WO2010097059A2 - Élément structural composite destiné en particulier à la construction de bâtiments - Google Patents

Élément structural composite destiné en particulier à la construction de bâtiments Download PDF

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Publication number
WO2010097059A2
WO2010097059A2 PCT/CZ2010/000020 CZ2010000020W WO2010097059A2 WO 2010097059 A2 WO2010097059 A2 WO 2010097059A2 CZ 2010000020 W CZ2010000020 W CZ 2010000020W WO 2010097059 A2 WO2010097059 A2 WO 2010097059A2
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Prior art keywords
elements
floor
structural element
composite structural
concrete
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PCT/CZ2010/000020
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English (en)
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WO2010097059A3 (fr
Inventor
Ivan Razl
Original Assignee
Ivan Razl
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Publication date
Application filed by Ivan Razl filed Critical Ivan Razl
Priority to EP10723910A priority Critical patent/EP2401445A2/fr
Publication of WO2010097059A2 publication Critical patent/WO2010097059A2/fr
Publication of WO2010097059A3 publication Critical patent/WO2010097059A3/fr

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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
    • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/38—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels
    • E04C2/384—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels with a metal frame

Definitions

  • the invention relates to a composite structural element, particularly for the construction of buildings, containing a supporting structure and a filling.
  • Stone buildings are firm and usually resistant to weather, but their disadvantages include limited architectural possibilities, low construction speed, demanding material handling, but also high transport costs, and reduced thermal insulation and so on.
  • Timber buildings provide more architectural possibilities. Timber is also used for floors and roofs. Its disadvantages include limited maximum load and strength, flammability, shorter lifetime, limited insulating properties and so on.
  • Brick buildings eliminate some of the disadvantages of the building materials mentioned above. Their disadvantages, however, include rather low speed of construction, high demands on accuracy, high transport costs, need of surface treatment and so on. Bricks are bonded with mortar, which also covers the joints between the individual bricks and is also used as plaster or render. Plaster can be applied from the outer as well as inner side of the wall. The ceilings and floors in these buildings were made of timber, and later metal and concrete .
  • Concrete and reinforced-concrete buildings have high strength, are sufficiently resistant to external effects, the speed of construction is rather high, but their insulating properties are limited, the demands on the transport of materials are quite high, construction requires the presence of heavy machinery, and the elimination of these buildings after their lifetime is not properly solved yet, and so on.
  • Individual stories are usually made using the so-called beam structure. Outer surfaces can be adjusted to match local weather, while inner surfaces can be treated as required by the customer .
  • Some rarer natural building materials are also known, such as clay, reed, bamboo, straw and so on. These materials are used to a limited extent in some territories only.
  • buildings can be divided into two fundamental groups. Buildings made on-site from individual building elements, such as stone, timber, bricks and so on, and buildings erected from imported prefabricated materials, such as panels.
  • Prefabricated materials with an iron or timber supporting structure are made in a production plant and transported to the construction site, where they are connected into a single resulting unit.
  • the unit can be made solely from prefabricated materials, or supplemented with other fillings on site.
  • Reinforced-concrete panels are widely used especially in the mass construction of houses. These panels, insulated as well as non- insulated, are used to build whole buildings, including floors, ceilings and roofs.
  • Prefabricated materials containing sandwiched elements with a supporting coating are also known. These sandwiched elements usually contain one or several insulating and other filling materials, such as plywood, honeycombs and so on, between the supporting coatings.
  • One well-known solution is specified in patent CA 1 284 571 from 1991, from the applicant Peter Kayne . There are quite a lot of patents based on this solution. These patents basically differ only by the materials used, and sometimes by the structure that forms the filling material . Some patents also involve the production procedure used for these prefabricated materials and the mutual bonding of the individual layers .
  • Patent CA 1 169 625 by the applicant Jack Slater, specifies the panel and the method of construction using this panel.
  • the panel comprises wooden or metal prism-shaped beams, with a filling of a polystyrene block between. These panels can be used for making a wall or floor.
  • the connection between the beams and the filling is made using ordinary glue.
  • the inner side is usually faced with plasterboard, while the outer side with bricks or another type of facing.
