EP0794301A1 - Production method of panels and obtained product - Google Patents

Abstract

The manufacture comprises the following operations. Raised edge panels (3) are placed on a support having fasteners complementary to those on the panel edges. The support has anchorings for a connection (4) to the concrete (5,8) along a predetermined template. The panels are fixed together and the concrete connectors are fixed to them. A removable external coffering (1) limits the external edges of the wall. A frame is placed on the bottom if necessary. Concrete is poured, with, if necessary, the inter-positioning of insulation (6). The complete wall, including the panels, is then removed. A complementary stage consists in covering the assembly with a finishing surface opposite to that already provided by the panels.

Description

Subject of the invention.

The present invention relates to a method for manufacturing walls, and more particularly facade walls but also ceiling / floor elements, of the composite type, that is to say made up of facing plates, in particular in the form of preformed elements, and poured concrete. It extends to the products resulting from this process.

Technological background and state of the art underlying the invention.

Over the past ten years, an interest has developed in a technology, which involves the use of modular elements of poured concrete coated, preferably in the factory, with a preformed facing on at least one face.

The aim generally sought is to combine an aesthetic effect, in particular a wide decorative variety in the choice of the facing or of the constituent elements of the facing, including with regard to the color or the combination of colors, with specific technical characteristics, in particular the stability and resistance of the concrete (which can be reinforced) as well as the possibility of incorporating insulation plates into the structure.

Everything must of course be combined with a price reasonable cost and ease of manufacture.

In addition, many sectors, in particular the agro-food sector, have health or hygiene requirements making it necessary to integrate a specific coating, for example stainless steel or plasticized film having food approval ("FOODSAFE film ") on the face of the wall element (on the interior side), requirements which are difficult to achieve by existing construction elements, which makes it necessary to have an adequate additional covering after erection of the construction.

Prescribers also often wish to be able to interpose an insulator between two concrete veils, which leads to significant difficulties due to the fact that the two concrete veils, usually successively poured, are not adequately secured.

It is also often required to be able to create a concrete element with a face having sound absorption properties, and generally, the only practical solution is to subsequently cover an existing wall with a sound absorption panel usually perforated.

There are very few solutions allowing to integrate into the wall manufacturing process all these finishing elements (aesthetics, hygiene, thermal insulation, acoustic insulation, etc.) that are necessary.

State of the art .

In document AT-170113-B, it is proposed to produce panels to be applied directly to walls or to a frame. These panels consist of preformed sheet metal elements with raised edges which can be assembled together, in particular by screws or rivets.

The preformed elements can be arranged in superimposed rows with alignment of the joints in the transverse direction or with offset thereof. These elements are fixed with a bonding mortar on the walls they must cover.

Document DE-1 808 506-A proposes an assembly of preformed elements in sheet metal with raised edges, by tongues and cutouts in the preformed elements.

The cavity formed by the preformed elements can be filled with insulating foam.

Document US-1,841,819 also proposes an assembly of preformed elements of sheet metal with raised edges provided with connecting pieces on the sides. This assembly is intended to cover floors and is preferably applied to a cement or asphalt base while the latter is still in plastic form, that is to say before setting.

None of these solutions includes suitable means for prefabricating in the factory or on site a complete wall comprising the decorative element formed by the assembly of the preformed elements and a structural concrete and no connecting members are provided between the concrete. and the assembly of the preformed elements.

In document AT-129 436-B, it is proposed to have ceramic tiles in a mold and to join them together by pouring concrete or cement over their rear face. In the mass of concrete, reinforcements or fasteners for fixing the panels can be incorporated.

There is no provision for joining the ceramics together, nor for fixing or anchoring them with the concrete mass.

Document DE-1 094 649-A describes a similar technique for elements of mosaic type in two stages. These elements are first placed in a mold and a jointing mass is poured between the mosaic elements by covering their rear face. Next, a mass of concrete is applied to the still fluid jointing material.

Again, no connection between the mosaic elements and no anchoring with the concrete mass are provided.

According to document FR-1555.470-A, prefabricated elements in cellular concrete have been proposed using lost formwork, made of preformed thin sheet metal.

To make a floor or wall element, it is proposed to form facing elements (U-shaped sheets), juxtaposed on a flat area and joined two by two by clips.

These elements are formed by long sheets, arranged side by side.

