US20100024355A1 - Prefabricated panel for building construction and process for manufacturing such a panel - Google Patents

Prefabricated panel for building construction and process for manufacturing such a panel Download PDF

Info

Publication number
US20100024355A1
US20100024355A1 US12/304,230 US30423007A US2010024355A1 US 20100024355 A1 US20100024355 A1 US 20100024355A1 US 30423007 A US30423007 A US 30423007A US 2010024355 A1 US2010024355 A1 US 2010024355A1
Authority
US
United States
Prior art keywords
panel
plate
concrete
face
reinforcement elements
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US12/304,230
Other languages
English (en)
Inventor
Philippe Malapert
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
SARL COMEPS FRANCE
Original Assignee
SARL COMEPS FRANCE
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by SARL COMEPS FRANCE filed Critical SARL COMEPS FRANCE
Assigned to SARL COMEPS FRANCE reassignment SARL COMEPS FRANCE ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: MALAPERT, PHILIPPE
Publication of US20100024355A1 publication Critical patent/US20100024355A1/en
Abandoned legal-status Critical Current

Links

Images

Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
    • E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
    • E04C2/288—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and concrete, stone or stone-like material

Definitions

  • This invention relates to the field of the construction of buildings using prefabricated panels, and it relates more particularly to the prefabricated panel per se, the assembly of several panels together, and the processes for manufacturing said panels, as well as the construction of the building using these prefabricated panels.
  • the important construction quality criteria include especially the mechanical strength and heat insulation of the walls that form the outer jacket of the building. These criteria can be met by the use of two materials with opposite but complementary properties, which are reinforced concrete and expanded polystyrene.
  • reinforced concrete is inexpensive, easy to use, has very good mechanical strength and is nonflammable, but it has the drawback of heavy weight and poor heat insulation.
  • expanded polystyrene which is also inexpensive, has excellent heat insulation and very low weight, but it has the drawback of being inflammable and having a very low mechanical strength.
  • a method that consists in mounting polystyrene panels on the construction site, in placing a reinforcement around these panels, then in spraying concrete on each of the faces of the polystyrene panel.
  • Another method comprises the installation of two parallel polystyrene panels that are used as a framework, the incorporation of crosspieces and metal frames, then the pouring of concrete inside the space that is formed by the two panels, and then the coating of the outer faces of the polystyrene with concrete.
  • Still another method consists in using polystyrene blocks in the form of parallelepiped hollow blocks, in placing metal reinforcements inside the recesses of the parallelepiped hollow blocks, and in pouring concrete into them, whereby the whole is then covered with concrete on the outside.
  • the object of this invention is therefore to eliminate the above-mentioned drawbacks by proposing a construction process that combines the use of reinforced concrete and expanded polystyrene and that is simple to execute, whereby the creation of thermal bridges that interfere with the thermal insulation of the manufactured walls is avoided.
  • Another object of the invention is to propose a process for the production of walls for low-cost and totally reproducible buildings.
  • Another object of the invention is therefore to design prefabricated panels and an assembly of these panels that is free of thermal bridges, while having high mechanical strength and being very light.
  • this invention therefore relates first of all to a prefabricated panel for building construction that comprises a core that is full of insulating material in the form of a plate that is covered on its two faces by a uniform concrete layer, characterized in that in said plate that forms the core, there are provided:
  • the prefabricated panel that comprises elements for connection with adjacent panels makes it possible to produce, in a very quick period of time, the construction of buildings whose walls, in particular the outer walls, consist of such panels.
  • the two faces of the insulating-material plate are covered at the factory with a concrete layer, the insulating layer is masked and is not at all visible during the construction.
  • the application of concrete can be carried out flat at the factory, the thickness of these concrete layers is uniform and very reproducible from one panel to the next. It is therefore possible to ensure—for all the panels—identical properties in terms of mechanical strength or thermal insulation, for example.
  • the first series of housings and the second series of housings provided in the plate that forms the core of the panel are free from communication zone between them so as to avoid the formation of thermal bridges.
  • the reinforcements that are arranged on one face are separated from the reinforcement elements that are arranged on the other face of the core that is made of insulating material.
  • the housings are advantageously made in the form of grooves whose longitudinal axes are orthogonal from one series to the next. These grooves can either be flush with the outer surface of the plate made of insulating material or come out on the surface of this plate.
  • the reinforcement elements are preferably metal elements.
  • a preferably metal trellis can be applied on—or be arranged parallel to—each face of the plate that forms the core of the panel in the immediate proximity of the latter.
  • the reinforcement elements can also be used as a support to this framework.
  • the dimensions of this trellis advantageously correspond to the surface of each of the faces of the plate.
  • the sections of the panel be at least partially beveled to adapt to the adjacent panels by forming an assembly of the groove-assembly type, whereby the assembly is interrupted to provide a free-angle zone that allows the belt elements of two adjacent panels to be connected.
  • a concrete layer covers the beveled section
  • the core is made of preferably high-density expanded polystyrene or of rigid foam with closed cells.
  • the faces of the plate that forms the core preferably have striated surfaces for a better adhesion of the concrete to the latter.
  • the thus manufactured panel is inexpensive and has good mechanical strength as well as excellent thermal insulation.
  • this panel has very little weight relative to the existing prefabricated panels. It is therefore easily transportable up to the construction sites. The reduced weight of these panels also entrains the limitation of the thickness of the necessary foundations to support these panels.