  • the finish of the inner and outer side is made independently of the beams, and these amending modifications therefore do not transfer any supporting forces or forces outside the panel to the basic structure, except for their own weight.
  • the disadvantages of this solution include high costs of a moulding press, a complicated change of the product portfolio, complicated erection, lower strength, difficult surface finish and so on.
  • the Dutch patent NL 1 018 156 named mecanic sandwiched floor system
  • a sandwich panel comprising a flat or corrugated board made of concrete, with a steel reinforcement, supported by walls or posts.
  • the supported board that forms the bottom surface of the sandwich floor carries steel rods in both directions, supported by crossbeams.
  • the crossbeams support the reinforcing rods above the board.
  • the board behaves as a permanent mould on which a layer of light concrete is spilt, which constitutes the sandwich core. After that, a layer of mortar is placed on top of the core, constituting the upper surface of the sandwich floor system.
  • the described system has numerous disadvantages.
  • a key disadvantage of the patented Dutch system is that it requires a supporting board.
  • Another disadvantage of this sandwich system is its structural limitation.
  • Modular wall panel of cement reinforced with fibres describes the panel wall of the cladding made of GRC, i.e. cement reinforced with glass fibre.
  • the panel of the cladding is made using the so-called spraying process of chopped glass and cement in a suitable mould.
  • the profile cut forms gaps, filled with a foam bonding agent.
  • the GRC panel wall of the cladding filled with a foam bonding agent uses a steel frame over its flexible metal anchor to fix the supporting structure.
  • the above patent describes only a non-supporting panel wall of the cladding.
  • the foam bonding agent described in the patent only serves as a thermal insulating material. There is no combined structural effect between GRC and the steel frame.
  • the steel frame only provides a safe and effective transfer of the load from the GRC layer and is only used to fix the GFR layer, filled with the foam bonding agent, to the supporting structure .
  • the Japanese patent JP 9 256 530 Half board and method of construction of a composite board using the half board, describes a floating floor made using the so-called structure of half boards, used in Europe under the namestern filigree" as early as before World War 2.
  • the Japanese patent, i.e. filigree includes a method of load transfer from the upper concrete layer to the lower concrete layer.
  • the flat concrete boards, i.e. panels with the type of couplings described in the Japanese patent, i.e. filigree are reinforced with couplings embedded in the prefabricated concrete board.
  • Porous concrete has been used in the form of a prefabricate or as on-site for many years.
  • a typical example is the system of the German company Neopor, which uses porous concrete made in metal or plastic moulds in the shape of panels. Its major limitation is the high cost of the moulds and the limited possibility of change of building design, depending on the number of used moulds.
  • the density of porous concrete is 1.10 to 1.7 g per cu cm,- this relatively high density increases weight and limits thermal insulation.
  • a composite structural element particularly for the construction of buildings, containing a supporting structure and a filling, as specified in this invention.
  • Its essence is a supporting structure in the shape of a four-square frame, with a filling of a lightweight material with a specific gravity of 0.3 to 1.5 g per cu cm, while the edges of the frame are made from interconnected U and/or C profiles, facing each other with their free ends, made of a metal material with a thickness of 0.5 to 2 mm, a base of 50 to 300mm, rims of 15 to 40mm and the bend at the C profile of 10 to 30mm.
  • the frame contains at least one brace of U and/or C and/or I profile.
  • the faces are advantageously fitted with a cladding of a shrinkage compensated levelling mortar made from Portland cement, aggregate and reinforced with fibres.
  • the surface of the filling can be fitted with grooves for the cladding material .
  • a layer of thermal insulating material can be placed between the cladding and the outer side of the edge rims.
  • the face and/or the cladding are advantageously fitted with thermal insulation with an external finish.
  • the faces of the floor elements are advantageously fitted with juts to place the reinforcing mesh of the concrete layer.
  • the faces of the floor elements may be fitted with elements to transfer the stress between the concrete layer and the frame.
  • the faces of the floor elements may be fitted with grooves for the concrete layer, with reinforcements placed in the grooves.
  • the composite structural element may be fitted with L profiles to attach other elements.
  • the cellular cement core is fiber reinforced. This is important for strength, toughness and freeze/thaw resistance of the core. It also increases the strength and toughness of the entire structure. But, the patent is "structural" in nature, so maybe this point not so important .
  • the groove is typically placed in the middle of the section and its size is from lcm by lcm to 4 cm by 4 cm.
  • the 15 cm U profile typically uses 2.5 cm by 2.5 cm groove.