On these sheets, a thermal insulating mat is placed and then sheet metal trays forming lost formwork, to produce a series of spaced cells between which there are provided insulating plates.

In this embodiment, the thermal insulation includes numerous continuity solutions favoring the establishment of thermal bridges.

In addition, there is no provision for a spacer ensuring the connection and securing of two layers of concrete with the interposition of a continuous layer of insulation.

It is not intended to achieve aesthetic effects by variations in the color of the sheets, for example in the alignment of these sheets or by alternating effects.

In document FR-60683-A (addition to French patent 1,016,035), the aim is to provide means for attaching elements of panels of different natures. These elements consist of pieces of sheet metal whose edges are folded, among other things, to 900. It is provided for the possibility of alternating different types of tiles. Tabs are provided to facilitate the hanging of the tiles in plaster or cement. The tiles can be joined together using rivets, clips or wires. The technique consists of cementing the pre-assembled elements or not on an existing wall, or possibly pouring concrete or plaster on the same coating: in this case the elements serve as formwork lost.

Prefabricated panels are described which consist of an insulating core, protected by a layer of cement or plaster and by a coating of tiles on the other face. This solution does not allow the installation of an insulator between two layers of concrete with bonding between them of these two layers. There are also no plans to produce acoustic panels with incorporated sound absorbent.

Goals of the invention.

The invention aims in particular to achieve the aforementioned objectives, and in particular to allow the production of large prefabricated panels, keeping the aesthetic aspects attractive, plain or with color contrast, while avoiding the difficulties associated with the construction of walls on the site.

It aims in particular to avoid the aforementioned drawbacks of the solutions of the prior art.

Main characteristic features of the present invention.

• dans un moule classique ou sur un support, on dispose des panneaux à bords relevés, pourvus de moyens d'accrochage mutuels sur leurs bords et de moyens d'accrochage pour un organe de liaison avec le béton selon un gabarit prédéterminé dans la position que ces éléments de panneau devront adopter sur une face de la paroi;
• on solidarise de manière appropriée les différents panneaux entre eux et on y fixe les organes de liaison avec le béton, un élément de coffrage extérieur amovible de dimension adéquate étant prévu pour limiter les bords extérieurs de la paroi selon le gabarit final;
• on pose éventuellement sur le fond une armature;
• on coule le béton avec interposition éventuelle d'éléments isolants s'il en est prévu, pratiquement jusqu'à la hauteur finale prévue pour le béton et
• on démoule ensuite une paroi complète, incluant les panneaux qui y sont solidarisés.

The present invention relates to a process for manufacturing walls, and in particular walls, characterized by the following operating steps:

• in a conventional mold or on a support, there are panels with raised edges, provided with mutual hooking means on their edges and hooking means for a connecting member with concrete according to a predetermined template in the position that these panel elements should adopt on one side of the wall;
• the various panels are suitably joined together and the connecting members with the concrete are fixed thereto, a removable external formwork element of adequate size being provided to limit the external edges of the wall according to the final template;
• a frame is optionally placed on the bottom;
• the concrete is poured with possible interposition of insulating elements if provided, practically up to the final height provided for the concrete and
• a complete wall is then removed from the mold, including the panels which are joined thereto.

Optionally, an additional step consists in covering the assembly with a finishing face opposite to the face already provided with said panels, this finishing face possibly being of a nature similar to this first face or of a totally different nature (for example rough concrete or washed flint).

The technique generally used consists of an assembly of panels whose size can vary depending on the modulation and the aesthetic research specific to the project, defined by the architect. To obtain a block or tiling effect, metric panels of 200 x 200 mm or 200 x 400 mm and of an appropriate thickness will generally be used, made, for example, of sheet metal such as aluminum or prepainted galvanized steel or plasticized, stainless steel, etc., so as to form at least one exterior or interior face of the wall. Other materials may also be suitable, for example molded resins, plastics, etc.

The standard panels are preferably produced in the form of a preformed element with four raised edges, which are practically perpendicular to the surface of the panel. More precisely, the edges are arranged at an angle of the order of 91 degrees relative to the face of the panels, and will deform by creating a certain seal along the edges when the elements are assembled. Of course, after setting of the concrete and demolding of the wall, the raised edges are included in the mass of the concrete and the panels will be arranged in a generally continuous plane with adjoining panels.

