RU2336395C2 - Multilayer wall panel, method for its manufacturing and method for erection of monolithic-framed building outer wall made of multilayer wall panels - Google Patents

Abstract

FIELD: construction.

SUBSTANCE: multilayer wall panel containing interconnected layers one of which is carrying layer and is formed between removable timbering and the other is heat-insulating layer. Carrying layer is made as inner one of expanded-clay concrete with embedded reinforcement of PVC (PolyVinylChloride) pipes installed vertically and of metal rods placed horizontally. Heat-insulating layer is made of foam plastic where communications are laid. Additionally, multilayer wall panel contains face layer of waterproof gypsum-fiber sheet (WPGFS), reinforcing layer of fine-meshed glass fiber net, thermo-, water- and soundproof layer of extruded polystyrene foam, layer for interior finish of waterproof gypsum board (WPGB). The layers are interconnected by bonding, and on top, between thermo-, water- and soundproof layer of extruded polystyrene foam and heat-insulating layer of foam plastic, gap is formed because face layer of waterproof gypsum-fiber sheet (WGFS) with thermo-, water- and soundproof layer of extruded polystyrene foam and heat insulating layer of foam plastic with layer for interior finish of WPGB are higher than inner carrier layer of expanded-clay concrete. Also method for wall panel manufacturing and method for building outer wall erection of wall panels are described.

EFFECT: improvement of service characteristics of multilayer wall panel, and improvement of works safety, lowering of labor consumption, construction costs during erection of monolithic buildings outer walls made of panels.

12 cl, 2 ex, 3 dwg

Description

The invention relates to the construction, namely, to the construction of a multilayer wall panel, to a method for its manufacture and to a method of erecting an outer wall of a monolithic frame building from such panels.

The development of multilayer wall panels, methods for manufacturing multilayer wall panels and methods for erecting the outer walls of buildings from multilayer wall panels has been quite intensive in recent decades.

Closest to the proposed multilayer wall panel is a multilayer wall, protected by patent for utility model RU U1 54058, selected as the closest analogue (prototype), containing a supporting layer of monolithic concrete formed between formwork, and insulation in the form of external plates based on polystyrene concrete, placed between the inner supporting layer of cast concrete and formwork made removable, while the insulation boards are made in the form of a single-layer panel of polystyrene concrete or a multilayer panel, containing the outer layers of polystyrene concrete and the inner layer of heat-insulating material, and the inner layer of the multilayer panel is made in the form of polystyrene foam slab or mineral wool.

The described multilayer wall, as well as the proposed multilayer wall panel, contains interconnected layers, while the supporting layer is formed between removable formwork. However, the implementation of the carrier layer of cast concrete makes the wall construction heavier, the absence of reinforcement reduces its strength and reliability, and the use of insulation from polystyrene foam plates does not provide the necessary heat, moisture and sound insulation. In addition, the design of the multilayer wall of the prototype does not provide for laying communications inside it, requires decorative decoration of the outer layers.

Closest to the proposed method of manufacturing a multilayer wall panel is a method of manufacturing a two-layer prefabricated wall panel, described in the patent application RU A 200121324, selected as the closest analogue (prototype), namely, that the two-layer wall panel formed by "face down", contains an outer face layer of reinforced expanded clay concrete and an inner layer of unreinforced structural and heat-insulating foam concrete.

In the described method according to the prototype, as well as in the proposed method for manufacturing a multilayer wall panel, layers are laid “face down”, while one of the layers is made of reinforced expanded clay concrete. However, the prototype method does not allow the manufacture of the proposed multilayer wall panel.

There is a method of erecting the outer walls of a monolithic building (Italian PLASTBAU technology), which consists in installing a formwork of two layers of expanded polystyrene on the floor, in which a reinforcing cage is placed in the gap, after which concrete is poured into the gap, while the expanded polystyrene serves as a heater, then carry out the decorative decoration of the facade, for which the mesh is fixed on the outer surface of the expanded polystyrene layer and outside the building, from scaffolding, the facade is plastered.

