WO2007147178A2 - Élément de construction - Google Patents

Élément de construction Download PDF

Info

Publication number
WO2007147178A2
WO2007147178A2 PCT/ZA2007/000035 ZA2007000035W WO2007147178A2 WO 2007147178 A2 WO2007147178 A2 WO 2007147178A2 ZA 2007000035 W ZA2007000035 W ZA 2007000035W WO 2007147178 A2 WO2007147178 A2 WO 2007147178A2
Authority
WO
WIPO (PCT)
Prior art keywords
outer layer
insert
layer
construction element
panel
Prior art date
Application number
PCT/ZA2007/000035
Other languages
English (en)
Other versions
WO2007147178A3 (fr
Inventor
Allen Michael Tucker
Original Assignee
Allen Michael Tucker
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 Allen Michael Tucker filed Critical Allen Michael Tucker
Publication of WO2007147178A2 publication Critical patent/WO2007147178A2/fr
Publication of WO2007147178A3 publication Critical patent/WO2007147178A3/fr

Links

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
    • E04C2/2885—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 with the insulating material being completely surrounded by, or embedded in, a stone-like material, e.g. the insulating material being discontinuous

Definitions

  • the invention relates to a construction element such as a panel for use in the construction of buildings and structures and a method of manufacturing of the construction element.
  • This invention aims to provide an alternative lightweight construction element and a method of manufacturing thereof which might alleviate some of the aforementioned problems.
  • the invention provides a construction element which includes an outer cementitious layer, a reinforcing scrim which is at least partially embedded in the outer layer and a lightweight cementitious insert which is bonded to the outer layer.
  • the outer layer may include a filler.
  • the filler may include polypropylene which
  • the insert is preferably fluorinated.
  • the insert may be foamed or may include expanded polystyrene.
  • the construction element may include an intermediate cementitious layer which is bonded to the outer layer and to the insert.
  • the scrim is at least partially trapped between the outer layer and the intermediate layer.
  • the invention also provides a method of manufacturing of a construction element which includes the steps of:
  • the outer layer may include a filler.
  • the filler may include polypropylene which is preferably fluorinated.
  • the first mould surface may include ornamentation or may be textured.
  • the insert may be foamed or may include expanded polystyrene.
  • the method of manufacturing may include the step of bonding an intermediate cementitious layer to the outer layer and to the insert.
  • the method of manufacturing may include the step of at least partially trapping the scrim between the outer layer and the intermediate layer.
  • the method of manufacturing may include the step of engaging the first mould surface with a second similar mould surface to form a cavity between the opposing outer layers on the respective surfaces.
  • the method of manufacturing may include the step of filling the cavity with the insert.
  • the method may include the step of allowing the outer layers and the insert to set.
  • the method may include the steps of disengaging the first mould surface from the second mould surface and the outer layer and disengaging the second mould surface from the outer layer.
  • the invention also provides a wall which includes a foundation, a plurality of spaced apart pillars wherein each pillar extends from the foundation and has at least one vertical slot, a plurality of construction elements of the aforementioned kind wherein each element extends between adjacent pillars and is at least partially located in the slot and an elongate coping member which has an elongate, horizontal recess wherein the panel is at least partially received.
  • the panel may be embedded in the foundation.
  • the coping member may extend on top of the panel between the adjacent pillars.
  • Figure 1 is a cross-sectional side view of a construction element or panel according to the invention.