The above-mentioned hanging means for the panels between them and with the connecting member preferably comprise perforations in said raised edges of the panels capable of receiving tongues or lugs.

In principle, the panels and the connecting elements can be provided with reinforcing elements in the form of ribs, but this is generally not necessary. The raised edges already provide good rigidity, especially if the panels are alternated, and if we consider the way they are implemented, namely the fact that they are, with the connecting members, included in the mass of concrete.

A wide variety of aesthetic effects can be obtained, in particular in the case of lacquered or plasticized galvanized sheets, in the sense that alternations of color are achievable in particular in the form of mosaic-type effects. In addition, the surface effect is particularly attractive to the prescriber and the technique is likely to seduce many contractors or prefabricators by its flexibility of use and its aesthetics.

The joining of the panels together is possible in different ways.

The raised edges can, for example, be provided on two opposite sides on one side with a perforation and on the other side with a tongue.

Rows of panels can be formed by inserting the tongue of a panel into the perforation of the adjacent panel and then deforming the tongue, for example by twisting using pliers or a suitable tool.

On the two remaining opposite sides, two perforations can be provided, in this case the connection being made by the connecting member which will be embedded in the concrete and which will be arranged perpendicular to the face of the panels. This liaison body may in particular be provided of a tongue which penetrates from distance to distance in corresponding perforations of the edges of panels. Also in this case, a simple deformation makes it possible to connect the above-mentioned rows of panels together.

Of course, other fixing techniques can be envisaged, taking into account the fact that the wall to be produced will comprise several rows of assembled panels.

Preferably, the concrete is poured at an appropriate fluidity in two stages, with the interposition of strips of insulating material corresponding in width to the spacing between the connecting members, and which are arranged at an appropriate height, for example approximately halfway height of the thickness of the finished panel. Additional reinforcements which have been previously calculated to ensure adequate mechanical strength can also be included in the concrete mass. In addition, since the concrete is poured onto the panels in a relatively small thickness, while these panels rest on a support, such as a flat table, distortions during casting do not occur. The external formwork element is of course of suitable shape and treated to facilitate formwork, which ensures edges of regular walls and without accidental roughness. Reserves can be provided on the outer edges of walls to receive fastening elements between modular walls and / or sockets between these modular walls.

The connecting member can be of any suitable material, metallic, synthetic or mixed. Stainless steel is particularly suitable because of its conduction coefficient reduced by 3 to 4 times compared to that of galvanized steel. In order to avoid thermal bridges, a thermal break can be provided on the connecting element, at the height of the insulating plates provided.

The arrangement of the neighboring rows of panels can be "aligned", that is to say that the joints between the panels of neighboring rows are arranged in a straight line, or "alternating" in the way we lay the bricks. Many other geometrical arrangements can be envisaged, for example a “honeycomb” arrangement starting from hexagonal panels, in this case comprising six raised edges.

The outer face of the panels forming the wall, that is to say that which faces towards said support, is optionally lacquered. Colored patterns can be provided and produced easily simply by placing on request, according to a precise scheme, lacquered panels of different colors depending on the desired pattern.

As has been mentioned, it is possible to keep the upper face of the wall after casting without additional coating, with a simple smoothing if it is intended to be mounted as it is, or with a gripping roughness if this face must be plastered or coated.

The face described as exterior above, that is to say that facing said support during the implementation of the method of the invention, is not necessarily the exterior face when the walls are mounted. In certain particular applications (slaughterhouses, dairies, fridges, sterile rooms, etc.), it may be advantageous, especially when this face is made using stainless steel panels, that this face is the inside face in a building, the face opposite being either bare or provided with plaster or any other finish.

The technique described also makes it possible to provide windows for doors and windows, by simply incorporating "reservations" in the prefabricated element, possibly reinforced by a lintel, or even by providing "pre-frames" for reinforcement during the mounting of doors and windows. in the berries.

The choice of concrete, in particular its thickness and its reinforcement, ensures the required stability. Each panel is in principle fixed to the concrete veil by at least two connecting members, which ensures an adequate connection. In the case of two concrete webs with the interposition of an insulating panel, the connecting member ensures the positioning of the insulating panel and at the same time the joining of the two concrete webs and the fixing of these panels.

