WO2016171587A1

WO2016171587A1 - Method for producing products with a layer of thermal insulation for the construction of buildings and structures

Info

Publication number: WO2016171587A1
Application number: PCT/RU2016/000207
Authority: WO
Inventors: Игорь Викторович ПРОХОРОВ
Original assignee: Игорь Викторович ПРОХОРОВ
Priority date: 2015-04-23
Filing date: 2016-04-11
Publication date: 2016-10-27
Also published as: EA034679B1; EA201700458A1

Abstract

The invention relates to a method for producing concrete products with a layer of thermal insulation, for the construction of buildings and structures, and specifically to wall panels for panel housing construction, horizontal ceiling/floor slabs, and also long structures such as beams, girders, supports, columns, etc., in which a layer of thermal insulation is reliably secured to concrete layers by means of the fibers of a mineral wool thermal insulation interacting with said concrete layers, thus allowing for significantly increasing the strength, reliability and longevity of such products, for increasing the operational lifetime of buildings and structures, for decreasing the outlay of capital and materials, and for simplifying the process of producing such products.

Description

TITLE OF THE INVENTION

METHOD FOR PRODUCING PRODUCTS WITH A HEAT-INSULATING LAYER FOR CONSTRUCTION OF BUILDINGS AND CONSTRUCTIONS

FIELD OF TECHNOLOGY

The invention relates to a method for manufacturing concrete products with a heat-insulating layer for the construction of buildings and structures, in particular wall panels for panel house building, floor slabs, as well as long structures such as beams, beams, supports, columns, etc.

BACKGROUND

A method for manufacturing a sandwich panel is known in the prior art, in which at the bottom of the mold, an outer layer of concrete with a thickness of 30-40 mm is first cast from a mixture of concrete and fibers, which is equipped with through metal bundles at the desired points while the outer layer of concrete is still uncured. After curing the outer layer, mineral wool insulation is laid on top of it, the fibers of which are located mainly perpendicular to the inner layer, and through ligaments pass between two adjacent rows of mineral wool fibers. Next, an inner concrete layer is formed. This panel has increased compressive strength, which ensures its resistance to various influences during transportation and installation.

The disadvantages of this method and the panel manufactured in this way is that when the panel is formed, reliable adhesion of its layers is not ensured, and to ensure their interaction it is necessary to use additional metal connections - through ligaments, on which, in fact, insulation and the outer layer hang. Over time, due to the high cantilever load caused by the significant thickness of the outer layer (30-40 mm) and its mass, as well as due to wind and atmospheric influences, bond deformation (tension) occurs and a gap arises between the thermal insulation layer and the concrete outer and inner layers, i.e. structural integrity of the structure is violated. Thus, it becomes possible to move the outer, insulating and inner layers of the panel relative to each other both in the vertical and horizontal directions, which leads to premature destruction of the panel. However, the most negative is that due to the violation of the integrity of the panel, the contact of the heat-insulating layer with the surface of the outer and inner layers is lost, and accordingly the mineral-wool thermal insulation begins to quickly sag (compact) under its own weight and other influences, especially in the spring-autumn period or in the regions with high humidity, and due to the specificity of the mineral wool thermal insulation used to increase stiffness, subsidence occurs much faster than when using mineral cotton thermal insulation with the direction of the fibers parallel to the outer and inner layer. Accordingly, in a sufficiently small time period, the heat-insulating layer loses its functional purpose, in this regard, the panel no longer provides its function - thermal insulation. Moreover, due to the rapid subsidence of the heat-insulating layer and the formation of the internal space, the destruction of the outer layer is accelerated, which is reflected in the appearance of cracks, and since the panel is affected by many heterogeneous factors, depending on the region of operation, it is impossible to predict the start of destruction of the panel and take the necessary measures in a timely manner, accordingly, such a panel quickly becomes unrepairable, which leads to the inability to operate the building, and as a consequence to its demolition due to the impossibility of dismantling and replacing panels.

Also, it should be noted that the bonds are metal rods, and with this installation technology they are simply stuck in the uncured outer layer, which does not provide reliable fastening, due to the small metal-concrete contact area due to the small thickness of the outer layer, and there is a high probability of deviation of bonds from the vertical to the curing of the outer layer. In addition, the bonds fall deep into the outer layer due to its small thickness and a sufficiently large bond weight, i.e. pass through the outer layer, which leads to their corrosion during operation and the formation of rust spots on the outer facing surface.