  • Figure 2 is a perspective view of a first mould used in the manufacturing of the panel of Figure 1 ;
  • Figure 3 is a perspective view of an enclosed mould body which is used in the manufacturing of the panel of Figure 1 ;
  • Figure 4 is a perspective view of a wall which is manufactured from the panels of Figure
  • Figure 5 is a front side view of the wall of Figure 4.
  • Figure 6 is a cross-sectional view from above of the wall of Figure 5 on the line 6-6 shown in Figure 5;
  • Figure 7 is a cross-sectional side view of the wall of Figure 4 on the line 7-7 shown in
  • Figure 1 illustrates a planar construction element or panel 10 which has an outer cementitious layer 12, a reinforcing scrim 14 which is at least partially embedded in the outer layer 12, an intermediate cementitious layer 16 which is bonded to the outer layer 12 and an insert 18 which is bonded to the intermediate layer 16 and to the outer layer 12 through the intermediate layer 16.
  • the panel 10 has a width W of between 30mm to 50mm, a height H of between 1600mm to 2000mm and a length L of between 2500mm and 2800mm.
  • the outer layer 12 has a thickness T1 of between 2mm to 5mm
  • the intermediate layer 16 has a thickness T2 of between 2mm and 5mm
  • the insert 18 has a thickness T3 of between 20mm to 45mm.
  • the outer layer 12 is made from high strength Portland cement which is mixed with a filler such as sand and/or fluorinated polypropylene.
  • a filler such as sand and/or fluorinated polypropylene.
  • Polypropylene and especially fluorinated polypropylene enhances the flexibility of the outer layer 12 and protects the outer layer 12 against cracking.
  • the scrim 14 is made of woven fibreglass or fluorinated polypropylene. It is important that the scrim 14 is made from a non-ferrous material as ferrous materials are prone to corrosion when brought into contact with Portland cement accelerants and corrosive environments. The scrim 14 is of high strength and has good cohesion with the outer layer 12. Importantly the scrim 14 is elastic.
  • the intermediate layer 16 is made from the same material as the outer layer 12.
  • the insert 18 is made from a mixture of Portland cement and an appropriate filler or foaming agent.
  • an appropriate filler or foaming agent can be used.
  • the panel 10 has a robust exterior formed by the outer layer 12 which can be shaped, handled and worked in the same manner as any other high strength cementitious product.
  • the panel 10 is relatively lightweight and is transportable. Despite a high slendemess ratio the panel 10 is substantially rigid but is flexible to a limited degree without cracking or breaking. This is caused by the fact that the reinforcement of the panel 10 by way of the scrim 14 is close to an outer surface of the panel 10.
  • the reinforced shell of the panel 10 which consists of the outer layer 12, the scrim 14 and the intermediate layer 16 surrounds the insert 18 and provides substantial rigidity and strength to the panel 10.
  • the scrim 14 is made from a non-ferrous material the ingress of water into the panel 10 does not result in corrosion of the scrim 14 and the possible separation of the scrim 14 from the outer layer 12. Accordingly the panel 10 can be used in exterior applications and in hostile environments.
  • the panel 10 is manufactured by way of two identical and opposing moulds 20.
  • Each mould 20 has a mould surface 22 which is surrounded by side walls 24.
  • a semicircular inlet 26 is formed in a wall 24A at one end of the mould 20.
  • the mould 20 is made from any appropriate material and the mould surface 22 includes surface ornamentation or texturing 28 which is used to impart a required ornamentation or texture to the outer layer 12.
  • the cementitious material of the outer layer 12 is sprayed onto the mould surface 22 and walls 24 while in liquid format. The material adheres to the inside of the moulds 20 to form the outer layer 12. Thereafter an appropriately sized scrim 14 is brought into contact with the outer layer 12 and at least partially embedded in the outer layer 12.
