WO2020236127A1

WO2020236127A1 - Ventilated curtain wall system with artifical stone panels

Info

Publication number: WO2020236127A1
Application number: PCT/UA2020/000022
Authority: WO
Inventors: Yuliya Yuriivna BONDARENKO
Original assignee: Bondarenko Yuliya Yuriivna
Priority date: 2019-05-22
Filing date: 2020-03-12
Publication date: 2020-11-26

Abstract

Ventilated curtain wall system comprising a structure to clad (3), insulating layer (2), moisture- and windproof membrane (3), mounting system with supporting profiles (4), decorative panel in the form of thin-walled artificial stone made by hyper-pressing a mixture of cement, natural materials filler and optionally reinforcing fibres.

Description

VENTILATED CURTAIN WALL SYSTEM WITH ARTIFICAL STONE PANELS

The invention relates to the field of industrial and civil engineering and namely to claddings of buildings of high tallness by a ventilated facade system.

The ventilated curtain wall system has gained wide popularity in the modern engineering and has been successfully applied for finishing of buildings of any kind and tallness. The ventilated claddings are mounted on the building walls quickly and easily, they protect the walls from weather impacts and other damaging environmental factors and at that they create distinctive aesthetic appearance.

The ventilated curtain walling is capable not only to protect the building from the environmental effects but also to make it stronger, more attractive and safe.

This is a special system in which the air is actively ventilated that provides excellent thermal covering.

Heat insulating facade systems allow to use them as a safety screen which fulfills a decorative function as well.

The ventilated curtain wall system contains mounting section, wind-protective and heat- protective section, and decorative section.

The mounting section contains metallic bearing brackets which are securely fixed to the walls and adjustment profiles for fixing the decorative section. At that the wind-protective and heat-protective layers are disposed tightly through the bearing brackets located on the wall. Over wind-protection with calculated split on the adjustment profiles the decorative section made mainly from the decorative plates is disposed.

All the ventilated facade systems are divided into three big groups of facade material disregarding the structure of the bearing frame system, method of fixing and mounting.

1. Light groups, weight up to 5 kg/m² (panels from monomaterials (metal) or composite panels (plastic or plastic-metal, etc.).

2. Middle group, weight from 5 kg to 35 kg/m² (glass, ceramic granite, cementitious panels, etc.).

3. Heavy group, weight from 35 kg and more/m² (natural stone, ceramics, plates on the basis of concrete mix“Marmarok”, etc.).

Each group of facade materials has its own advantages and disadvantages.

The main advantage of the light groups is low load on facade and building footing. The disadvantages are low acoustic isolation, vibration caused by airflow which may lead to crack appearance and plate destruction as well as high production costs.

The middle group has higher acoustic isolation and vibration characteristics however, as well as the first group, it has the disadvantages concerning strength characteristics (it is damaged relatively easily in the heavy working conditions).

The facade system with finish tile according to the patent [1] can relate to the middle group which is made from polymeric- areneceous mix with various fillers in the view of waste of wood, pottery, glassmaking or pebble gravel.

The disadvantages may also be significant weight and low accuracy of production as the tile is produced by the method of casting into molds.

Cementitious panels for ventilated facades contain cement, various mineral constituents and up to 10% of cellulosic fiber and can imitate various natural cladding materials. At that they are resistant to environmental temperature differential and have good acoustic isolation and heat isolation.

The disadvantages of cementitious panels are significant weight, low resistance to mechanical damage and high parameters of water absorption.

The ventilated facades with ceramic granite panels can be used for high-rise construction and serve up to 50 years, they are resistant to chemical action and heavy frosts. Mounting to subsystems of adjustment profiles can be effected by various methods.

The disadvantages of ceramic granite panels are significant weight, low resistance to mechanical damage.

The ventilated facades with tiles“MARMAROK” [2] are known which are used for hi- rise buildings as well as for low-rise buildings.

The finish tile“MARMAROK” contains marble aggregate which is protected from moisture and sun impact via special strengthening additives.

Special vertical and horizontal guides are provided in the mount system which are produced from hot-galvanized steel.