The invention will be described in more detail with reference to particular embodiments, given by way of illustration, of the invention, with reference to the accompanying drawings.

Brief description of the drawings.

Figure 1

shows in perspective the arrangement of the panels in a manufacturing mold with two examples of nesting: "aligned" or "alternated".

Figure 2

represents an orthogonal section A - B in FIG. 1 at the level of the connecting members.

Figure 3

schematically illustrates the assembly of the panels together.

Figure 4

shows a view of a connecting member.

Description of an embodiment of the invention.

In FIG. 1, the general reference 1 represents a prefabrication mold in which are arranged individual panels 3 provided with connecting members 4.

The mold is designed so that it can receive a whole number of panels. These can be arranged in an aligned or alternating interlocking, as shown. In the case of an alternate arrangement, each row of panels is offset from the previous row, and in this case, of course, to occupy the entire mold, it is necessary to provide panels of smaller size, for example 200 X 200 mm panels, if the main series consists of 200 X 400 mm panels, this in order to fill the free spaces on the edges of the mold.

Although a rectangular mold has been shown, it should be understood that other arrangements can be made, in particular to allow interlocking of the walls with one another for example, or to allow to receive fastening elements between the panels, or any other element such as racks, electrical boxes, etc.

In Figure 2, there is shown schematically a partial section A - B of a wall produced according to the invention.

In the mold 1, the panels 3 are arranged as indicated above, advantageously with the interposition of a protective coating 2, for example a sheet of expanded or unexpanded polyethylene. The panels 3 will constitute the decorative panels of the wall, for example a prefabricated facade wall or a ceiling.

As a variant, this wall 3 may consist of a perforated acoustic absorption panel (generally 20% to 30% of holes), lined with a thickness of rock wool 7, of the order of 3 to 5 cm. In the same drawing, this alternative embodiment is shown in the form of a 3 'panel.

Complementary reinforcements 10 are in the embodiment shown encompassed in the mass of concrete.

It is however understood that in principle, all the panels of the same wall are of the same nature, except for particular application, and that the representation of FIG. 2 only serves to illustrate the possibilities of execution.

The connecting members 4 are mounted as shown in Figure 1, and serve to secure the panels 3 between them. This connecting member can also be used to support any reinforcements resting on the connecting members 4, for example by means of perforations 24 with which these connecting members are provided. In the mold, a first layer of concrete 5 is first poured with a thickness to be defined essentially as a function of the nature of the wall, user preferences, and stability calculations.

On this first layer of concrete is superimposed an insulator 6, preferably rough on both sides, which is slid between the connecting members 4. It can for example be sheets of extruded or expanded polystyrene foam succeeding one another. length equal to the length of the mold and having a width equal to the distance between the spacers. Of course, in certain particular cases, this insulator may not be necessary, but one of the advantages of the embodiment is the fact that its possible presence does not affect the integrity of the wall produced, since the two walls of concrete which are created are joined by the connecting members which also ensure the anchoring of the decorative panels.

Then, a second layer of concrete, of thickness also to be defined, is poured, the gross surface of the concrete overflowing the connecting members so as to completely encompass them.

On the raw surface of the fluid concrete, it is possible, if desired, to lay other finishing elements depending on the type of wall desired, for example traditional washed flint.

In Figure 3, there is shown the panels, made - for example - sheet metal, and their assembly. The panels are, in this case, provided for example, on three of their raised edges, with perforations or openings 11 and on the fourth raised edge, tongues or tenons. This is done very easily, in particular from prepainted metal coils, by simple cutting and stamping in a die.

The panels are assembled together in one direction simply by fitting the tongues 13 into the corresponding openings 11 and twisting these tongues.

In the perpendicular direction, the lateral joining of the panels is simply carried out by fitting a connecting member 4 provided with pins penetrating into the aligned openings of two panels and twisting these tongues or tenons. If necessary, a special tool allows this twist to be produced very easily.

The detail of the design of a connecting member 4 is shown in FIG. 4.

The connecting member can be produced, for example, from a metal plate (for example galvanized or stainless steel), from synthetic plastic materials or from a combination of the two.

Many forms of execution are of course possible. By way of example, the anchor 21 is shown on this plate by the anchor which will be provided in the poured concrete in the form of a tongue cut out in the plane of the sheet and raised at 90 °.