Installation of mineral wool thermal insulation on this type of connection leads to the bending of some of them, and accordingly, such connections do not fulfill their function, which reduces the design strength of the panel. To eliminate this drawback, it is necessary to dismantle the thermal insulation and straighten the bonds, which, obviously, no one will do, at least because of the complexity and duration of the operation to pull out the mineral wool plates and their inevitable partial destruction during this operation, and which is more likely due to the lack of control on at this stage since verification is carried out only finished plate.

In addition, at present, the installation of a heat-insulating layer to protect structures, such as floor slabs, beams, crossbars, etc., from temperature effects, is carried out after the installation of these elements. However, in the case of the creation of such structures by the claimed method, it eliminates the need for mounting a large area of thermal insulation at the facility, because it remains only to close the joints of structures, which significantly reduces the time of construction of buildings and structures and reduces the capital intensity of construction, while ensuring a controlled reliable fastening of the insulating layer to the surface of the concrete structure, which in turn provides reliable protection of structures, and accordingly reduces the risk of structural failure under the influence of various factors. SUMMARY OF THE INVENTION

The problem to which the claimed invention is directed is to create concrete products universal for all regions with a heat-insulating and / or fire-retardant layer of thermal insulation with minimal material consumption and labor costs, with reliable fastening of the layers together, while ensuring the simultaneous achievement of such technical results as an increase in strength characteristics places of contact of the layers, reducing the time for their manufacture, a significant increase in the overhaul interval and an increase in durability buildings in general.

The claimed technical results are achieved by the method of manufacturing a wall panel, characterized in that the outer protective layer made on the basis of the binder is laid or poured into the mold, the thermal insulation layer is laid, which is mineral wool thermal insulation, so that the mineral wool fibers are directed mainly perpendicular to the outer layer and the subsequent inner a layer based on a binder, lay the reinforcing cage of the inner layer, and then lay or fill the inner layer, and all operations are carried out until the curing of the outer and inner layers, while providing the possibility of at least partial penetration of mineral wool at least in a large area of the inner and outer layers.

The inner layer, during curing, has the ability to freely move vertically at least under its own weight, and the weight of the inner layer is sufficient to create pressure to ensure at least partial indentation of the mineral wool fibers into at least the inner layer.

The weight of the inner layer is sufficient to create pressure to ensure at least partial indentation of the fibers of the insulation layer into a large area of the outer layer.

Additionally, a vertical load is applied and / or vibrated.

Elements are laid on the thermal insulation layer to create a gap between the thermal insulation layer and the reinforcing cage of the inner layer, and the reinforcing cage of the inner layer is already laid on them.

Elements that allow you to create a gap between the insulation layer and the reinforcing cage of the inner layer are made of non-metallic materials.

The thermal insulation layer is formed from mineral wool boards obtained by cutting mineral wool boards so that the fibers are directed mainly perpendicular to the surface of the inner layer.

Before laying mineral wool thermal insulation, at least one element for attaching the thermal insulation layer to the inner layer is mounted in it.

Before laying mineral wool boards, at least one fastening element of the heat insulation layer to the inner layer is mounted in at least one plate.

The fastening element is made in the form of a rod in such a way that one end of the rod protrudes outward and is intended for fastening in the inner layer, and at the other end an element is made that provides contact with the insulation surface facing the outside. On the rod protruding outward and intended for fastening into the inner layer, protrusions and / or recesses are made or it is made wavy.

The element that provides contact with the surface of the insulation facing the outer surface is made in the form of a plate or L-shaped.

The fastening element of the insulation layer to the inner layer is made of polymer or metal, or of fiberglass or composite materials.

The fastening element is made in the form of a dish-shaped anchor.

On the surface of the plate of a dish-shaped anchor facing the outer layer, elements are made that provide adhesion of the outer layer to the surface of the plate.

On the surface of the plate of a dish-shaped anchor facing the outer layer, protrusions and / or recesses and / or holes are made.

The element that provides contact with the surface of the insulation facing the outer surface is recessed into the insulation layer, and the resulting gap is closed with a plug of heat-insulating material.

The outer layer is reinforced with a mesh made of fiberglass or polymers or metal, or the outer layer contains a fiber made of metal or polymers or fiberglass or viscose.

The mesh or fiber is pressed into the outer layer.

The binder of the outer and / or inner layer is a cement and / or polymer or gypsum or silicate or cinder alkaline binder or binder used to create heat-resistant or acid-resistant concrete.

The reinforcement cage is made of metal and / or composite and / or polymeric materials.

