RU209449U1 - Polymer panel for formwork of concrete walls or ceilings - Google Patents

Abstract

The utility model relates to the construction and repair of buildings and structures, namely to the panels (deck) of wall and ceiling formwork. Panel for formwork of concrete walls or ceilings, characterized by the fact that it is a longitudinal cellular structure, the layers of which are made of polypropylene, while the cells are isolated from each other. The technical result achieved by implementing the proposed solution is to increase the bearing capacity of the wall and floor formwork panels due to mechanical strength and uniform load distribution over the entire panel, which is achieved by using polypropylene and creating a cellular structure.

Description

The utility model relates to the construction and repair of buildings and structures, namely to the formwork panels of walls and ceilings.

From the utility model patent of the Russian Federation No. 168326, a formwork panel made of foamed polyvinyl chloride - PVC is known, which is a single structure with a variable density in width from the center of the panel to at least one of its outer surfaces in such a way that the density is at least one its outer surface is higher than the density in the center of the panel. While the panel consists of: PVC 50-55 wt.%; wood flour 10-15 wt.%; calcium carbonate (CaCO ₃ ) 20-30 wt.%; chemical additives up to 10 wt.%.

The disadvantages of such panels are high cost, low environmental friendliness, and in the production of such panels it is technologically difficult to obtain a uniform structure.

The closest analogue is a formwork with stiffeners known from the utility model patent of the Russian Federation No. 64242, which is mounted before pouring concrete and is used to hold concrete and ensures concrete drying, and which is mounted and maintained in the mounted state for a certain period of time after concrete drying , made of flexible polyvinyl chloride - PVC, and having walls between the upper and lower levels, which will ensure uniform load distribution over them.

Such panels have a number of disadvantages, namely: high cost and complexity in manufacturing; there is no possibility of restoring damage resulting from use; uneven load distribution on one sheet, where there are walls and in places where there are air cavities, use only in slab formwork and the inability to use for the production of wall formwork.

The objective of this utility model is to create wall and floor formwork panels that do not have the above disadvantages.

By solving the problem, a technical result is achieved, which consists in increasing the bearing capacity of the wall and ceiling formwork panels due to mechanical strength and uniform load distribution over the entire panel, which is achieved by using polypropylene and creating a cellular structure.

Bearing capacity refers to the ability of panels to withstand the ultimate load while maintaining normal operation. An increase in the ultimate load of the structure leads to plastic deformation of the panels.

The specified technical result is achieved in a panel for formwork of concrete walls or ceilings, which, according to the utility model, is a longitudinal cellular structure, the layers of which are made of polypropylene, while the cells are isolated from each other. Preferably, recycled polypropylene can be used. At the same time, the panels can be used repeatedly, with the possibility of restoring damaged sections of the panel with a special polymer material.

In one of the preferred embodiments, the panel contains outer layers made of primary polypropylene of increased rigidity with modifying additives. In this case, each cell in the cross section is a square.

The utility model is illustrated by drawings, where in Fig. 1 shows a general view of the formwork panel with a circular section of the cells; in fig. 2 - general view of the formwork panel with a square section of the cells; fig. 3 - photograph of a panel with a circular section of the cells; fig. 4 is a photograph of a panel with a square section of the cells.

The panel for formwork of concrete walls or ceilings is a longitudinal cellular (honeycomb) structure (Fig. 1, 2), three layers of which are made of recycled polypropylene, while the cells inside the panel are isolated from each other and are located along the entire length of the panel.

In the manufacture of panels, polypropylene (PP) is used with the possible addition of modifying additives of about 20% by weight, which may include: polyethylene additives to impart plasticity, special additives to increase frost resistance, plasticity, rigidity, etc., which give the panels the required physical and mechanical properties , unlike PVC panels, which use a complex chemical formula in their manufacturing process. In addition, a cellular structure cannot be made from foamed PVC.

Working surface - the outer layers of the panel, which are in direct contact with concrete, have a thickness of 2 to 3 mm and consist of polypropylene with a density of about 900 kg / m ³ and are formed by a special matrix during the manufacture of the product.