There is also known a method of erecting walls of a monolithic building (technology of Germany "TECH-COLOR", see the technical certificate of Gosstroy of the Russian Federation - TF-07-0049-97), consisting in the fact that they form a multilayer, in particular a three-layer structure, including an inner reinforced concrete layer, which is formed by pouring concrete of a reinforcing cage placed between two layers of formwork, after hardening the pouring, the formwork is removed and from the outside of the building a layer of insulation is glued to the concrete and the anchor elements are fixed, after which they are applied and a layer of plaster for the final decoration of the facade of the building.

This method, as described above, is characterized by increased labor intensity, danger and adverse working conditions when conducting outdoor work from scaffolding.

Closest to the proposed method of erecting the outer wall of a monolithic frame building is the method of erecting the outer wall of a monolithic building, protected by patent RU C2 2193635, selected as the closest analogue (prototype). The known method consists in the fact that the multilayer wall structure is formed from the inside of the building under construction, for which the facade plate is first fixed to the ceiling, then a layer of insulation is fixed on its inner surface, after which the reinforcing cage and the inner formwork are installed, concrete is poured and, after the concrete has hardened, the internal the formwork is removed. Sealing joints between the plates is also carried out from the inside of the building. The facade plate has a decorative outer surface, and four anchor elements are mounted in its body from the side of the inner surface, one in each corner zone, two located along the lower edge of the plate have the shape of rods and two along the upper edge, are U-shaped trusses with downward slope, while the height of the anchor elements is essentially equal to the total thickness of the layers of the multilayer wall following the facade plate.

In the described method according to the prototype, as well as in the proposed method, the installation of panels is carried out from the inside of the building being erected. However, the prototype method is not without drawbacks, namely, it is time-consuming and expensive, since for its implementation special facade plates with anchor elements are required. In addition, the multilayer structure formed by this method is quite heavy, does not provide the necessary heat, moisture, sound insulation, requires internal initial decoration, laying communications.

The task of the group of inventions is the creation of a multilayer wall panel with integrated communications, light but strong, providing heat, moisture, sound insulation, not requiring external and internal initial finishing, suitable for implementing a simple and quick method of its manufacture at a construction site, and for the implementation of a simple and quick way to erect the outer wall of the building.

The technical result from the use of the proposed group of inventions is to increase the operational properties of a multilayer wall panel, as well as to increase the safety of work, reduce labor costs, construction costs when erecting the outer walls of monolithic buildings from such panels.

The problem is achieved in that in a multilayer wall panel containing interconnected layers, one of which is a supporting and formed between removable formwork, and the other is heat insulating, the supporting layer is made of expanded clay concrete with reinforcement made of PVC pipes installed inside vertical direction, and of metal rods laid in the horizontal direction, the insulating layer is made of foam, in which the communications are laid, an additional many the lacquered wall panel contains a facade layer of gypsum fiber sheet moisture-proof (GVLV), a reinforcing layer of fine-mesh fiberglass mesh, a heat, moisture and sound insulating layer of extruded polystyrene foam, a layer for interior decoration of gypsum plasterboard of moisture-proof (GKLV), while the layers are connected between by gluing, and on top between the heat, moisture and sound insulating layer of extruded polystyrene foam and the heat insulating layer of foam formed a cavity due to the implementation of the facade layer and h moisture-resistant gypsum fiber sheet (GVLV) with a heat-, moisture- and sound-insulating layer of extruded polystyrene foam and a heat-insulating layer of foam plastic with a layer for the interior decoration of moisture-proof gypsum plasterboard (GKLV) larger in height than the inner supporting layer of expanded clay concrete; PVC pipes are made with a diameter of 100-200 mm; the facade layer of gypsum fiber sheet moisture resistant (GVLV) is made primed and painted; before the facade layer of moisture-resistant gypsum fiber sheet (GVLV), a decorative layer can be made with a reinforcing layer glued to it from a fine-mesh fiberglass mesh; openings for doors and windows are formed by installing shuttering walls in the designed places.