  • the groove increases strength and stiffness in compression as well as in bending. The increase in stiffness in bending is very important in deflection-control in floor and roof elements.
  • the groove simplifies construction and connections and increases the strength and toughness (erthaquake) resistance of the structure. It is typically used in vertical sections of wall elements and longitudional sections of floor/roof elements. Of course all sections described will be used.
  • the groove is produced during rectif roll -forming" or ,,press breaking" of the U and C sections.
  • An advantage of the specified solution is the high strength of the composite structural element because the structural element according to this invention behaves as a single unit, because all external and internal stresses are transferred to the other parts, distributing the stresses to the individual sections of this element.
  • the composite structural element can be therefore used for walls as well as for floors, ceilings and roofs.
  • the composite structural element as specified in this invention is light, easy to store, strong, and therefore requires rather low transport costs, while its production does not necessitate any heavy construction machinery or complicated machines or tools; only basic tools and small machines, such as a mixer, a pump and so on, are sufficient. Construction workers can be only informed because the mounting operations as such are not too demanding. When erecting abroad, the builder need not send its own workers, it is enough to easily train local personnel.
  • the composite structural element and the materials used for construction are environmentally friendly and can be reprocessed.
  • the lifecycle of the composite structural elements is comparable to existing panels, possibly even longer.
  • Their resistance to various weather conditions, including strong winds and soil vibrations, is comparable to solid structures, sometimes even higher.
  • Another advantage is a rather easy treatment of the exterior and the interior, as needed or as required by the customer. It is possible to create many variants that give the final structure a different look.
  • the equipment of the buildings can be plain and simple, but they can be also luxurious buildings, and it is not possible to recognize that the building is prefabricated.
  • Another advantage is the possibility to use existing accessories, such as doors, windows and the like, which can be selected from available local sources.
  • Another advantage is that the material is highly- resistant, inflammable, waterproof, and watertight, if necessary.
  • Yet another advantage is the possibility to create a suitable base for the sealing compound for floor elements. In this way it is possible to create a sufficiently strong floor with the required surface.
  • the speed of construction is also a big advantage.
  • the whole house can be built in 2 or 3 days, by 3 or 4 workers.
  • the design process is very simple. Designing a floor layout plan involves the positioning of right angles that constitute a horizontal cross section of the wall element to the module axis.
  • the grid has the same dimensions as the element - typically 1.2m, which is applicable to imperial as well as metric systems. The same applies to the floor layout plan on the same grid.
  • the structural design is simplified because the mechanical, i.e. weight-carrying and deflective properties for each element are easy to determine. The structural designer simply verifies places with a high concentration of load and joints.
  • the module concept offers production and structural advantages, as well as design advantages.
  • the structural system proposed in this invention combines the economic benefits of prefabrication with a complete freedom of design.
  • the installation of an external insulating system provides a joint less, undisturbed appearance.
  • the module structure also facilitates easier extensions and annexes to structures than is the case of ordinary structures.
  • the frame is placed on a flat concrete floor with a separating film, and the space created by the frame is filled with a porous bonding agent.
  • a typical element 1.2m wide, 3m long and 15cm high, is filled in less than 3 minutes.
  • a ply-based separator is then placed on the first frame and another frame is placed on top and filled with a porous bonding material.
  • About 5 or 6 elements can be simply stacked and moved to an external warehouse within 12 hours. This production process allows a high productivity in element production without the need for steel structures used for casting common concrete wall and floor panels.
  • the formwork required for the traditional prefabrication of concrete systems is expensive, i.e. their quantity has to be low, which limits design and architectural flexibility.
  • the typical weight of the elements described above is about 300kg, while an ordinary concrete panel of the same size weighs about 2,500kg.
  • the high costs of demolition, cleaning and re-assembly under the traditional concrete prefabricate process are eliminated.
  • Stacking also allows a setting blanket to be put over multiple elements and conducting steam through a hose to speed up the setting of the porous bonding agent.
  • the lighter element under the presented invention allows an easier transport of the produced elements because of their significantly lower weight, while they still offer a sufficient strength.