The reinforcing frame is made in the form of a spatial frame. The outer layer is made of a thickness of 2-25 mm from a solution of a semi-liquid consistency with a spreading cone of more than 10 cm.

The outer layer is based on solutions that provide quick hardening and / or vapor permeability of the hardened layer and / or crack resistance of the hardened layer and / or vandal resistance of the hardened layer.

Inserts are placed on the lower surface of the mold to form holes and / or grooves and / or recesses, which are removed after curing the wall panel.

The ratio of compression of mineral wool insulation, in the direction of the fibers, to the mass of the inner layer is in the range from 0.01 to 2 kPa / kg.

After curing, the mold and / or the table on which the mold is mounted are tilted and then the wall panel is removed. DETAILED DESCRIPTION OF THE INVENTION

A method of manufacturing wall sandwich panels is as follows.

An outer protective layer based on a binder is laid or poured into the mold. Level it either mechanically or manually. A thermal insulation layer is laid, which is mineral wool thermal insulation so that the mineral wool thermal insulation fibers are directed mainly perpendicular to the outer and subsequent inner layer. The reinforcing cage of the inner layer is laid in such a way that a gap is formed between the thermal insulation layer and the reinforcing cage of the inner layer to prevent the reinforcement from contacting the thermal insulation and the airspace. Then make laying or filling of the inner layer, performed on the basis of a binder. All operations are carried out until the curing of the outer and inner layers. Due to the fact that the mineral wool insulation fibers are directed perpendicular to the inner and outer layers, and the outer and inner layers are not hardened, the fibers of the heat-insulating layer are pressed (penetrated) into these non-hardened layers for a length of 1 mm and over an area of more than 30%. Thus, not only the fibers are fixed in the layers over a large contact area of the thermal insulation layer and the outer and inner layers, but also a part of these layers is reinforced, which, after the product is cured, creates a reliable thermal insulation fastening without any additional fastening elements that affect the strength products. Moreover, the contact point is so strong that separation of the thermal insulation is possible only when the fibers are broken.

Thus, intermediate reinforced layers of fiber-concrete are created, which have the greatest strength in the entire product, i.e. the weakest point of the product with the claimed manufacturing method is the most durable, and accordingly it is no longer possible to peel the insulation from the inner and / or outer concrete layer, which eliminates the rapid subsidence of the insulation, and provides a reliable connection between the outer and inner layers.

In addition, with a small thickness of the outer layer and / or with a large weight of the inner layer, there is a through reinforcement of the outer layer with fibers of the heat-insulating layer, which makes its destruction almost impossible, because there is a multiple increase in its strength, and, accordingly, the possibility of cracking under normal operating conditions is excluded.

Such a product can be used in any region, regardless of climatic features, which ensures its versatility and allows you to significantly expand the field of construction of panel houses and structures.

To implement this method, there are several options. First, the inner layer should have, in the process of manufacturing the structure, the possibility of free vertical movement under its own weight, and then the weight of the inner layer should be sufficient to create pressure to ensure at least partial indentation of the mineral wool fibers into the inner and outer layers.

The second - it is necessary to apply an additional vertical load, for example, to act on the upper surface of the manufactured product with a press.

Third - the penetration of fibers is ensured by vibration of the mold or the platform on which it is installed.

However, the second and third options are the least preferred due to the complexity of manufacturing technology and a significant increase in material and energy consumption of such production. In addition, additional exposure can destroy the reinforcing cage (at additional pressure) or lead to destruction of the concrete mixture (exit to the surface of the binder water layer, movement of aggregate, etc.), which will not allow to obtain the estimated strength characteristics of the layers. However, when using thick or rigid concrete mixtures, a combination of the first and second and / or third options will be desirable, as this will ensure guaranteed penetration of the insulation fibers into the inner and outer layers.

In addition to the manufacture of wall panels, according to the claimed technology, it is possible to manufacture lengthy products whose length exceeds the width and thickness, or floor slabs.

Carry out the manufacture of these products as follows.

A thermal insulation layer is laid in the mold, which is mineral wool thermal insulation, so that the mineral wool insulation fibers are directed mainly perpendicular to the carrier layer, made on the basis of a binder (in the context of this application, the carrier layer should be understood as the concrete product itself, to which the insulation layer is attached). Then, the reinforcing frame of the carrier layer is laid in such a way that a gap is formed between the thermal insulation layer and the reinforcing frame of the carrier layer, after which the carrier layer is laid or filled. This ensures the possibility of at least partial penetration of mineral wool fibers at least into a large area of the carrier layer.