The disadvantages of the ventilated facades with tiles“MARMAROK” are significant weight, low resistance of the tiles to mechanical damage, high dependence of the tile quality on the quality of the strengthening additives, usage of the special vertical and horizontal guides intended only for this kind of tile. The closest analogue to the applied technical solution is a ventilated curtain wall system [3] which includes cladding structure, insulating layer, moistureproof and windproof membrane, mount system with vertical and horizontal guides, decorative cladding panel. At that, finish brick tiles are used as a decorative cladding panel.

It is known that a brick tile is a ceramic product for production of which slaty clay, flux material and coloring pigment are used. All that mass undergoes single baking in the tunnel kiln having the length of 150 m at a temperature of 1360 °C. The process lasts till complete baking of the product. Such the technology allows to obtain a strong cladding material which does not have any cavities and pores inside and has high resistance to environmental factors. The production technology is strictly followed at the tile production. In case of minor failure the material becomes deformed that leads to disarrangement of linear dimensions and reduction of quality of the end product.

The disadvantages of this system are not enough high strength characteristics due to low resistance of the cladding panel to mechanical damage.

Besides, this system does not have high accuracy of the geometrical dimensions of the panel due to the process of its production. This leads to the difficulties at mounting as the tiles do not always correspond to the designed sizes.

The disadvantage is also that such the system has a limited range of use as it limits the usage of the tiles of big size due to that with increasing of the panel surface area its weight increases significantly and vibration and mechanical characteristics decrease especially at wind load.

The object of the present invention is providing of the ventilated curtain wall system in which by the construction improvement increasing of strength characteristics at weight decreasing is achieved, as well as increasing of strength margin at wind load, increase of service life, increasing of accuracy of geometrical dimensions at lowering costs of production, expansion of the range of use.

The indicated object is achieved by that in the known ventilated curtain wall system including cladding structure, insulating layer, moistureproof and windproof membrane, mount system with vertical and horizontal guides, decorative cladding panel according to the proposed technical solution the decorative cladding panel is made from the artificial stone in the view of a thin-walled hyperpressed slab. At that, the hyperpressed slab contains strengthening ribs which have the height of 0.008- 0.05 of the length of the hyperpressed slab.

Preferable is the execution of the hyperpressed slab with the thickness of 0.012-0.025 of the length of the hyperpressed slab.

Preferable is the execution of the hyperpressed slab from the mixture containing cement and a filler.

It is preferable that the hyperpressed slab is executed from the mixture containing cement, a filler and reinforcing fibres.

At that, the filler is chosen from the group of natural materials which contains shelly limestone or limestone, or dolomite, or travertine, or marble, or manufacturing waste.

Execution of the panel from the artificial stone in the view of the thin-walled hyperpressed slab allows to obtain the panel of high strength and cold resistance with the low factor of water absorption and high accuracy of geometric dimensions.

The presence of strengthening ribs on the hyperpressed slab allows to significantly reduce the thickness of the slab and to decrease the slab weight without the loss of strength and vibration characteristics.

Execution of the strengthening ribs with the height of 0.008-0.05 of the length of the hyperpressed slab allows to create the optimal ratio between the slab weight and its strength and vibration characteristics at the usage of the slab in the high-rise construction.

Execution of the hyperpressed slab with thickness of 0.012-0.025 of its length allows to make the slab to be stable enough to the applied mechanical and vibratory loadings in the ventilated curtain wall system.

Execution of the hyperpressed slab from the mixture containing cement and a filler allows to significantly reduce cement consumption and obtain the slab with high strength characteristics and low water absorption.

Execution of the hyperpressed slab from the mixture containing cement, a filler and reinforcing fibres allows to significantly improve bend strength characteristics and to increase vibration characteristics of the slab as the reinforcing fibres chaotically disposed inside the filler add flexural rigidity to the slabs, reduce linear expansion under the influence of the temperatures and act as inner armoring of the material.

Due to that the filler is chosen from the group of the natural materials which includes shelly limestone or limestone, or dolomite, or travertine, or marble, or manufacturing waste the panel production cost is significantly reduced and environmental friendliness of production increases.