  • the construction process is also simple and only involves installing the wall elements next to each other and connecting their faces using steel plates with screws or by welding.
  • Floor / ceiling elements are placed on top of wall panels and are also connected using steel plates with screws or by welding.
  • the shear pins that allow the transfer of load between the concrete layer and the steel U- or C-sections are welded or screwed onto the C-sections.
  • the other floor and the flat roof are constructed using the same procedure. Plumbing and wiring can be pre- installed in the elements or can be easily inserted in the core of the porous bonding agent by cutting, or by slotting using a simple wood saw.
  • the concrete layer is put on top of the elevated floor panel.
  • the exterior is finished with insulation and external plaster in a cold climate, or it can only comprise an external structural coating without any insulation in a warmer climate.
  • the structural cladding can be connected with the porous concrete core of the wall using the slots made in it.
  • heat or cold transfer is reduced by installing insulating plates or insulating coatings on the surface of the bare steel.
  • the interior is finished with a dry facing or interior plaster.
  • the thermal insulator is placed on top of the roof panels and the roof structure is completed using common finishing works.
  • a metal frame can be easily manufactured and can be quickly and easily filled with porous concrete.
  • the frame serves as a mould for the production of the elements, while increasing the maximum load.
  • cellular cement - porous concrete usually has a density of 0.4 to 0.7g per cu cm. This low density gives the element a sufficient maximum load, sound insulation and heat resistance, while providing strength.
  • the mentioned solution does not require any supporting plate, which makes construction easier.
  • the core made of lightweight bonding agent has a very low tensile and shearing strength, which are required to transfer the load between the upper and lower surfaces of the sandwich.
  • the C- and U-shaped steel parts are fixed to the upper concrete layer. Both components, the steel part and the concrete layer, therefore can share the load by transferring the shear between concrete and the steel parts, allowing the maximum utilization of the high compressive force of the concrete layer and the high compressive force of the steel part.
  • the rib reinforcements in the concrete layer are an integrated part of the concrete layer, which is very efficient structurally.
  • the steel frame of the presented invention allows a highly efficient and simple connection of floor elements to the supporting wall.
  • a connection to transfer the load is not described in the Dutch patent and the description of the floor sandwich clearly shows that the floor, the connection to the wall and the corresponding necessary load transfer are very inefficient structurally.
  • the Dutch patent NL 1 018 156 describes a structurally inefficient sandwich.
  • the presented invention is not a sandwich, but a structurally efficient combination of concrete and steel profiles.
  • the specified invention describes a complete structural system comprising a supporting wall, a floor and roofing elements.
  • the foam reinforced with fibres is used as a structural element, and at the same time serves as a permanent mould in the floor structure.
  • Steel and concrete form a composite support for the load.
  • the reinforcing C- and U-section provides a double function. It works as an article providing tensile strength in the composite element and at the same time provides a formwork for casting the elements, which eliminates the need for a formwork during plate prefabrication, as describe in the above-mentioned three patents .
  • figure 1 is a schematic cross-section of the lightweight structural element as given in this invention.
  • Figure 2 shows a side view of an exemplary element with a bracket .
  • Figure 3 shows a plan view of this element shown in figure 2.
  • Figure 4 shows a schematic plan view of the element, with a cladding fixed to it.
  • Figure 5 shows a schematic plan view of the element, with grooves for the cladding material.
  • Figure 6 shows a schematic plan view of the element, with a thermally insulating material between the cladding and the frame.
  • Figure 7 shows a schematic plan view of the element, with thermal insulation.
  • Figure 8 shows a schematic side view of the joint between the wall and the floor.
  • Figure 9 shows a schematic side view of the floor element.
  • Figure 10 shows a schematic side view of another embodiment of the floor element.
  • Figure 11 shows a schematic plan view of the floor element with reinforcement.
  • a composite structural element for the construction of buildings contains a supporting structure and a filling 1.
  • the supporting structure is in the shape of a four-square frame 2_, with a filling I ⁇ of a lightweight material with a specific gravity of 0.3 to 1.5 g per cu cm, while the edges of the frame 2_ are made from interconnected U- and/or C- profiles 3 ⁇ , facing each other with their free ends, made of a metal material with a thickness of 0.5 to 2 mm, with a base 3_1 of 50 to 300mm, rims 3_2 of 15 to 40mm and the bend 3_3_ at the C-profile of 10 to 30mm.
  • the faces of the floor elements are fitted with juts 7. to place the reinforcing mesh of the concrete layer.
