels. The method of claim 1, wherein the connector is a concrete building panel having the minimum cross-sectional area of 125mm ² ~ 5625mm ² in the middle along the duct. The concrete building panel according to claim 1 or 2, wherein the rib is curved to extend outward from the connector, and a tangent with the curved portion crosses the skin at an angle. The concrete building panel according to claim 1, wherein the rib extends along the connector or adjacent and integrally extends also through the center of the panel. The concrete building panel according to any one of claims 1 to 4, wherein a thermal insulation layer is disposed in the duct to separate the connectors into two, and a structural tie member extends through the thermal insulation layer connecting the two parts of the connector together. . 6. The concrete building panel according to claim 1, wherein the concrete building panel comprises an integral reinforcement outer circumferential beam. 7. 7. Concrete building panel according to any one of the preceding claims, wherein said channel in the panel, erected vertically in use, is larger than the other channels and comprises a rod reinforcement. The method according to any one of claims 1 to 7, The lightweight spacer member has at least one duct having two opposing faces and extending from one face to the other face, and a series of channels are formed on the face of the member extending away from the duct. Lightweight non-concrete spacer members for building panel forming applications. 9. The spacer member of claim 8, wherein a plurality of ducts are provided, the channels extending between the ends of the ducts and extending along or along the duct and integrally extending through the center of the member. The method according to any one of claims 1 to 7, Providing a mold having a base and a side for placing a lightweight non-concrete spacer member in a mold on a concrete layer disposed therein, the light weight non-concrete spacer member forming a plurality of spaced ducts and channels extending away from the ends of the duct to adjacent ducts Doing; Stirring the spacer member into the concrete to promote any air suspended below the spacer to be discharged around the space or through the duct to the surface of the concrete and forcing the concrete into the duct and the channel; Injecting additional concrete over the spacer member to fill the mold; Finishing the surface of the concrete in a configuration suitable for the wall; And Curing the panel Containing Method of manufacturing building panels. The method according to any one of claims 1 to 7, Providing two spaced boards in a substantially vertical direction; Each board is arranged to form a structure by placing a lightweight non-concrete spacer member between the spaced boards that forms a plurality of spaced ducts and channels extending away from the ends of the ducts to the ends of adjacent ducts to form a structure. Fixing to a surface facing inward of the; Closing the sides and bottom of the structure to form a mold structure or inserting the structure into a vertically standing mold; Providing support means to the mold structure such that the structure can fill the mold sufficiently to sustain hydraulic pressure due to concrete; Injecting superplastic concrete into the mold structure through the top of the mold structure; And Curing the panel Containing Method of manufacturing building panels. The method according to any one of claims 1 to 7, Forming a vertical mold; Positioning a lightweight non-concrete spacer member in the mold, the spacer member forming a plurality of spaced ducts extending therethrough and channels extending away from the ends of the ducts to the ends of the adjacent ducts; Securing the spacer member in a mold; Injecting superplastic concrete into the mold through the top of the mold; And Curing the panel Containing Method of manufacturing building panels. 13. A method according to claim 11 or 12, wherein a plurality of molds are formed side by side in a battery-like assembly mounted on a base frame. 15. The method of claim 13, wherein the mold assembly is modular, and after the first set of panels is molded, the components of the mold assembly are systematically disassembled to move and reassemble onto the second base frame to form a second set of panels. And forming and storing the first set of panels in a rack or the like adjacent to the first base frame. 15. The building panel of any one of claims 11 to 14, comprising using a graduated spacer member of strength during the forming process to withstand the high water pressure of the mold base relative to the low water pressure at the top of the mold. Manufacturing method.