  • This invention also relates to an assembly of prefabricated panels for building construction as described above, whereby the reinforcement elements that extend between two parallel edges of the panel are housed in horizontal grooves made in the core of the panel, on its face turned toward the outside of the building, so as—after connection of the projecting ends of the reinforcement elements of adjacent panels—to form a horizontal framework of the construction, by thus constituting a self-supporting-type structure.
  • Such a structure is stable, rigid and undeformable.
  • This invention also relates to a process for manufacturing a prefabricated panel as described above, comprising the following successive stages:
  • This invention also relates to a process for building construction using such prefabricated panels, including the process for manufacturing above, and also comprising:
  • Openings such as doors and windows, can be arranged in said panel at the factory.
  • the plate that is made of insulating material and that constitutes the core can also be cut or machined so as to provide sheathing for electric cables or pipes. The only thing left to do on the construction site is to make the connections for these cables or pipes.
  • the upper ends of the vertical reinforcement elements can project from the upper edge of the panel so as to constitute hooking elements (for example for towing chains) for the purpose of handling and transport of said panel at the factory or on the construction site. These projecting ends can also make possible the attachment or the affixing to said panel of various other construction elements, in particular roof elements.
  • This invention also relates to a building that is constructed by the process above, characterized in that the outer walls consist of an assembly of prefabricated panels as described above.
  • FIG. 1 is a longitudinal top view of a panel according to this invention
  • FIG. 2 is a partial top view of an assembly of three adjacent panels according to this invention.
  • FIG. 3 is a front view of the assembly according to FIG. 2 .
  • a panel according to this invention consists of a core 2 , preferably made of expanded polystyrene, sandwiched between two concrete layers 3 A (outer layer) and 3 B (inner layer).
  • the core 2 forms a plate that can itself consist of an assembly of polystyrene blocks that are glued together, as shown in FIGS. 1 and 3 , and referenced 2 a, 2 b, 2 c, 2 d . . . (the words “inner” and “outer” refer, in the entire text, to the positioning of the faces of the panel during the construction of the building).
  • housings 4 that are parallel to one another and that consist of grooves (vertical when the panel is set up on the ground) are provided.
  • These housings 4 shown here in FIG. 1 as opening on the inner face of the core 2 , accommodate metal reinforcements 5 that are kept in place in the housing by wedges (not shown).
  • the inner trellis 6 that is arranged parallel to the inner face of the core 2 is attached to these vertical reinforcements 4 .
  • this concrete forms the inner concrete layer 3 B and also fills the grooves that form housings 4 by embedding the framework 6 and the vertical reinforcements 4 .
  • housings 7 horizontal when the panel is set up on the ground
  • housings 7 that are designed to accommodate the horizontal reinforcement elements 8 are cut out.
  • An outer trellis 9 is arranged parallel to the outer face of the plate that forms the core 2 . This trellis is connected by multiple connections 10 to the horizontal reinforcement elements 8 to keep it in place in particular during the pouring of the concrete, and to separate it (by a small distance) from the outer face of the core 2 .
  • this concrete When the concrete of layer 3 A is poured over the outer face of the core 2 , this concrete also fills the openings that are left in the housings 7 around the reinforcement element 8 and covers the reinforcement element 8 and the outer trellis 9 .
  • the spacing of the inner trellis 6 and the outer trellis 9 of the respective faces of the polystyrene plate can also be done using ribs or projections made on the surface of said plate so that the trellis are almost entirely covered in the concrete.
  • the grooves that are used as housing in the metal reinforcements 5 and 8 can have various shapes, for example U, T, dovetailed, etc. . . . : they are also used as molds for the concrete that has been poured there.
  • the preferably self-smoothing concrete can be cast all at once or in several times; in this latter case, it is possible to use concretes of different natures.
  • the reinforcement elements 5 and 8 can consist of a single rod or profile, or advantageously, as in the example shown in FIGS. 1 and 2 , of an assembly of several rods (four here) that are connected together by crosspieces, for example, of the zigzag type, as is the conventional method at construction sites using reinforced concrete.
  • the vertical sections of the panel 1 are partially beveled 11 , here at 45°.
  • This beveled form 11 allows the panel 1 to be applied against two adjacent panels 21 or 22 , as can be seen in FIG. 2 .
  • the angle zone that is then left free 12 between two adjacent panels is a space that makes it possible to join the horizontal reinforcement elements of two adjacent panels and to link them, for example, by welding them to one another and/or to a framework 13 that is positioned vertically as shown in FIG. 2 .
  • Such a connection between two adjacent panels thus considerably solidifies the structure.
  • a formwork 14 can be installed around the angle zone 12 so that the concrete can be cast into it.
  • openings 16 , 17 can be made in the entire panel so as to affix it at the factory or on the site respectively of windows or doors.
  • the thus manufactured panel can be easily anchored on the ground 15 in particular using lower projecting ends 18 of the reinforcement elements 5 that form vertical struts and that are connected to construction elements, such as roofing, by means of upper projecting ends 19 of these same reinforcement elements 5 , which are also used for hooking during handling and for transport of said panel.
  • the horizontal reinforcement elements 8 that form a belt of the construction are arranged—when there are openings provided for windows or doors—on both sides of these openings in the vertical direction.
  • Each panel can, by itself, constitute the entire wall of a building; the assembly of four panels according to the invention makes it possible to produce, for example, the four outer walls of a house, thus constructed very quickly.
  • the composite walls that are made using panels according to this invention are both rigid and light.
  • the thickness of the polystyrene core can be, for example, on the order of 30 centimeters; the thickness of the inner and outer concrete layers 3 A and 3 B can be, for example, between 2 to 3 centimeters, approximately.
  • longitudinal housings made in the upper and/or lower horizontal sections of the panel 1 and designed to accommodate beams, for example made of concrete, can be provided.