  • the cementitious material of the intermediate layer 16 is thereafter sprayed onto the scrim 14 and the outer layer 12 while in a liquid format so that the scrim 14 becomes trapped between the outer layer 12 and the intermediate layer 16 and the intermediate layer 16 bonds to the outer layer 12. [0032] At this point the outer layer 12 and intermediate layer 16 are allowed at least partially to set while the mould 20 lies in a horizontal position.
  • the mould 20 and the second mould 2OA are locked to one another in this position in any appropriate manner.
  • the combined mould 20 and second mould 2OA form an enclosed mould body 30.
  • the mould body 30 is placed in a vertical orientation so that the opposing inlets 26 face upwards.
  • the mould body 30 is laid in a horizontal position.
  • a cavity 32 is formed in the mould body 30 between the opposing outer layers 12, scrims 14 and intermediate layers 16.
  • the cavity 32 is filled by pouring or pumping liquid material of the insert 18 into the cavity 32 through the inlets 26. As the material of the insert 18 flows into the cavity 32 it contacts with and bonds to the intermediate layer 16. In this manner the insert 18 becomes bonded to both the intermediate layer 16 and the outer layer 12 by way of the intermediate layer 16.
  • the intermediate layer 16 is optional and can be omitted from the panel 10.
  • the insert 18 is in direct contact with and bonded to the outer layer 12 and the scrim 14 is at least partially trapped between the outer layer 12 and the insert 18.
  • the panel 10 can be used in the construction of various buildings and structures and has high insulation, fire resistant and impact resistance characteristics.
  • FIGS 4 to 7 illustrate the use of the panel 10 in the construction of a wall 50.
  • the wall 50 has a base or foundation 52, a plurality of spaced apart pillars 54, a cap 56 on each pillar 54, a panel 10 which extends between each pair of adjacent pillars 54 and an elongate coping member or tile 58 which is positioned on each panel 10 and which extends between the adjacent pillars 54.
  • the foundation 52 is made from concrete and is cast in a trench 60 in for example the ground 62 in a known manner.
  • Each pillar 54 is inserted vertically into the foundation 52 before same has set.
  • Each pillar 54 is square or rectangular shaped in cross section and has two elongate and vertical slots 64 which extend in the pillar 54 for a substantial portion of its length. y
  • Each slot 64 is dimensioned so that a panel 10 can fit snugly and at least partially into the slot 64 so that the panel 10 can at least partially be trapped in the slot 64.
  • each pillar 54 at the end of the wall 50 can have a single slot 64. Accordingly each pillar 54 has at least one slot 64.
  • Each of the pillars 54 is manufactured in the same manner as the panel 10 and, except for its dimensions, has a similar structure to that of the panel 10.
  • the cap 56 is known and fits over the upper end of the pillar 54.
  • Each panel 10 is fitted into the slot 64 of each of the opposing pillars 54 and is also at least partially embedded into the wet foundation 52.
  • the tile 58 has an elongate and horizontal recess 66 which is complementary shaped to a top 68 of the panel 10 so that the top 68 of the panel 10 fits at least partially into the recess 66. In this manner the panel 10 is at least partially received and trapped within the recess 66 of the tile 58 and the tile 58 extends on top of the panel 10.
  • the cap 56 and tile 58 are respectively fixed to each pillar 54 and panel 10 in any appropriate manner and can for example be bolted or glued.
  • each panel 10 is framed on its respective sides by the foundation 52, opposing pillars 54 and the tile 58.
  • the framing rigidifies and strengthens the panel 10 along its border and limits possible buckling of the panel 10 against sideways and downward pressures on the panel 10.
  • the wall 50 can have different appearances resembling different finishes.
  • the wall 50 requires less construction time and is less expensive than walls with similar finishes which are built by hand and from traditional materials which give a similar finish.