Optional perforations 24 can be provided for the installation of sheaths or reinforcements. Tenons 22, practically at the end of the connecting member, serve, after having been introduced into the aligned openings of two adjoining panels, to secure these panels together by twisting said tenons.

It should however be noted that the total length of the connecting member is greater than the distance between the pins 22 and 22 'at each end of the connecting member. This extra length serves as a guide for easily finding the holes in the panels, the extra length corresponding to the height of the openings relative to the bottom of the panels, and it is therefore sufficient to simply slide the connecting members onto the bottoms of the panels to be practically at the height of the openings provided on the raised edges of these panels.

There is shown by a brace 25 a free area for laying an insulator on the first layer of concrete. Of course, the thickness of this insulator should not correspond to the height of the free zone 25 completely. On the contrary, the space provided allows a variation in the positioning of the insulator 6.

The length "1" is slightly less than the total thickness of the wall, so that the joining element is completely incorporated in the mass of concrete constituting the wall, the tongues 21, the studs 22 and the perforations 24 serving as anchoring in the concrete.

Although preferred embodiments of the invention have been described, it should be understood that numerous variant embodiments are possible, while remaining within the scope of the invention.

The invention is in particular not limited as regards the choice of materials, the dimensions and shapes of the various constituent elements, such as dimension and material of the panels, thickness and nature of the insulation, thickness of the concrete veils, shape of the connecting element, forms panels between them, and of the connecting element to these panels, etc.

Claims (12)

Method for manufacturing walls, in particular walls or floors / ceilings, characterized by the following operating steps: - On a support, there are elements of panels (3) with raised edges, provided with means for hooking (11, 13) mutual of the panels on their edges and means for hooking (11, 22) for a member of connection (4) with the concrete (5, 8) according to a predetermined template in the position that these panel elements (3) must adopt in the wall; - The various panels (3) are appropriately joined together and the connecting members (4) are fixed there with the concrete, a removable formwork element (1) of adequate size being provided to limit the outer edges of the wall according to the final template; - a frame is possibly placed on the bottom; - the concrete is poured with possible interposition of insulating elements (6) if provided, practically up to the final height provided for the concrete and - a complete wall is then removed from the mold, including the panels which are joined thereto. Method according to claim 1, characterized by an additional step consisting in covering the assembly with a finishing face opposite to the face already provided with said panels (3), this finishing face possibly being of a similar nature to this first face or a totally different nature. Method according to claim 1 or 2, characterized in that an assembly of standard panels is used, made of sheet metal such as aluminum or prepainted or plasticized galvanized steel or stainless steel, so as to form at least one outer face or inside the wall, or made of other materials, especially molded resins or plastics. Method according to any one of Claims 1 to 3, characterized in that the standard panels are preferably produced in the form of a cut and / or preformed element with four raised edges, which are practically perpendicular to the surface of the panel. Method according to any one of claims 1 to 4, characterized in that said means for hooking (11, 13) mutual of the panels on their edges and the means for hooking (11, 22) for said connecting member (4 ) have perforations in said raised edges of the panels. Method according to any one of Claims 1 to 5, characterized in that the said hooking means (11, 2) between the panels are constituted by perforations (11) aligned on the panels, capable of receiving said connecting member (4 ). Method according to any one of claims 1 to 6, characterized in that reinforcing reinforcements (10) are positioned in said wall. Method according to any one of Claims 2 to 7, characterized in that the said finishing face opposite the face already provided with the said panels (3) consists of a perforated sound absorption panel (preferably 20% to 30% of holes), lined with a sufficient thickness of rock wool or any other absorbent material (7). Method according to any one of Claims 2 to 7, characterized in that the said finishing face opposite the face already provided with the said panels (3) is constituted by a coating meeting the sanitary and hygienic standards of the agro-industrial food, in particular in stainless or plasticized steel having food approval ("FOODSAFE" film). Wall characterized in that it consists of panel elements (3) with raised edges hooked by mutual hooking means (11, 13) on their edges and provided with hooking means (11, 22) by a connecting member (4) with concrete poured on the rear face of said panel elements (3) encompassing the raised edges thereof. Wall according to claim 10, characterized in that it comprises a frame (10) in the mass of poured concrete. Wall according to claim 10 or 11, characterized in that it comprises insulating elements (6) in the mass of concrete.

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