Polypropylene as a material is characterized by high moisture resistance. Panels made of this material do not absorb water, remain elastic in the cold, do not break, do not increase in size due to the intake of water, are highly resistant to acids and alkalis, do not rot and are not subject to corrosion, i.е. keep their dimensions constant during operation. Thus, the use of polypropylene makes it possible to increase the bearing capacity due to mechanical strength, and also makes it possible to manufacture panels with a cellular structure, which also makes it possible to increase the bearing capacity due to the uniform distribution of the load over the entire panel.

The panels used the technology of creating a longitudinal cellular structure along the entire length of the product (Fig. 3 and 4).

The use of a cellular structure made of polypropylene ensures uniform distribution of the load over the entire panel and high mechanical strength of the panel. Each cell is divided by a partition. Each partition acts as an additional stiffening rib, which leads to an increase in the load-bearing capacity of the panel. The load on the polypropylene panel, as a result of exposure to the concrete mixture, is distributed evenly over the entire external surface and internal structure of the panel, which ensures a constant quality of the concrete surface around the entire perimeter of the concrete pour.

An additional result in the manufacture of the proposed panels is a reduction in the cost of panels, which is achieved through the use of recycled polypropylene in the production.

Panel cells forming a honeycomb structure can have a round inner base (see Fig. 1, 3) or a square section (Fig. 2, 4). The cellular structure of the products simultaneously reduces the weight of the panels and increases their load-bearing characteristics.

The type of panels with a round cell section better forms bends when forming complex monolithic structures and better holds nails and screws during formwork installation, and also slightly reduces the cost of the product due to the use of a simplified panel manufacturing process, with the possibility of producing panels in one layer and are used mainly for formwork floors.

If it is necessary to increase the service life of the panel, which is especially important for the formwork of walls that experience heavy loads in the manufacture of monolithic structures, they are produced with square cells and reinforced outer layers 3 (Fig. 2), consisting of primary polypropylene of increased rigidity with modifying additives, which give additional wear resistance of the formwork panel and increase water-repellent properties.

The production of all layers of the panel takes place during one production cycle and eliminates the delamination of the outer layers.

The panel manufacturing method is injection molding. The panels are manufactured on a special production line, which includes: an extruder, a forming head, a calibration device, a cooling unit for finished products, receiving table, equipment for automatic stacking of panels, as well as equipment used for cutting panels into standard sizes 1220×2440 mm and 1500×3000 mm with a thickness of 15 to 21 mm.

As an example of the implementation of a panel with a square section of cells, a panel can be considered, each cell of which in the cross section is a square of 4×4 mm. The number of cells per 1 cm ² is 9 pieces. The thickness of the panels is from 15 to 21 mm. When resizing, the number of cells per 1 cm ² does not change.

For panels with a circular section, the cell diameter can be 3.0-4.5 mm. The thickness of the panels in this case also ranges from 15 to 21 mm.

During the production process, the panel is homogeneous and monolithic around the entire perimeter of the structure. Due to the rolling rollers, which in the course of their work refine the outer layers of the panel in order to reduce adhesion to concrete, the layers are smooth and no lubricants are required during operation, which saves on construction and installation work.

The proposed design of panels for formwork of concrete walls or slabs of a cellular structure, in addition to increased mechanical strength, is additionally characterized by reduced cost, ease of operation, lighter weight, ease of use of nails and screws compared to analogues applicable in the construction industry.

The use of recycled polypropylene granules in the manufacture of panels also makes it possible to reduce the final cost of the product, and due to the special design, an increase in the formwork turnover by about 50% is achieved. Repurchase of panels from manufacturers of monolithic works makes it possible to reduce the cost of the product and additionally ensures environmental protection.

Panel Specifications

Shore D hardness ≤58 Impact strength with Charpy notch, kJ/m ² ≤14 Bending strength, MPa ≤30 Flexural modulus, MPa ≤3000 Water absorption, % ≤0.5

Claims (4)

1. A panel for formwork of concrete walls or ceilings, characterized in that it is a longitudinal cellular structure, the layers of which are made of polypropylene, and the cells are isolated from each other, while it has reinforced outer layers made of primary polypropylene of increased wear resistance with modifying additives. 2. Panel for formwork according to claim 1, characterized in that the inner layers are made of recycled polypropylene. 3. Panel for formwork according to claim 1, characterized in that each cell in the section is a square. 4. Panel for formwork according to claim 1, characterized in that each cell has a circular cross section.

Images