  • the faces of the floor elements may be also fitted with elements JJ to transfer the stress between the concrete layer and the frame £.
  • the faces of the floor elements are fitted with grooves 9_ for the concrete layer material, with reinforcements placed in the grooves £.
  • the composite structural element is fitted with L-profiles K[ to attach other elements.
  • the wall elements are described first.
  • the width and height of all supporting walls as well as non-supporting parts are 1.2m and 2.8m, respectively.
  • the depth of the element is 0.15m.
  • the rim 32_ of the U-profile is 35mm.
  • the thickness of the U-profile of galvanized steel is 1.52mm.
  • the density of the cellular cement - dry porous bonding agent reinforced with fibres used as a filling 1 is 0.57kg per cu dm. This creates the element's total weight of about 290kg.
  • the compressive strength of the cellular cement 1 is 2 to 3MPa and its modulus of elasticity is 0.7 to 2.5GPa.
  • the wall elements on the ground floor contain three vertical U-brackets 2_1.
  • the wall elements for the upper storey contain only two vertical brackets 21.
  • the width of the floor elements is 1.2m and their maximum length, i.e. the spacing of the floor elements, is 6 metres.
  • the depth of the U-profile 3_ of galvanized steel is 0.15m and the rim 3>2. 35mm, and the thickness of steel profiles 3 ⁇ i- s 1.52mm.
  • the floor elements with a floor spacing of 5 and 6 ⁇ metres include four steel U-profiles 3_ and two floor grooves £ with a width of 5cm and a depth of 12cm from the top of the porous filling 1- Tne floor grooves j) are reinforced with standard reinforcing rods 12mm in diameter, installed on saddles to allow the flow of concrete around the reinforcing0 rods.
  • the floor grooves 9_ for casting concrete are made in a porous concrete reinforcement 1 when the steel frames 2 are filled with concrete.
  • the cellular cement used in the structure of the floor elements is identical with the cement used on the wall elements; its dry density is 0.57kg per cu dm, compressive strength 2 to 3MPa and modulus of elasticity 0.7 to 2.5GPa.
  • the roof elements of the structure are identical to those used in the structure of the floor elements, but no grooves are cast in the porous concrete core, unless the roof includes a concrete layer.
  • the specific number of longitudinal C-profiles are identical to those used in the structure of the floor elements, but no grooves are cast in the porous concrete core, unless the roof includes a concrete layer.
  • 3_ is determined by the structural design of the given span and the wind / snow load based on the building requirements in the given location.
  • the cellular cement - porous concrete filling I ⁇ is identical with the design of the wall and floor elements with a dry density of 0.57kg per cu dm, modulus of elasticity of 0.7 to 2.5GPa and compressive strength of 2 to 3MPa.
  • a cellular cement filling 1. For a flat roof, the necessary inclination to discharge rain water is created by a cellular cement filling 1.
  • Construction proceeds as follows.
  • the wall elements are placed on a flat concrete floor plate and anchored using steel L-profiles, installed outside the wall elements.
  • the typical dimensions of the anchoring L-profiles are 6mm for thickness and 10cm for rims, and their length is identical with that of the wall.
  • the L-profiles are anchored to the concrete plate using ordinary concrete anchors, typically with a diameter of 10mm and a spacing of 0,5m or as often as required by the structural design for the given structure and location.
  • the steel frames 2_ of the elements are then welded to the anchoring L-profiles.
  • additional connecting means are installed to connect the horizontal rail of the wall elements and the anchoring L-profile.
  • the individual wall elements are connected together by galvanized steel plates with a width of 3m and dimensions of 3cm x 15cm, welded to the adjacent wall elements.
  • the joints between the elements are sealed with ordinary insulation.
  • the anchoring screws are welded to the top of the rail of the wall elements.
  • the wooden heads, 15 x 15cm, are then screwed down using the anchoring screws.
  • the function of the wooden head is to divide the load along the top of the wall and to balance any weight differences caused by the production and construction, within the tolerance limits.
  • Another step is to install floor elements.
  • the floor elements are attached from the bottom using 3mm L-profiles, with a rim of 4 x 4cm, welded to the vertical posts. Additional connections are made by external plates, 3mm thick and with dimensions of 6 x 15cm.
  • the wall elements of the upper storey are then placed on the floor elements and attached with L- profiles, 6mm thick, and with dimensions of 10 x 10cm. These L- profiles are placed on the inside of the wall elements and connected by welding.
  • the wall elements of the upper floor are connected using the same method as the wall elements on the ground floor.
  • a wooden head of 15 x 15cm is then fixed to the top of the wall element using screws welded to the top of the rails of the wall elements. The number of screws is determined by the structural design of the building, but typically two screws per element are sufficient to transfer the load.
  • the roof elements are then placed and attached in the same way as the above-described elevated elements.