The task is also achieved by the fact that in the method of manufacturing a multilayer wall panel, including laying the layers "face down", one of which is made of reinforced expanded clay concrete, on the bottom of a special shape equipped with wheels, the facade layer is laid from moisture-resistant gypsum fiber sheet (GVLV), gluing on it a reinforcing layer of a fine-mesh fiberglass mesh, to it - a heat-, moisture- and sound-insulating layer of extruded polystyrene foam, the implementation of the inner bearing layer of expanded clay concrete, for which formwork partitions are installed on the sides of the form, inside which reinforcement is made of PVC pipes in the vertical direction and from metal rods in the horizontal direction, after which reinforcement is filled in the formwork with expanded clay concrete mixture, ramming the expanded clay mixture with vibration, glued to the inner load-bearing layer from expanded clay concrete reinforcing layer from a fine-mesh fiberglass mesh, to it - a heat-insulating layer of foam, in which cavities and punctures are cut various communications come, to it is a layer for interior decoration from a gypsum plasterboard sheet moisture-proof (GKLV), the formation from above between a heat, moisture and sound insulating layer of extruded polystyrene foam and a heat-insulating layer of foam plastic cavity by performing a facade layer of gypsum fiber sheet moisture-proof (GVLV ) with a heat-, moisture- and sound-insulating layer of extruded polystyrene foam and a heat-insulating layer of foam with a layer for interior decoration from a gypsum-plasterboard sheet moisture-proof (GKLV) larger in height than the inner supporting layer of expanded clay concrete, transportation of the finished multilayer wall panel on a mold equipped with wheels to the installation site, removal from the mold, removal of formwork partitions; PVC pipes are made with a diameter of 100-200 mm; the front layer is painted, pre-primed; in front of the facade layer, a decorative layer is laid in the form with a reinforcing layer glued to it from a fine-mesh fiberglass mesh with glue; openings for doors and windows can form during the manufacture of the panel by installing shuttering walls in the designed places.

The task is also achieved by the fact that in the method of erecting the outer wall of a monolithic frame building, including installing multilayer wall panels from the inside of a building being constructed, the manufacture of multilayer wall panels by the method described above is carried out on a construction site in special forms equipped with wheels, ready-made multilayer wall panels on molds equipped with wheels to the installation site are removed from the mold, formwork partitions are removed, multilayer wall panels are installed on the perimeter foundation, fix multilayer wall panels to each other by ligating metal rods protruding from them from the side, put metal rods in PVC pipes and cavities in the cavity, fill the reinforcement with concrete in small portions, periodically tamp, install slabs, connect communications, install windows and doors PVC pipes are made with a diameter of 100-200 mm.

Figure 1 shows a diagram of a multilayer wall panel.

Figure 2 shows a diagram of the outer wall of a monolithic frame building.

Figure 3 shows a diagram of the outer wall of a monolithic frame building, inside view.

Figure 1-3 indicated:

1 - a facade layer of gypsum fiber sheet moisture resistant (GVLV);

2 - a reinforcing layer of fine-mesh fiberglass mesh;

3 - heat, moisture and sound insulating layer of extruded polystyrene foam:

4 - inner supporting layer of expanded clay concrete;

5 - PVC pipe;

6 - metal rods;

7 - a heat-insulating layer of foam;

8 - communications;

9 - layer for interior decoration of gypsum plasterboard moisture resistant (GKLV);

10 - cavity;

11 - a decorative layer of finishing materials.

The assembly of the proposed multilayer wall panel of the proposed method is as follows.