Thus, similar beneficial effects are achieved as for a wall plate.

The penetration of the fibers into the carrier layer, provide the same methods as in the manufacture of wall panels.

Thus, this method allows to obtain concrete products, the external surface of which (directed towards the premises, in case of designation of the product for protection against thermal effects) is reliably protected from temperature effects, and accordingly, the permissible time of exposure to high temperatures is significantly increased.

The following are additional operations and elements used in the method that provide significant advantages.

To exclude contact of the heat-insulating layer with the reinforcing cage, elements are laid on the thermal insulation layer, which allow creating a gap between the thermal insulation layer and the reinforcing cage of the inner or supporting layer, and the reinforcing cage is already laid on them. Such elements must be made of non-metallic materials, as this will exclude their corrosion (for wall panels) and / or metal (for floor panels or long products), as will provide their longer resistance to high temperatures.

To obtain a layer of thermal insulation, the fibers of which are directed mainly perpendicular to the surface of the inner layer, a carpet or mats of mineral wool thermal insulation, the fibers of which are directed horizontally, cut to the length necessary for the formation of the thickness of the insulation layer, thereby obtaining mineral wool plates from which I form the heat-insulating layer.

At the same time, with a large thickness of the thermal insulation layer and / or with a large weight of the outer layer, as well as for the construction of multi-storey buildings and structures in which wind exposure to the panel is a significant factor, it is necessary to mount additional fasteners. In the claimed method, it is much simpler, because such fasteners can be mounted directly into the thermal insulation before being laid in the mold. In addition, this technology allows you to control the correct installation of fasteners (eliminate distortions, insufficient rod exit from the mineral wool plate, etc.) and greatly facilitates the process of replacing fasteners in case of breakage during installation, which allows to obtain a high-quality final product.

An additional advantage is that with this method of manufacturing there is no need to mount fasteners in each insulation plate, because its reliable fastening is already ensured, and, in fact, the fastening elements provide only the maintenance of the thermal insulation layer and / or the outer layer, i.e. prevent their displacement relative to the inner or supporting layer. Thus, depending on the size of the structure and / or the design loads, the fastener can only be mounted on one and only one thermal insulation plate.

It is optimal to use the rod as one fastening element, the one end of which extends outward when mounted in thermal insulation, and is intended for fastening in the inside (for wall panels) or the carrier layer (for floor panels or long products), and an element is provided on the other end that provides contact with the insulation surface facing the outer layer, as this will ensure the vertical position of the rod without any effort with side of the installer and with further laying of the insulation in the mold, it will also provide additional pressing (fixing) of the insulation to the inner or supporting layer after the product has cured.

An element providing contact with the thermal insulation surface facing the outer layer should be made in such a way that significantly reduces the likelihood of its penetration into the uncured outer layer, for example, made in the form of a plate, i.e. A plate anchor can be used as an element.

In addition, to protect the fastener from temperature effects or to provide less heat loss through the anchor, it is recessed into the heat-insulating layer, and the resulting gap is closed with a plug made of heat-insulating material, for example, mineral-insulated heat insulation.

If the outer layer is made of large thickness, for example, such an implementation is desirable for lower floors, because allows you to provide greater vandal resistance, and the penetration of the fibers of the insulating layer is not enough to increase its strength, before laying the insulation layer, the outer layer is reinforced with a mesh made of fiberglass or polymers or metal, or fiber made of metal or polymers or fiberglass or viscose. Moreover, when reinforcing the mesh cross-reinforcement occurs in the vertical and horizontal directions, because thermal insulation fibers penetrate into the mesh cells, which significantly increases the strength of the outer layer, and, accordingly, with a smaller thickness (10-25 mm instead of 30-40 mm), significantly greater strength is achieved, thereby reducing the capital and material consumption of the panel due to savings on the thickness of the outer layer. For reliability, before laying the insulation, the mesh or fiber is pressed into the outer layer, although this operation is not necessary for the mesh, because the mesh is pressed in subsequent operations. Optimal for the outer and / or inner or supporting layers is the use of cement and / or polymer binder, both from the point of view of fire protection, and from the point of view of economy and versatility of the material, which is necessary for production in any region. However, it is possible to use gypsum or silicate or slag-alkali binders or binders used to create heat-resistant and acid-resistant concrete.

In order to be able to create a strong in all directions and a rigid inner or supporting layer, it is reinforced with a spatial framework made of metal and / or composite and / or polymeric materials, depending on the operating conditions of the structure and the required design strength.