  • the reinforcing rods are installed in the floor grooves 9_ - the cavities of the floor elements, together with a reinforcing mesh installed on beams.
  • the floor structure is completed by casting the concrete layer on the top of the floor element .
  • the typical thickness of the floor layer is 7 to 8cm.
  • the concrete spills to the floor grooves 9_, creating reinforcing ribs.
  • the roof is typically finished with thermal insulation £, attached mechanically to the U-profiles 3_, and with common ceramic roofing installed on a supporting frame attached to the C-profiles 3_-
  • the structure exterior is finished with a mechanical attachment of the insulation £ and with plaster.
  • the external thermal insulation [ is not needed and the surface cladding 4 of the structure, made from fibre- reinforced shrinking mortar, is applied directly on the wall elements.
  • the surface layer of the cladding 4_ is applied directly on the cellular cement, the created grooves ⁇ l will form vertical ribs that increase the wall's maximum load and strength.
  • these grooves IjL and the surface layer of the cladding 4_ are used to provide a better connection of the wall elements, as shown in figure 5.
  • Wiring and plumbing are installed in the concrete covering layer on the ground and the elevated floor and in the porous concrete filling I 1 of the wall elements before the finishing interior elements are mounted.
  • the interior finish is fitted with dry wall panels directly attached on the wall elements.
  • the wall elements as specified in this invention combine a thin galvanized metal frame 2 ⁇ and a porous concrete filling I 1 as shown in figure 1.
  • the frames 2_ are made from U- or C- profiles 2_, shown in figure 2, made of galvanized metal 0.5 to 2mm thick.
  • the base 3J 1 of tne u ⁇ or C-profile 3_ can range between 50 and 300cm; the rims 2?_ between 15 and 40mm, and the back bend 22 °f tne C-profile 2 between 10 and 30mm.
  • the thickness of the frame 2_ can range between very narrow elements with a width of 10 to 15cm to several metres.
  • the maximum length of the frames 2_ is usually limited by the loading space of trucks or by the length of containers.
  • the typical width of the wall is Im or 1.2m.
  • the wall height can be between 20cm and several metres, with the typical height being 2.9m.
  • the frames 2! are made by connecting the U- or C-profiles 3_ by their welding, mechanical connection using screws and rivets and the like, into the shape of a rectangular frame 2_, as shown in figure 3.
  • the frames £ can be fitted with multiple brackets 21.
  • a typical example of the frame £ with multiple brackets £1 is shown in figure 2 and its cross-section in figure 3.
  • the number of vertical brackets 2JL depends on the required maximum load. For walls with a thickness of 1 to 1.2m, with arms of 100mm to 150mm and galvanized metal with a thickness of 1.5mm, two U- or C- brackets 2JL are sufficient. If the element is to support the ceiling, the same frame 2_, 1.2m wide, can contain one or two other brackets 2 ⁇ . Other brackets TL are also required if the element contains openings, such as windows and doors.
  • the frames 2_ are placed horizontally and filled with cellular cement, as shown in figure 4.
  • the cellular cement hardens, the elements are ready for mounting.
  • the cellular cement filling 1. with a density of 0.3 to 1.5g per cu cm has the following properties: it creates a transverse reinforcement, increases vertical bearing capacity, has sound insulating properties, and has thermal insulating properties at lower temperatures. It provides for transfer between the external layer of the cladding 4 applied to the element from both sides, see figure 5, and the layers are applied on the element on-site, when the walls are created using the connecting elements.
  • the ceiling and floor elements are made identically using U- and C-profiles 3_, their connection and filling with porous concrete.
  • the usual width of the frames £ is 1 or 1.2 metres, but the thickness can range between 20 and 30cm and several metres.
  • the number of longitudinal U- or C-profiles 3_ depends on the transferred stress and on the length of the ceiling or floor elements.
  • the prefabricated wall elements are vertically placed on a concrete plate and attached using plates of galvanized steel, fixed to the flanges of U- or C-profiles 3_- ⁇ he building surface layer of the cladding 4_ is then applied by spraying or spreading with a trowel on the elements to provide protection of the building layers as shown in figure 5.
  • the building surface layers are reinforced with fibres and using shrinkage compensated Portland cement mortar.
  • the fibre reinforcement increases tensile strength, fracture toughness and impact strength.
  • Common water-reducing agents in concrete, porcelain admixtures such as essential micro-oils, fly-ash and slag, are used to increase strength and reduce permeability.
  • Polymeric emulsions such as latex and dry polymeric modifiers, can be used to increase elasticity and reduce permeability.
  • Building surface treatment is applied by means of a wet or dry spraying process or can be applied manually using a trowel, just like ordinary plaster.
  • the building surface treatment has multiple functions. Its non-building function involves water protection, waterproofing and impact resistance. Its building function involves support for part of the vertical, bending and shear, i.e. side load. This function is possible thanks to the transfer of load of the porous concrete filling I 1 from one building surface treatment to another, as mentioned above, which protects the relatively thin surface layer of the cladding 4_ against deformation under vertical stress.