On the bottom of a special form, equipped with wheels, lay the front layer 1 of a gypsum fiber sheet moisture-proof (GVLV) “face down”, onto which glue is applied and a reinforcing layer 2 of a fine-mesh fiberglass mesh is glued, to it is a heat, moisture and sound insulating layer of extruded polystyrene foam 3. Perform the inner bearing layer of expanded clay 4. For this, formwork partitions are installed on the sides of the mold. Reinforcement is installed in the formwork: in the vertical direction, in accordance with the cavities laid, PVC pipes 5 are installed, metal rods are laid in the horizontal direction 6. Then the reinforcement in the formwork is poured with a prepared claydite-concrete mixture. Expanded clay mixture is rammed with vibration, for example, using a motor with a displaced axis of rotation connected to the mold. After setting the inner supporting layer of expanded clay concrete 4, glue is applied to it and the reinforcing layer 2 is glued from a fine-mesh fiberglass mesh, to it is a heat-insulating layer of foam 7, in which cavities are cut out and various communications 8 are laid, for example, water pipes, electric cable, etc. .P. A layer for interior decoration of moisture-resistant gypsum plasterboard (GKLV) 9 is glued onto the heat-insulating layer of polystyrene foam 7. The finished multilayer wall panel is transported on a mold equipped with wheels to the installation site, removed from the mold, the formwork partitions are removed.

A cavity 10 is formed between the heat, moisture, and sound insulating layer of extruded polystyrene foam 3 and the heat insulating layer of polystyrene 7 by performing a facade layer of gypsum fiber sheet moisture resistant (GVLV) 1 with a heat, moisture, and sound insulating layer of extruded polystyrene foam 3 and heat insulating a layer of foam 7 with a layer for interior decoration of gypsum plasterboard moisture resistant (GKLV) 9 larger in height than the inner bearing layer of expanded clay 4.

PVC pipes 5 are installed with a diameter of 100-200 mm. The choice of the diameter of the PVC pipe 5 is carried out depending on the number of storeys of the building being constructed. The use of PVC pipes with a diameter of less than 100 mm does not provide the necessary strength of a multilayer wall panel, and the use of PVC pipes with a diameter of more than 200 mm is technologically disadvantageous, since the inner supporting layer of expanded clay concrete 4 is usually made with a thickness of not more than 200 mm.

The facade layer of gypsum fiber sheet moisture resistant (GVLV) 1 can, for example, be painted, pre-primed.

Before the facade layer of gypsum fiber sheet moisture-resistant (GVLV) 1, a decorative layer 11 of finishing materials, for example, of brick tiles, onto which a reinforcing layer 2 of a fine-mesh fiberglass mesh with glue can be glued, can be laid into the mold.

Openings for doors and windows can be formed during the manufacture of the panel by installing shuttering walls in the designed places.

The erection of the outer wall of the building from the proposed multilayer wall panels is as follows.

At the construction site in special forms equipped with wheels, multilayer wall panels are made by the proposed method described above. Finished multilayer wall panels are transported on forms equipped with wheels to the installation site and installed on a perimeter foundation. The panels are fixed to each other by ligation of metal rods 6, protruding from the panels on the side. At the same time, the gaps between the multilayer wall panels are minimal, which does not require special sealing. Metal rods 6 are laid in the PVC pipes 5 and in the cavity 10 and concrete is poured in small portions, periodically rammed, for example, with a vibrating machine, while a reinforced concrete rod is formed in the PVC pipe. After the flooded structure gets stronger, install floor slabs, connect communications 8, install windows and doors.

The design of the proposed multilayer wall panel has a relatively light weight, provides heat, moisture, sound insulation, which increases its operational properties.

The use of PVC pipes as reinforcement in the vertical direction in the expanded clay concrete layer allows the reinforced concrete core to be erected during the erection of the building’s external walls; in addition, PVC pipes are not prone to expansion and contraction, such as metal pipes, which prevents structural damage, increases reliability and its service life.

The reduction of labor costs is facilitated by the presence of communications inside the multilayer panel.

The presence of a supporting facade layer (or decorative layer) and a layer for interior decoration also helps to reduce labor costs, and also increases the safety of work, since it eliminates the need for decoration of the building from the outside and initial finishing inside.

The manufacture of multilayer panels at a construction site on special molds equipped with wheels, as well as the transportation of finished panels to the place of their installation on the same molds also helps to reduce labor costs, and reduces construction costs.

The following are examples of specific performance of the proposed monolithic multilayer wall panels using the proposed method.