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Laminated Bodies (AREA)
  • Finishing Walls (AREA)
  • Panels For Use In Building Construction (AREA)

Abstract

L'invention concerne un élément de construction ou panneau (10) possédant une couche cimentaire externe (12), une grille de renforcement (14) qui est au moins partiellement enrobée dans la couche externe, une couche cimentaire intermédiaire (16) qui est liée à la couche externe et un élément encastré (18) qui est lié à la couche intermédiaire et à la couche externe par l'intermédiaire de la couche intermédiaire.
PCT/ZA2007/000035 2006-06-14 2007-07-02 Élément de construction WO2007147178A2 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
ZA200604897 2006-06-14
ZA2006/04897 2006-06-14

Publications (2)

Publication Number Publication Date
WO2007147178A2 true WO2007147178A2 (fr) 2007-12-21
WO2007147178A3 WO2007147178A3 (fr) 2008-02-07

Family

ID=38704950

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/ZA2007/000035 WO2007147178A2 (fr) 2006-06-14 2007-07-02 Élément de construction

Country Status (1)

Country Link
WO (1) WO2007147178A2 (fr)

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2013010545A1 (fr) * 2011-07-19 2013-01-24 Connovate Aps Procédé de fabrication d'un élément en béton de haute résistance isolé complet ayant une excellente surface, et élément en béton de haute résistance fabriqué par ledit procédé
US20140272284A1 (en) * 2013-03-15 2014-09-18 David M. Franke Multi zone cementitious product and method
WO2016041559A1 (fr) * 2014-09-15 2016-03-24 Thörngren Pontus Petter Paroi de construction et son procédé de fabrication
WO2019157595A1 (fr) * 2018-02-13 2019-08-22 Nexii Building Solutions Inc. Panneau de construction isolé préfabriqué doté d'au moins une couche cimentaire durcie liée à un matériau isolant
GR1009631B (el) * 2018-07-09 2019-10-25 Κωνσταντινος Δημητριου Ζαβλιαρης Πολυστρωματικα φυλλα απο ινες υαλου σε ανοργανη μητρα υπερυψηλης αντοχης με βαση το τσιμεντο και παχος δεκατων χιλιοστου
RU2777582C2 (ru) * 2018-02-13 2022-08-08 Нэксии Билдинг Солюшнз Инк. Готовая изолированная строительная панель с по меньшей мере одним отвержденным цементным слоем, сцепленным с изоляцией

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3284980A (en) * 1964-07-15 1966-11-15 Paul E Dinkel Hydraulic cement panel with low density core and fiber reinforced high density surface layers
FR2447437A1 (fr) * 1979-01-26 1980-08-22 Valkeniers Serge Procede de fabrication d'un produit imitant un assemblage de briques ou de pierres naturelles, et mur-palissage obtenu selon ce procede
GB2187446A (en) * 1986-01-20 1987-09-09 Lam Cheong How Concrete components
US5030502A (en) * 1990-02-02 1991-07-09 Teare John W Cementitious construction panel
EP1012422A1 (fr) * 1997-09-12 2000-06-28 National Gypsum Company Panneau a base de ciment avec bords renforces
US20040251026A1 (en) * 2003-06-10 2004-12-16 Bernard Dargaud Cementing compositions and application of such compositions for cementing oil wells or the like

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3284980A (en) * 1964-07-15 1966-11-15 Paul E Dinkel Hydraulic cement panel with low density core and fiber reinforced high density surface layers
FR2447437A1 (fr) * 1979-01-26 1980-08-22 Valkeniers Serge Procede de fabrication d'un produit imitant un assemblage de briques ou de pierres naturelles, et mur-palissage obtenu selon ce procede
GB2187446A (en) * 1986-01-20 1987-09-09 Lam Cheong How Concrete components
US5030502A (en) * 1990-02-02 1991-07-09 Teare John W Cementitious construction panel
US5030502B1 (fr) * 1990-02-02 1992-09-15 W Teare John
EP1012422A1 (fr) * 1997-09-12 2000-06-28 National Gypsum Company Panneau a base de ciment avec bords renforces
US20040251026A1 (en) * 2003-06-10 2004-12-16 Bernard Dargaud Cementing compositions and application of such compositions for cementing oil wells or the like

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2013010545A1 (fr) * 2011-07-19 2013-01-24 Connovate Aps Procédé de fabrication d'un élément en béton de haute résistance isolé complet ayant une excellente surface, et élément en béton de haute résistance fabriqué par ledit procédé
US20140272284A1 (en) * 2013-03-15 2014-09-18 David M. Franke Multi zone cementitious product and method
WO2016041559A1 (fr) * 2014-09-15 2016-03-24 Thörngren Pontus Petter Paroi de construction et son procédé de fabrication
WO2019157595A1 (fr) * 2018-02-13 2019-08-22 Nexii Building Solutions Inc. Panneau de construction isolé préfabriqué doté d'au moins une couche cimentaire durcie liée à un matériau isolant
US10961708B2 (en) 2018-02-13 2021-03-30 Nexii Building Solutions Inc. Prefabricated insulated building panel with cured cementitious layer bonded to insulation
RU2777582C2 (ru) * 2018-02-13 2022-08-08 Нэксии Билдинг Солюшнз Инк. Готовая изолированная строительная панель с по меньшей мере одним отвержденным цементным слоем, сцепленным с изоляцией
GR1009631B (el) * 2018-07-09 2019-10-25 Κωνσταντινος Δημητριου Ζαβλιαρης Πολυστρωματικα φυλλα απο ινες υαλου σε ανοργανη μητρα υπερυψηλης αντοχης με βαση το τσιμεντο και παχος δεκατων χιλιοστου

Also Published As

Publication number Publication date
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