The cladding panel of the facade system is produced according to the technology of semidry hyperpressing when the moistened cement-mineral mixture disposed in the press moulds is exposed by pressure of more than 40 MPa. In the process of hyperpressing the particles of the raw mass experience significant mutual friction interlinking with each other on the molecular level. The obtained product does not require baking and has high strength characteristics and it is maximally close to the natural stone in regards to texture, strength, cold resistance and moisture resistance. The hyperpressed slab has high homogeneity throughout and high accuracy of production with sizing error from 0.2mm to 0.5 mm that corresponds to the designed size and allows to effect assembly operations of high quality with minimum clearance.

The essence of the invention is illustrated op the drawings where

Fig. 1 represents general view in assembly of the ventilated curtain wall system.

Fig. 2 represents side-view of the hyperpressed slab of the ventilated curtain wall system.

The ventilated curtain wall system consists of the cladding structure (1) (for example, of the outer part of the wall of a building/structure), insulating layer (2), moistureproof and windproof membrane (3), mount system with supporting profile (4) as well as decorative cladding panel executed from the artificial stone in the view of a thin-walled hyperpressed slab (6). The hyperpressed slab (6) is executed with strengthening ribs (7) the height of which is 0.008-0.05 of the length of the hyperpressed slab that allows to increase the strength characteristics of the slab depending on its overall size. The thickness of the hyperpressed slab is chosen within 0.012-0.025 of the length of the slab (3-25mm) depending on the overall size of the slab and its function. For example, a thicker slab can be used at installation of the ventilated facade in the basement part of the building as an anti-vandal slab as well as at the usage of the big size slabs, for example up to 2m that will increase its strength characteristics.

At that the hyperpressed slab is executed according to the known technology of semidry hyperpressing from the mixture containing cement and a filler or from the mixture containing cement, a filler and reinforcing fibres. The reinforcing fibres allow to significantly improve bend strength characteristics and to increase vibration characteristics of the slab as the reinforcing fibres chaotically disposed inside the filler add flexural rigidity to the slabs, reduce linear expansion under the influence of the temperatures and act as inner armoring of the material. At production of the hyperpressed slab the group of the natural materials has been chosen as the filler which includes shelly limestone or limestone, or dolomite, or travertine, or marble, or manufacturing waste that significantly reduces the panel production cost and increases environmental friendliness of production.

If required a weather-resistant colorant can be added into the mixture for giving the definite colour to the slab surface depending on the design conception.

Besides, the decorative cladding panel can have a smooth face or a face texturized of stone design or have relief surface with various decorative patterns.

The invention is carried out the following way.

On the cladding structure (1) executed in the view of the outer part of the building wall the elements of the mount system are installed at a given distance from each other, for example, executed in the view of brackets (not shown). Further, the insulating layer (2) and moistureproof and windproof membrane (3) are mounted. After that supporting profiles (4) are installed which are disposed at the calculated distance from each other. On the supporting profile the decorative cladding panel is mounted which is executed from the artificial stone in the view of the thin- walled hyperpressed slab (5). At that the slab can be made with the strengthening ribs (6) the height of which is 0.008-0.05 of the length of the hyperpressed slab. Depending on the function the thickness of the hyperpressed slab is 0.012-0.025 of the slab length. The slab (5) is fixed on the guides by means of clips or rivits or other fastening elements of the system depending on the size and form of the slab.

The obtained hyperpressed slab has high strength characteristics in regards to texture, strength, cold resistance and moisture resistance maximally close to the natural stone and allows to use the ventilated curtain wall system for claddings of the buildings of high tallness.

Example 1.