Example 1:

A primed and painted facade layer of moisture-resistant gypsum-fiber sheet (GVLV) is laid “face down” on the bottom of a special form equipped with wheels, onto which glue is applied and a reinforcing layer of fine-mesh fiberglass mesh is glued, and a heat-, moisture- and sound-insulating layer is applied to it from extruded polystyrene foam. Perform the inner bearing layer of expanded clay concrete. To do this, formwork partitions are installed on the sides of the form. The reinforcement is installed in the formwork: in the vertical direction, in accordance with the enclosed cavities, PVC pipes of d 100 mm are installed; in the horizontal direction, metal rods are laid. Then the reinforcement in the formwork is poured with a pre-prepared expanded clay mixture. Ceramsite-concrete mixture is rammed with vibration, using a motor with an offset axis of rotation connected to the mold. After setting the inner supporting layer of expanded clay concrete, adhesive is applied to it and a reinforcing layer of fine-mesh fiberglass mesh is glued to it, a heat-insulating layer of foam is applied to it, in which cavities are cut out and communications are laid from water pipes, electric cable, etc. A layer for the interior decoration of a gypsum plasterboard moisture-proof (GKLV) is glued to the heat-insulating layer of foam. A cavity is formed between the heat-, moisture- and sound-insulating layer of extruded polystyrene foam and the heat-insulating layer of foam plastic due to the implementation of the facade layer of gypsum-fiber sheet moisture-proof (GVLV) with a heat-, moisture- and sound-insulating layer of extruded polystyrene foam and a heat-insulating layer of foam for interior decoration of gypsum plasterboard moisture-proof (GKVL) greater in height than the inner supporting layer of expanded clay concrete. The finished multilayer wall panel is removed from the mold, the formwork partitions are removed.

Example 2:

A decorative layer of brick tiles is laid “face down” on the bottom of a special form equipped with wheels, on which a reinforcing layer of fine-mesh glass cloth is glued, to it is a facade layer of moisture-resistant gypsum fiber sheet (GVLV), to which glue is applied and reinforcing is glued a layer of fine-mesh fiberglass mesh, to it is a heat-, moisture- and soundproofing layer of extruded polystyrene foam. Perform the inner bearing layer of expanded clay concrete. To do this, formwork partitions are installed on the sides of the form. The reinforcement is installed in the formwork: in the vertical direction, in accordance with the enclosed cavities, PVC pipes of d 200 mm are installed; in the horizontal direction, metal rods are laid. Then the reinforcement in the formwork is poured with a pre-prepared expanded clay mixture. Ceramsite-concrete mixture is rammed with vibration, using a motor with an offset axis of rotation connected to the mold. After setting the inner supporting layer of expanded clay concrete, adhesive is applied to it and a reinforcing layer of fine-mesh fiberglass mesh is glued to it, a heat-insulating layer of foam is applied to it, in which cavities are cut out and communications are laid from water pipes, electric cable, etc. A layer for the interior decoration of a gypsum plasterboard moisture-proof (GKLV) is glued to the heat-insulating layer of foam. A cavity is formed between the heat-, moisture- and sound-insulating layer of extruded polystyrene foam and the heat-insulating layer of foam plastic due to the implementation of the facade layer of gypsum-fiber sheet moisture-proof (GVLV) with a heat-, moisture- and sound-insulating layer of extruded polystyrene foam and a heat-insulating layer of foam for interior decoration of gypsum plasterboard moisture-proof (GKLV) greater in height than the inner supporting layer of expanded clay concrete. The finished multilayer wall panel is removed from the mold, the formwork partitions are removed.