The most optimal from the point of view of cost-effectiveness and simplicity of laying (pouring) is the implementation of the outer layer with a thickness of 2-25 mm, from a solution of semi-liquid consistency with a cone spreadability of more than 12 cm, based on solutions that provide quick hardening and / or vapor permeability and / or crack resistance and / or vandal resistance of the hardened layer.

To create various technological grooves and / or recesses and / or holes, for example, window or door openings, inserts are laid on the lower surface of the mold, which are removed after curing.

After curing, the mold and / or the table on which the mold is mounted tilt, dismantle the sides and remove the product, this ensures easy dismantling of the product and reduces the risks of its destruction or chip formation during dismantling from the mold or formwork.

To obtain a high-quality product for all the described methods, the requirement regarding the compressive strength of the insulation in the direction of the fibers will be important. So, the ratio of compression of mineral wool insulation to the mass of the inner layer should be in the range from 0.01 to 2 kPa / kg, as with a smaller value of the interval, the thermal insulation will be flattened by the weight of the inner or supporting layer, which will lead to a loss of the calculated heat-insulating or fire-retardant characteristics, and with a larger weight, the use of thermal insulation loses its usefulness, both from an economic point of view and from the point of view of its heat-insulating characteristics. The same parameters will be characteristic of the method in which an additional load is applied, for example, by a press.

The claimed methods are easily feasible using well-known equipment using known materials both in the factory and at the construction site, and with this manufacturing method there is no need to use additional adhesive compositions for attaching thermal insulation.

Claims

FORMULA

1. A method of manufacturing a wall panel, characterized in that the outer protective layer, made on the basis of the binder, is laid or poured into the mold, a thermal insulation layer is laid, which is mineral wool thermal insulation, so that the mineral wool insulation fibers are directed mainly perpendicular to the outer layer and the subsequent inner layer performed on the basis of a binder, lay the reinforcing cage of the inner layer, lay or fill the inner layer, and all operations about odyat before curing the outer and inner layers, while providing the possibility of at least partial penetration of mineral fiber thermal insulation at least in a large area portion of the inner and outer layers.

2. The method according to claim 1, characterized in that the inner layer, in the process of curing, has the ability to move freely vertically at least under its own weight, and the weight of the inner layer is sufficient to create pressure allowing at least partial indentation of the mineral wool insulation fibers at least in the inner layer.

3. The method according to claim 1, characterized in that the weight of the inner layer is sufficient to create pressure to ensure at least partial indentation of the fibers of the insulation layer into a large area of the outer layer.

4. The method according to claim 2 or p. 3, characterized in that it additionally apply a vertical load and / or carry out vibration.

5. The method according to claim 1, characterized in that elements are laid on the thermal insulation layer to create a gap between the thermal insulation layer and the reinforcing cage of the inner layer, and the reinforcing cage of the inner layer is already laid on them.

6. The method according to claim 5, characterized in that the elements that allow you to create the gap between the thermal insulation layer and the reinforcing cage of the inner layer is made of non-metallic materials.

7. The method according to claim 1, characterized in that the thermal insulation layer is formed from mineral wool boards obtained by cutting mineral wool insulation so that the fibers are directed mainly perpendicular to the surface of the inner layer.

8. The method according to claim 1 or claim 7, characterized in that before laying the mineral wool insulation, at least one fastening element of the insulation layer to the inner layer is mounted in it.

9. The method according to claim 8, characterized in that the fastening element is made in the form of a plate anchor.

10. The method according to claim 9, characterized in that the element providing contact with the surface of the insulation facing the outer surface is recessed into the insulation layer, and the resulting gap is closed with a plug of heat-insulating material.

1 1. The method according to claim 1, characterized in that the outer layer is reinforced with a mesh made of fiberglass or polymers or metal, or the outer layer contains a fiber made of metal or polymers or fiberglass or viscose.

12. The method according to claim 1, characterized in that the reinforcing cage is made of metal and / or composite and / or polymeric materials.

13. The method according to claim 1, characterized in that the outer layer is 2-25 mm thick from a solution of a semi-liquid consistency with a cone spreadability of more than 12 cm.

14. The method according to claim 1, characterized in that the ratio of the compression of mineral wool insulation, in the direction of the fibers, to the mass of the inner layer is in the range from 0.01 to 2 kPa / kg

15. The method according to claim 1, characterized in that after curing, the mold and / or the table on which the mold is mounted are tilted, and then the wall panel is removed.