On the cladding structure (1) executed in the view of the outer part of the wall of the hi- rise building from concrete the elements of the mount system are installed at a given distance from each other, for example, executed in the view of brackets. Further, the insulating layer (2) and moistureproof and windproof membrane (3) are mounted. After that supporting profiles (4) are installed which are disposed at the calculated distance from each other. On the supporting profile (4) the decorative cladding panel is mounted which is executed from the artificial stone in the view of the thin-walled hyperpressed slab (5) with the size of 100x300mm having a smooth surface. At that the hyperpressed slab (5) has the thickness of 4mm and is executed with the strengthening ribs (6) the height of which is 2.4mm. The slab (5) is made according to the known technology of semidry hyperpressing from the mixture containing cement, a filler and reinforcing fibres, at one of the known presses, for example, the press“TITAN 900F” [4],

At that, at production of the hyperpressed slab (5) the filler is chosen as shelly limestone with addition of a weather-resistant colorant for giving the defined colour.

Example 2.

On the cladding structure (1) executed in the view of the outer part of the wall of the hi- rise building from concrete the elements of the mount system are installed at a given distance from each other, for example, executed in the view of brackets. Further, the insulating layer (2) and moistureproof and windproof membrane (3) are mounted. After that supporting profiles (4) are installed which are disposed at the calculated distance from each other. On the supporting profile (4) the decorative cladding panel is mounted which is executed from the artificial stone in the view of the thin-walled hyperpressed slab (5) with the size of 150x400mm having a surface texturized of stone design.

At that the hyperpressed slab (5) has the thickness of 4mm and is executed with the strengthening ribs (6) the height of which is 3.2mm. The slab (5) is made according to the known technology of semidry hyperpressing from the mixture containing cement, a filler and reinforcing fibres, at one of the known presses, for example, the press“TITAN 900F” [4].

At that, at production of the hyperpressed slab the filler is chosen as limestone with addition of a weather-resistant colorant for giving the defined colour.

Example 3.

On the cladding structure (1) executed in the view of the outer part of the wall of the hi- rise building from concrete the elements of the mount system are installed at a given distance from each other, for example, executed in the view of brackets. Further, the insulating layer (2) and moistureproof and windproof membrane (3) are mounted. After that supporting profiles (4) are installed which are disposed at the calculated distance from each other. On the supporting profile (4) the decorative cladding panel is mounted which is executed from the artificial stone in the view of the thin-walled hyperpressed slab (5) with the size of 200x400mm having a relief surface.

At that the hyperpressed slab (5) has the thickness of 5mm and is executed with the strengthening ribs (6) the height of which is 3.5mm. The slab (5) is made according to the known technology of semidry hyperpressing from the mixture containing cement, a filler and reinforcing fibres, at one of the known presses, for example, the press“TITAN 900F” [4].

At that, at production of the hyperpressed slab the filler is chosen as dolomite with addition of a weather-resistant colorant for giving the defined colour.

Example 4.

On the cladding structure (1) executed in the view of the outer part of the wall of the hi- rise building from concrete the elements of the mount system are installed at a given distance from each other, for example, executed in the view of brackets. Further, the insulating layer (2) and moistureproof and windproof membrane (3) are mounted. After that supporting profiles (4) are installed which are disposed at the calculated distance from each other. On the supporting profile (4) the decorative cladding panel is mounted which is executed from the artificial stone in the view of the thin-walled hyperpressed slab (5) with the size of 200x500mm having a surface texturized of stone design.

At that the hyperpressed slab (5) has the; thickness of 6mm and is executed with the strengthening ribs (6) the height of which is 4mm, The slab (5) is made according to the known technology of semidry hyperpressing from the mixture containing cement, a filler and reinforcing fibres, at one of the known presses, for example, the press“TITAN 900F” [4].

At that, at production of the hyperpressed slab the filler is chosen as travertine with addition of a weather-resistant colorant for giving the defined colour.

Example 5.

On the cladding structure (1) executed in the view of the outer part of the wall of the hi- rise building from concrete the elements of the mount system are installed at a given distance from each other, for example, executed in the view of brackets. Further, the insulating layer (2) and moistureproof and windproof membrane (3) are mounted. After that supporting profiles (4) are installed which are disposed at the calculated distance from each other. On the supporting profile (4) the decorative cladding panel is mounted which is executed from the artificial stone in the view of the thin-walled hyperpressed slab (5) with the size of 250x600mm having a surface texturized of stone design.