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Building Environments (AREA)
  • Panels For Use In Building Construction (AREA)
  • Load-Bearing And Curtain Walls (AREA)
  • Forms Removed On Construction Sites Or Auxiliary Members Thereof (AREA)
US12/304,230 2006-06-14 2007-06-04 Prefabricated panel for building construction and process for manufacturing such a panel Abandoned US20100024355A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
FR0605297 2006-06-14
FR0605297A FR2902447B1 (fr) 2006-06-14 2006-06-14 Panneau prefabrique pour construction de batiment et procede de fabrication d'un tel panneau
PCT/FR2007/000921 WO2007144481A1 (fr) 2006-06-14 2007-06-04 Panneau prefabrique pour construction de batiment et procede de fabrication d'un tel panneau

Publications (1)

Publication Number Publication Date
US20100024355A1 true US20100024355A1 (en) 2010-02-04

Family

ID=37882230

Family Applications (1)

Application Number Title Priority Date Filing Date
US12/304,230 Abandoned US20100024355A1 (en) 2006-06-14 2007-06-04 Prefabricated panel for building construction and process for manufacturing such a panel

Country Status (15)

Country Link
US (1) US20100024355A1 (fr)
EP (1) EP2029827A1 (fr)
JP (1) JP2009540164A (fr)
CN (1) CN101466905B (fr)
AU (1) AU2007259110B2 (fr)
BR (1) BRPI0713427A2 (fr)
CA (1) CA2655169A1 (fr)
EA (1) EA015993B1 (fr)
EG (1) EG25072A (fr)
FR (1) FR2902447B1 (fr)
IL (1) IL195617A0 (fr)
MA (1) MA30512B1 (fr)
TN (1) TNSN08514A1 (fr)
WO (1) WO2007144481A1 (fr)
ZA (1) ZA200810126B (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2013020228A1 (fr) * 2011-08-05 2013-02-14 Bradfield Jeffrey Rae Module de paroi préfabriquée et procédé de fabrication

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
RU2629510C2 (ru) * 2015-11-02 2017-08-29 Федеральное государственное бюджетное образовательное учреждение высшего образования "Приокский государственный университет" (ФГБОУ ВО "ПГУ") Стеновая панель и способ ее изготовления
RU177130U1 (ru) * 2017-11-29 2018-02-09 Владимир Алексеевич Коннов Плита изоляционная облицовочная