Claims (12)

1. A multilayer wall panel containing interconnected layers, one of which is a supporting and formed between removable formwork, and the other is heat insulating, characterized in that the supporting layer is made of expanded clay concrete with reinforced PVC pipes inside, installed in a vertical direction, and of metal rods laid in the horizontal direction, the insulating layer is made of foam, in which communications are laid, an additional multilayer wall the spruce tree contains a facade layer of gypsum-fiber sheet moisture-proof (GVLV), a reinforcing layer of fine-mesh fiberglass mesh, a heat-, moisture- and sound-insulating layer of extruded polystyrene foam, a layer for interior decoration of gypsum-plasterboard sheet moisture-proof (GKLV), while the layers are interconnected by gluing and on top between the heat, moisture and sound insulating layer of extruded polystyrene foam and the heat insulating layer of polystyrene, a cavity is formed due to the implementation of the facade layer of GVLV with heat, moisture - and a sound-insulating layer of extruded polystyrene foam and a heat-insulating layer of polystyrene with a layer for interior decoration made of gypsum plasterboard greater in height than the inner supporting layer of expanded clay concrete. 2. The multilayer wall panel according to claim 1, characterized in that the PVC pipe is made with a diameter of 100-200 mm 3. The multilayer wall panel according to claim 1, characterized in that the facade layer of GVLV is made primed and painted. 4. The multilayer wall panel according to claim 1, characterized in that in front of the facade layer of GVLV, a decorative layer can be made with a reinforcing layer glued to it from a fine-mesh glass fabric. 5. The multilayer wall panel according to claim 1, characterized in that the openings for doors and windows are formed by installing shuttering walls in the designed places. 6. A method of manufacturing a multilayer wall panel, including laying the layers “face down”, one of which is made of reinforced expanded clay concrete, characterized in that at the bottom of a special shape equipped with wheels, the facade layer is made from GVLV, gluing the reinforcing layer of it from fine mesh fiberglass mesh, to it - a heat, moisture and sound insulating layer of extruded polystyrene foam, the implementation of the inner carrier layer of expanded clay concrete, for which formwork is installed on the sides of the mold partitions, inside which reinforcements of PVC pipes are laid in the vertical direction and of metal rods in the horizontal direction, after which reinforcement is filled in the formwork with expanded clay mixture, ramming the expanded clay mixture with vibration, gluing a reinforcing layer of fine-mesh mesh to the inner supporting layer of expanded clay concrete to the fine-mesh it - a heat-insulating layer of foam, in which cavities are cut out and various communications are laid, to it is a layer for interior decoration from GKLV, the formation from above between the heat, moisture and sound insulating layer of extruded polystyrene foam and the heat insulating layer of foam cavity due to the implementation of the facade layer of GVLV with a heat, moisture and sound insulating layer of extruded polystyrene and a heat insulating layer of foam with a layer for GKLV interior finishes larger in height than the inner supporting layer of expanded clay concrete, transportation of the finished multilayer wall panel on a mold equipped with wheels to the installation site, removed removal from form, removal of formwork partitions. 7. A method of manufacturing a multilayer wall panel according to claim 6, characterized in that the PVC pipe is made with a diameter of 100-200 mm 8. A method of manufacturing a multilayer wall panel according to claim 6, characterized in that the facade layer is painted, pre-primed. 9. A method of manufacturing a multilayer wall panel according to claim 6, characterized in that in front of the facade layer, a decorative layer is laid in the form with a reinforcing layer glued to it from a fine-mesh fiberglass mesh with glue. 10. A method of manufacturing a multilayer wall panel according to claim 6, characterized in that the openings for doors and windows can be formed during the manufacture of the panel by installing shuttering walls in the designed places. 11. The method of erecting the outer wall of a monolithic building, including installing multilayer wall panels from the inside of a building being constructed, characterized in that the manufacture of multilayer wall panels by the method of claims 6-10 is carried out at a construction site in special forms provided with wheels, ready-made multilayer wall panels are transported to forms equipped with wheels to the installation site are removed from the mold, the formwork partitions are removed, multilayer wall panels are installed on the foundation around the perimeter, many are fixed layered wall panels to each other by ligating metal rods protruding from them from the side, they are placed in PVC pipes and metal rods in the cavity, the reinforcement is poured with concrete in small portions, periodically tamping, installing floor slabs, joining communications, windows and doors are installed. 12. The method of construction of the outer wall of the monolithic building according to claim 11, characterized in that the PVC pipe is made with a diameter of 100-200 mm

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