  • the bearing capacity for vertical load of the building surface layer of the cladding 4 ⁇ is increased by creating brackets in the shaped grooves 11 of the porous concrete filling 1, as shown in figure 6.
  • the surface layer of the cladding 4_ also provides a sufficient connection of one prefabricated wall element to another.
  • thermal insulating layers 5 ⁇ in the form of self-adhesive foam strips can be placed on the flanges of the steel stud bolts, as shown in figure 6.
  • the external thermal insulation j > is placed on the external side of the wall elements, as shown in figure 7.
  • the external thermal insulation £ can be covered with plaster or another type of wall finish, such as plastics, metal facing, and brick facing and so on.
  • the thermal insulation £ is fixed mechanically or by gluing.
  • the external lapping is mechanically connected to the porous concrete filling 1 and to steel stud bolts and rail parts.
  • the interior of the wall element is finished with a surface layer, plaster or dry wall .
  • a reinforcing through-stone is placed on the top of the wall .
  • the through-stone can be prefabricated or cast on-site.
  • the width of the through-stone is identical with the depth of the wall sections and its height is usually 5 to 7cm, but it can be also higher depending on the required load transfer.
  • the type of reinforcement, the geometry and the position inside the through- stone are adjusted by the structural engineer for the required load transfer.
  • the through-stone can be mounted by positioning the U-section of the rail, filled with concrete with or without an additional reinforcement.
  • the through-stone is placed on top of the wall element before the surface layer, the external insulating systems and the finishing work in the interior are applied, as shown in figure 8.
  • the prefabricated floor elements are placed on the wall structure and connected using steel plates and steel L-profiles 10, typically 2 to 3mm thick, from panel to panel and the wall elements, as shown in figure 9.
  • the reinforcing mesh is placed directly onto the wall elements or the supporting top wall, as shown in figure 9.
  • the longitudinal stud bolts of the floor elements have pre-shaped holes for pins intended to transfer shearing force, as shown in figure 10. Concrete is placed directly on the floor elements.
  • the floor elements depending on their span, may require support to bear the load of fresh concrete before sufficient strength is created.
  • the elevated floor is adjusted for concrete to bear the compressive load and the steel U- or C-profiles 3_ carry tensile stress.
  • the transfer of shearing stress between the concrete layer and the steel profiles may be provided by other methods apart from shear pins, as shown in figure 11.
  • L-shaped welded plates secured or fixed with screws or rivets.
  • L-shaped plates can be installed longitudinally or across the length of the floor elements.
  • top-wall parts supporting the reinforcing mesh as shown in figure 9, attached along the steel profiles 3_ of the floor elements, which also provide a very good mechanism for the transfer of shearing stress from the concrete filling 1 onto the steel profiles 3_ of the floor elements .
  • Flat roof elements are made identically to the elements of the elevated floor.
  • the concrete layer is replaced by an insulation layer mechanically, or attached by adhesion to the steel profiles 3_ and the cellular cement filling 1. After that, standard finishing work is performed.
  • a modified polymeric cement layer with or without fibre reinforcement is applied on the insulation.
  • the water-resistant layer of the modified polymeric cement is applied directly on the roof elements.
  • the groove is typically placed in the middle of the section and its size is from lcm by lcm to 4 cm by 4 cm.
  • the 15 cm U profile typically uses 2.5 cm by 2.5 cm groove.
  • the groove increases strength and stiffness in compression as well as in bending. The increase in stiffness in bending is very important in deflection-control in floor and roof elements.
  • the groove simplifies construction and connections and increases the strength and toughness (erthaguake) resistance of the structure. It is typically used in vertical sections of wall elements and longitudional sections of floor/roof elements. Of course all sections described will be used.
  • the groove is produced during constructive roll -forming" or ,,press breaking" of the U and C sections.
  • the load-carrying composite elements described in this application can be reinforced with pillars and beams made of U-profiles 3_. These can be filled with concrete to increase their load capacity during the construction of pillars fixed during the construction of beams.
  • ordinary steel I beams can be used as posts or beams.
  • the composite structural element in particular for the construction of buildings, as specified in this invention, can be especially used for the construction of family houses, industrial, commercial and residential buildings up to the height of about three storeys.
  • the structural elements can be also used as filling panels for buildings of iron and reinforced-concrete structures.