At that the hyperpressed slab (5) has the thickness of 7.5mm and is executed with the strengthening ribs (6) the height of which is 5mm. The slab (5) is made according to the known technology of semidry hyperpressing from the mixture containing cement, a filler and reinforcing fibres, at one of the known presses, for example, the press“TITAN 900F” [4].

At that, at production of the hyperpressed slab the filler is chosen as marble with addition of a weather-resistant colorant for giving the defined colour.

The above indicated examples characterize the embodiments of this technical solution and have illustrative character and do not limit other variants of realization of the invention.

Due to improvement of the construction the ventilated curtain wall system with the decorative cladding panel executed from the artificial stone in the view of the thin-walled hyperpressed slab allows to increase the strength characteristics at weight reduction, to increase strength margin at wind loads as well as to increase the service life. At that the slab has high accuracy of geometrical dimensions within 0.5mm and low production cost as it uses the wastes of other productions and does not require energy-consuming baking. The decorative panel executed from the artificial stone in the view of the thin-walled hyperpressed slab can be applied at mounting of the ventilated facade system at building of the buildings and constructions of various tallness that expands the range of its usage as it allows to use the panels of different sizes depending on project specifications.

In the process of experimental research tl^e samples of the cladding hyperpressed slabs for the ventilated facades have been obtained.

The following is the table of comparative characteristics of the cladding panels for the ventilated facades executed from different materials and of the product samples with the calculated size of the strengthening ribs obtained according to the provided examples. Table

As it is seen from the table the cladding panels for the ventilated facades executed from the artificial stone in the view of the thin-walled hyperpressed slab have improved technical characteristics in regards to strength, service life and others. Thus, the proposed technical solution allows to increase the strength of the ventilated curtain wall system at weight reduction, to increase strength margin at wind loads, to increase the service life, to increase the accuracy of the geometrical dimensions at production cost reduction and to expand the range of usage.

References

1. Russian Federation Patent RU 100019 U1, IPC B44C 3/00 (2006) published on

10.12.2010.

2. Internet web-page “Finish tile Marmarok” «http://fasadpro.com.ua/produktsiya/oblitsovochnaya-plitka-marmopoc/).

3. Russian Federation Patent RU 117477 U1, E04F 13/00 (2006.01) published on 27.06.2012.

4. Internet web-page “Hydraulic press TITAN 900F” (http://titan- machinery.com/ru/giperpressv/titan-900-f/).

5. Internet web-page “Kinds of existing panels for ventilated facade” http://fasadoved.ru/ventiliruemye-sistemy/kakie-byvavut-paneli.html.

6. Internet web-page “Varieties of panels for ventilated facades” http://fasadoved.ru/ventiliruemve-sistemv/raznovidnosti-panelei.html.

7. Internet web-page“Cladding materials” http://www.kraspan.ru/products/facing-ceramic- granite-slabs/ .

Claims

1. Ventilated curtain wall system which includes cladding structure, insulating layer, moistureproof and windproof membrane, mount system with supporting profile, decorative cladding panel wherein the decorative cladding panel is executed from the artificial stone in the view of the thin-walled hyperpressed slab.

2. Ventilated curtain wall system according to claim 1 wherein the hyperpressed slab contains strengthening ribs.

3. Ventilated curtain wall system according to claim 2 wherein the strengthening ribs have the height of 0.008-0.05 of the length of the hyperpressed slab.

4. Ventilated curtain wall system according to claim 1 wherein the hyperpressed slab has thickness of 0.012-0.025 of the length of the hyperpressed slab.

5. Ventilated curtain wall system according to claim 1 wherein the hyperpressed slab is made from the mixture containing cement and a filler.

6. Ventilated curtain wall system according to claim 1 wherein the hyperpressed slab is made from the mixture containing cement, filler and reinforcing fibres.

7. Ventilated curtain wall system according to any of claims 5-6 wherein the filler is chosen from the group of natural materials which includes shelly limestone or limestone, or dolomite, or travertine, or marble, or manufacturing waste.