Citations (18)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3338011A (en) * 1963-12-09 1967-08-29 Nat Gypsum Co Simulated curtain wall construction with sheet clad mullions
US3353315A (en) * 1964-09-30 1967-11-21 Barker George Grooved panel with load-bearing strips
US3992844A (en) * 1975-08-28 1976-11-23 Joseph Clemens Gretter Building panel
US4249354A (en) * 1979-03-05 1981-02-10 Wynn Gayle B Reinforced insulated wall construction
US4318258A (en) * 1979-03-14 1982-03-09 Friedrich Heck Thermal insulation for buildings
US4841702A (en) * 1988-02-22 1989-06-27 Huettemann Erik W Insulated concrete building panels and method of making the same
US5067296A (en) * 1989-07-10 1991-11-26 Robert T. K. Brown Modular insulated wall panel system
US5086598A (en) * 1989-03-23 1992-02-11 Derrell J. Weldy Wall board joint reinforcing system
US5146721A (en) * 1991-07-01 1992-09-15 Monolite S.R.L. Wall panel with thermoacoustic insulation characteristics
US5172532A (en) * 1988-04-01 1992-12-22 Gibbar Jr James H Prefabricated polymer building wall panels
US5596853A (en) * 1992-09-29 1997-01-28 Board Of Regents, University Of Texas Building block; system and method for construction using same
US5678372A (en) * 1995-11-22 1997-10-21 Constru-Plus Internacional, S.A. System for building construction using preformed, reinforced concrete panels
US6817150B1 (en) * 2003-03-20 2004-11-16 Patrick E. Boeshart Form system for poured concrete
US6848228B1 (en) * 2000-03-21 2005-02-01 Chester W. Williams Method and apparatus for making foam blocks and for building structures therewith
US6898912B2 (en) * 2002-04-15 2005-05-31 Leonid G. Bravinski System and method for the reinforcement of concrete
US20080041004A1 (en) * 2006-08-15 2008-02-21 Gibbar James H Multiple layer polymer foam and concrete system for forming concrete walls, panels, floors, and decks
US20080313990A1 (en) * 2007-06-19 2008-12-25 Plastedil S.A. Composite article for constructing floors
US7627997B2 (en) * 2002-03-06 2009-12-08 Oldcastle Precast, Inc. Concrete foundation wall with a low density core and carbon fiber and steel reinforcement

Family Cites Families (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS5211246Y1 (fr) * 1970-04-25 1977-03-11
DE2409493A1 (de) * 1974-02-28 1975-09-11 Otto Einhaeupl Tafelfoermiges fertigbauelement
JPS5712089Y2 (fr) * 1978-04-03 1982-03-10
JP2531033B2 (ja) * 1991-02-12 1996-09-04 鹿島建設株式会社 壁の構造
DE9218494U1 (de) * 1992-12-01 1995-03-23 Schurig, Burkhart, 01561 Brößnitz Bewehrtes Leichtbauelement
CN2303885Y (zh) * 1996-01-12 1999-01-13 张成模 轻型预制楼板
JP3833791B2 (ja) * 1997-09-26 2006-10-18 株式会社アステックコーポレーション コンクリート基礎の型枠

Patent Citations (18)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3338011A (en) * 1963-12-09 1967-08-29 Nat Gypsum Co Simulated curtain wall construction with sheet clad mullions
US3353315A (en) * 1964-09-30 1967-11-21 Barker George Grooved panel with load-bearing strips
US3992844A (en) * 1975-08-28 1976-11-23 Joseph Clemens Gretter Building panel
US4249354A (en) * 1979-03-05 1981-02-10 Wynn Gayle B Reinforced insulated wall construction
US4318258A (en) * 1979-03-14 1982-03-09 Friedrich Heck Thermal insulation for buildings
US4841702A (en) * 1988-02-22 1989-06-27 Huettemann Erik W Insulated concrete building panels and method of making the same
US5172532A (en) * 1988-04-01 1992-12-22 Gibbar Jr James H Prefabricated polymer building wall panels
US5086598A (en) * 1989-03-23 1992-02-11 Derrell J. Weldy Wall board joint reinforcing system
US5067296A (en) * 1989-07-10 1991-11-26 Robert T. K. Brown Modular insulated wall panel system
US5146721A (en) * 1991-07-01 1992-09-15 Monolite S.R.L. Wall panel with thermoacoustic insulation characteristics
US5596853A (en) * 1992-09-29 1997-01-28 Board Of Regents, University Of Texas Building block; system and method for construction using same
US5678372A (en) * 1995-11-22 1997-10-21 Constru-Plus Internacional, S.A. System for building construction using preformed, reinforced concrete panels
US6848228B1 (en) * 2000-03-21 2005-02-01 Chester W. Williams Method and apparatus for making foam blocks and for building structures therewith
US7627997B2 (en) * 2002-03-06 2009-12-08 Oldcastle Precast, Inc. Concrete foundation wall with a low density core and carbon fiber and steel reinforcement
US6898912B2 (en) * 2002-04-15 2005-05-31 Leonid G. Bravinski System and method for the reinforcement of concrete
US6817150B1 (en) * 2003-03-20 2004-11-16 Patrick E. Boeshart Form system for poured concrete
US20080041004A1 (en) * 2006-08-15 2008-02-21 Gibbar James H Multiple layer polymer foam and concrete system for forming concrete walls, panels, floors, and decks
US20080313990A1 (en) * 2007-06-19 2008-12-25 Plastedil S.A. Composite article for constructing floors