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Building Environments (AREA)
  • Floor Finish (AREA)
  • Rod-Shaped Construction Members (AREA)

Abstract

La présente invention concerne un élément structural composite destiné en particulier à la construction de bâtiments, comprenant une structure de support et une matière remplissage (1). La structure de support a la forme d'une armature quadrigonale (2) et contient une matière de remplissage (1) qui est une matière légère ayant une densité de 0,3 à 1,5 g/cm3, alors que les bords de l'armature (2) sont réalisés à partir de profilés en U et/ou en C qui se font face avec leurs extrémités libres, sont faits d'un matériau métallique d'épaisseur de 0,5 à 2 mm avec une base (31) d'épaisseur de 50 à 300 mm, des côtés (32) de 15 à 40 mm et un retour (33) - dans le cas du profil en C - de 10 à 30 mm.
PCT/CZ2010/000020 2009-02-25 2010-02-24 Élément structural composite destiné en particulier à la construction de bâtiments WO2010097059A2 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP10723910A EP2401445A2 (fr) 2009-02-25 2010-02-24 Element structural composite destine en particulier a la construction de batiments

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
CZPV2009-113 2009-02-25
CZ20090113A CZ2009113A3 (cs) 2009-02-25 2009-02-25 Konstrukcní kompozitní prvek, zejména pro stavbu budov

Publications (2)

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WO2010097059A2 true WO2010097059A2 (fr) 2010-09-02
WO2010097059A3 WO2010097059A3 (fr) 2013-05-10

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Country Status (3)

Country Link
EP (1) EP2401445A2 (fr)
CZ (1) CZ2009113A3 (fr)
WO (1) WO2010097059A2 (fr)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
RU2633624C1 (ru) * 2016-08-23 2017-10-16 Федеральное государственное автономное образовательное учреждение высшего образования "Сибирский федеральный университет" Длинномерный сталебетонный элемент
NL1044008B1 (nl) * 2021-04-21 2022-11-01 Prefast B V Volledig geprefabriceerde vloer ten behoeve van prefab-bouw

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20030183742A1 (en) * 2002-03-27 2003-10-02 Deloach W. Michael Tilt-up concrete wall panel form and method of fabricating same
US20050284098A1 (en) * 2003-02-26 2005-12-29 Amazon Forms One, Inc. Lightweight concrete composite wall panels

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20030183742A1 (en) * 2002-03-27 2003-10-02 Deloach W. Michael Tilt-up concrete wall panel form and method of fabricating same
US20050284098A1 (en) * 2003-02-26 2005-12-29 Amazon Forms One, Inc. Lightweight concrete composite wall panels

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
RU2633624C1 (ru) * 2016-08-23 2017-10-16 Федеральное государственное автономное образовательное учреждение высшего образования "Сибирский федеральный университет" Длинномерный сталебетонный элемент
NL1044008B1 (nl) * 2021-04-21 2022-11-01 Prefast B V Volledig geprefabriceerde vloer ten behoeve van prefab-bouw

Also Published As

Publication number Publication date
EP2401445A2 (fr) 2012-01-04
CZ2009113A3 (cs) 2010-09-08
WO2010097059A3 (fr) 2013-05-10

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