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2013020228A1 (fr) * 2011-08-05 2013-02-14 Bradfield Jeffrey Rae Module de paroi préfabriquée et procédé de fabrication

Also Published As

Publication number Publication date
EA200802386A1 (ru) 2009-04-28
CN101466905B (zh) 2011-04-13
CN101466905A (zh) 2009-06-24
TNSN08514A1 (fr) 2010-04-14
AU2007259110A1 (en) 2007-12-21
IL195617A0 (en) 2009-09-01
JP2009540164A (ja) 2009-11-19
AU2007259110B2 (en) 2011-10-27
ZA200810126B (en) 2009-08-26
WO2007144481A1 (fr) 2007-12-21
FR2902447B1 (fr) 2008-09-05
CA2655169A1 (fr) 2007-12-21
MA30512B1 (fr) 2009-06-01
FR2902447A1 (fr) 2007-12-21
EP2029827A1 (fr) 2009-03-04
EG25072A (en) 2011-07-28
BRPI0713427A2 (pt) 2012-03-13
EA015993B1 (ru) 2012-01-30

Similar Documents

Publication Publication Date Title
US4454702A (en) Building construction and method of constructing same
US4942707A (en) Load-bearing roof or ceiling assembly made up of insulated concrete panels
EP1941104B1 (fr) Nouveau type de batiment, procede et moyens pour sa realisation
US6438923B2 (en) Method of assembling lightweight sandwich wall panel
US20090113820A1 (en) Prefabricated wall panel system
CN214302533U (zh) 一种预制夹心保温墙板
WO2012114122A2 (fr) Panneau de construction
US20120124927A1 (en) Foam injected wall panel
AU2007259110B2 (en) Prefabricated panel for building construction and the manufacturing process thereof
US20210324629A1 (en) Unified Prefinished Panel
US20180223526A1 (en) Fast Construction of Energy-Efficient Buildings
JP2002339451A (ja) プレキャストコンクリート板およびその製造方法、バルコニー用プレキャストコンクリート板、外断熱構造物
CN210117854U (zh) 预制门窗一体化叠合墙板
EP2402525A1 (fr) Procédé d'édification d'un bâtiment à structure monolithique avec façade externe décorative
CN106638978B (zh) 装配式pc预制承重墙板结合轻型钢骨架的节点结构
CN216340223U (zh) 一种基于无机保温砂浆的膨胀珍珠岩复合墙板及建筑
CN2911049Y (zh) 现浇轻质复合墙体
US7146775B2 (en) Wall system
KR101895803B1 (ko) 주택 시공방법
KR100555320B1 (ko) 오픈조인트식 외벽 패널 및 이를 이용한 외벽체 시공방법
CN214941333U (zh) 一种外挂墙板的墙角连接节点及装配式建筑外墙
CN211762332U (zh) 混凝土箱模
AU2014265071B2 (en) A building and methods of constructing the building
CN101089308A (zh) 现浇轻质复合墙体及生产方法
RU2745262C1 (ru) Сборная соединительная конструкция из кровельных панелей, карнизных панелей и стеновых плит и способ её соединения

Legal Events

Date Code Title Description
AS Assignment

Owner name: SARL COMEPS FRANCE,FRANCE

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:MALAPERT, PHILIPPE;REEL/FRAME:022559/0339

Effective date: 20090323

STCB Information on status: application discontinuation

Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION