GRC SANDWICH PANEL WITH THERMAL BREAK FOR MODULAR CONSTRUCTION

Abstract

GRC sandwich panel with thermal break for modular construction, characterized by being constituted by a multi-layer panel composed of a rectangular mechanical tubular frame (1) with 5 vertical metal tubular pillars (2), separated at mid-height by two tubular cross members (4) of the same dimensions and a horizontal metal tubular reinforcement cross member (3) at the top. A 10 / 14 mm layer of GRC is applied to the inner face of the frame, forming the inner face of the GRC panel (11), followed by a 200 mm thick layer of thermal insulation (19), and finally, a 10 / 14 mm thick layer of GRC, forming the outer face (10) of the panel. Between the two GRC faces are L-shaped connectors made of low-conductivity material to create a thermal break.

Description

GRC SANDWICH PANEL WITH THERMAL BREAK FOR MODULAR CONSTRUCTION OBJECT OF THE INVENTION The GRC sandwich panel with thermal break for modular construction proposed by the invention refers to a multi-layer panel that serves as a lightweight facade cladding for both civil and light industrial construction, which in turn acts as a structural element and is composed of two exterior and interior faces of GRC (Glass Reinforced Concrete is a cement-based mineral composite reinforced with glass fiber resistant to the alkali of cement (AR fiber) in a fiber proportion between 4 and 5% of the total weight), connected by means of a profile of material of low thermal conductivity, for the thermal break and, which has as a central core a thermal insulator, generally of expanded polystyrene or EPS and, the assembly is stiffened with a tubular metal frame. The panel, thus constituted, is capable of supporting the loads due to itself and to the thrust of the wind, without forming part of the resistant structure of the building. In this way, it allows to receive loads from the slab, roof and from itself if more levels are built. These panels can be used to create three-dimensional modules that can be pre-assembled in the workshop and then installed on site to form the final building. It is therefore a useful panel for a lightweight construction system, allowing great versatility in shapes, textures, colors and even some type of decorated exterior face, as well as its easy transport and installation. TECHNICAL FIELD OF THE INVENTION The invention falls within the technical field of manufacturing self-supporting panels for the construction of habitable spaces for homes and light industrial buildings. BACKGROUND OF THE INVENTION The need to reduce on-site work time, minimize construction delays, and reduce imperfections inherent in human labor is driving the development of industrialized modular construction systems. GRC sandwich panels are a suitable solution for lightweight facade cladding, as they are a composite material highly resistant to bending, tension, and impacts, as well as wear and erosion caused by atmospheric agents. This led to the idea of ​​applying them as an alternative in modular construction, using a load-bearing wall structure consisting of GRC sandwich panels with an internal grid of steel tubes. It is, therefore, a new structural and at the same time architectural option in structural envelopes, acting as a resistant element and simplifying the technical requirements of the structure. The construction using the material called GRC or GFRC, consisting of cement reinforced with glass fiber, used to make facade panels, as seen in patent documents CN209637097U, CN209637097U. A system for making GRC facade panels with the help of a grid of steel tubes, called "stud frame", is also known, as can be seen in patents CN206752772U, CN205530872U, CN109138235A. Modular GRC housing is also known in which the GRC or GFRC stud frame panels serve only as enclosure, requiring a main supporting structure for the building, as can be seen in the patent documents GB2365454A, ES2386052A1. Finally, the present invention differs from all of them in that the GRC panels proposed here also serve as the main structure of the building due to the structural and construction details that will be seen later, obtaining a self-supporting panel that does not require any structure as in the cited patents. DESCRIPTION OF THE INVENTION The present invention consists of a GRC sandwich panel with thermal break for modular construction, which refers to a multi-layer panel that serves as a lightweight facade enclosure for both civil works and light industrial works, which in turn acts as a structural element and is composed of two exterior and interior faces of GRC (Glass Reinforced Concrete is a cement-based mineral composite reinforced with glass fiber resistant to the alkali of cement (AR fiber) in a fiber proportion between 4 and 5% of the total weight), connected by means of a profile of material of low thermal conductivity for the thermal break and, which has as a central core a thermal insulator, generally of expanded polystyrene or EPS and, the assembly is stiffened with a tubular metal frame. This panel, manufactured in this way, is the basis of a modular construction system for the construction of homes and other buildings, based on GRC sandwich panels. The construction of the modules consisting of floor, walls and roof will be carried out in a workshop, and subsequently transported to the construction site and assembled to configure the house. The panels are composed of an outer and inner layer of GRC, reinforced by a metal tubular frame, with several vertical pillars separated by about 60cm and with a metal tubular reinforcement in the middle. The frame can also include a tubular metal piece of similar dimensions running parallel to the width along the upper outer edge. A layer of GRC is then deposited onto this frame to form the inner face of the panel. On the outer face of the vertical pillars and by means of joining bolts, a double "T" shaped profile is attached, made of low conductivity material to promote the breaking of the thermal bridge of the panel. On the outer face of the inner GRC panel, there is a layer of thermal insulation approximately 200mm thick and the insulating material will preferably be expanded polystyrene or EPS. The next layer would be the extension of a 10 / 14mm thick GRC layer that would form the outer face of the panel. The inner surface of this outer face rests on the other outer surface of the low-conductivity profile. This low-conductivity profile, which joins both GRC layers, is what breaks the thermal bridge of the panel. This manufactured panel can support loads from the slab, roof, and even additional levels. These panels can be used to create three-dimensional modules that can be pre-assembled in a workshop and then installed on-site to form the final structure. Thanks to its easy installation, it is very useful for mid-rise buildings, as it is a moldable and interlocking material. It also provides good thermal and acoustic insulation, is fire-resistant, and, above all, has excellent mechanical and economic characteristics. Therefore, it is a lightweight construction system that allows for great versatility in shapes, textures, and colors, as well as easy transport and installation. DESCRIPTION OF THE DRAWINGS To complement the description being made and in order to help a better understanding of the characteristics of the invention, this descriptive report is accompanied by, and forms an integral part of, drawings which, for illustrative and non-limiting purposes, depict the following: FIGURE 1 - Perspective view of the frame. FIGURE 2.-Top plan view of the panel. And in that figure, using the same reference, identical elements are named, among which we distinguish: (1) .- tubular metal frame, (2) .- vertical tubular metal pillars, (3) - upper horizontal tubular metal reinforcement crossbar, (4) - tubular crossbars, (5) .- metal pins, (10) .-outer face of the panel in GRC, (11) .- inner face of the panel in GRC, (12) .- steel temples, (13) .- GRC pellets, (14) .- low conductivity profile, (15) .- GRC overlay, (16) .-reinforcing bars, (17) .- bolts joining the reinforcing bars (16) , (18) .- low conductivity profile joining bolts (14) , (19) .- thermal insulator, (20) .- GRC filling DESCRIPTION OF A PREFERRED EMBODIMENT OF THE INVENTION The GRC sandwich panel with thermal break for modular construction proposed by the invention refers to a multi-layer panel that serves as a lightweight facade cladding for both civil and light industrial construction, which in turn acts as a structural element and is composed of two exterior and interior faces of GRC (Glass Reinforced Concrete is a cement-based mineral composite reinforced with glass fiber resistant to the alkali of cement (AR fiber) in a fiber proportion between 4 and 5% of the total weight), connected by means of a profile of material of low thermal conductivity, for the thermal break and, which has as a central core a thermal insulator, generally of expanded polystyrene or EPS and the assembly is stiffened with a tubular metal frame. In a preferred manufacturing form, the sandwich panel consists of the following elements and in this order: - a mechanical tubular frame (1), rectangular in shape and measuring 3,880 mm wide and 3,152 mm high, made of 40*20 mm square tubing with a thickness of 2 mm. This tubular frame (1) has 5 vertical metal tubular pillars (2) separated at mid-height by two tubular crossbars (4) of the same dimensions and a horizontal metal tubular crossbar (3) at the top for reinforcement across the entire width of the frame (1) and at a distance of 140 mm from its upper edge and on the outside of the frame (1). - This frame (1) thus constituted, is placed on a rectangular straight parallelepiped formwork and, on the inner face, a layer of approximately 10 / 14mm of GRC is extended which will form the inner face of the GRC panel (11). The mechanical characteristics of the GRC used must be within the following values ​​(taken at 28 days of age): - Compressive strength: 5.- 80Mpa - Modulus of elasticity: 1.- 20G.Pa - Elastic limit: 7 - 11Mpa - Modulus of rupture: 1.- 25Mpa - Conductivity: 0.57W / mK - On the sides of the vertical tubular metal pillars (2), two steel tabs (12) in the shape of a rounded "l" angle are welded, which are solidly fixed to the inner face of GRC (11) by means of two GRC balls (13). - A double "T" shaped profile (14), made of low-conductivity material to break the thermal bridge of the panel, is attached to the outer face of the vertical tubular metal pillars (2) using connecting bolts (18). - A layer of thermal insulation (19), approximately 200 mm thick and preferably made of expanded polystyrene or EPS, is placed on the outer face of the inner GRC panel (11). This thermal insulation is fixed by metal tabs (5) located perpendicular to the vertical tubular metal pillars (2). - This thermal insulation leaves a small gap (20) around the vertical tubular metal pillar (2) which is filled with GRC. - At this stage, various elements that will become part of the panel can be placed on a rectangular formwork similar to that used for preparing the inner face of the panel (11). These elements may include a relief engraving that will later appear on the outer face of the panel, photovoltaic cells for electricity production, recessed LED lights, or other components. A 10 / 14mm thick layer of GRC is then spread over these elements or directly onto the smooth back wall of the formwork, forming the outer face (10) of the panel. On the inner face of this outer face (10) of the panel, rests the other outer face of the profile (14), to which horizontal reinforcing rods (16) have been attached by means of joining bolts (17). This assembly has been covered with a GRC overlay (15) so that the low-conductivity "T" profile (14), which is firmly anchored to the inner face of the GRC panel, is also firmly anchored to the outer GRC face of the panel. This low-conductivity profile (14), which joins both layers of GRC, constitutes the thermal bridge of the panel. The advantages of using these GRC panels for the manufacture of building modules can be summarized as follows: they are lightweight products, which can have different appearances on their visible side, are economical to manufacture, are corrosion and rot resistant, and are also non-combustible. Having sufficiently described the nature of the invention, as well as the manner of carrying it out, it should be noted that the provisions indicated above and represented in the attached drawings are subject to detailed modifications as long as they do not alter their fundamental principles, established in the preceding paragraphs and summarized in the following claims.

Claims

1a.- GRC sandwich panel with thermal break for modular construction characterized by being constituted by a multilayer panel composed of the following elements and in this order: - a mechanical tubular frame (1) of rectangular shape and dimensions of 3,880mm wide 3,152mm high, made with 40*20mm square tube by 2mm thick and which has, 5 vertical tubular metal pillars (2) separated at half height, by two tubular crossbars (4) of the same dimensions and a horizontal tubular metal upper reinforcement crossbar (3) across the entire width of the frame (1) and, at a distance of 140mm from its upper edge and located on the outside of the frame (1), - this frame (1) thus constituted, is placed on a rectangular straight parallelepiped formwork and on the inner face of the same a layer of 10 / 14mm of GRC is extended, which will form the inner face of the GRC panel (11),- Two L-shaped steel tabs (12) with rounded angles are welded to the sides of the vertical tubular metal pillars (2), which are firmly fixed to the inner face of the GRC (11) by means of two GRC pellets (13), - A double "T" shaped profile (14), made of low conductivity material, is attached to the outer face of the vertical tubular metal pillars (2) by means of connecting bolts (18), - A 200mm thick layer of thermal insulation (19) is placed on the outer face of the inner GRC panel (11), fixed by means of metal tabs (5) located perpendicular to the vertical tubular metal pillars (2), - This thermal insulation leaves a small gap (20) around the vertical tubular metal pillar (2), which is filled with GRC, - on a rectangular formwork similar to that used for the preparation of the inner face of the panel (11) , a 10 / 14mm thick GRC layer is extended,that forms the outer face (10) of the panel, - on the inner face of this outer face (10) of the panel, rests the other outer part of the profile (14) to which, by means of bolts (17), resistant horizontal rods (16) have been fixed, and this assembly has been covered with a GRC overlay (15) as an anchor for the low conductivity "T" profile (14), 2a.- GRC sandwich panel with thermal break for modular construction according to claim 1, characterized in that the GRC (Glass Reinforced Concrete) used is a cement-based mineral composite reinforced with glass fiber resistant to the alkali of cement (AR fiber), in a fiber proportion between 4 and 5% of the total weight. 3a.- GRC sandwich panel with thermal break for modular construction according to claim 1 and characterized in that the mechanical characteristics of the GRC used,The following values ​​(taken at 28 days of age) must be included: - Compressive strength: 5.- 80 MPa - Modulus of elasticity: 1.- 20 GPa - Yield strength: 7 - 11 MPa - Modulus of rupture: 1.- 25 MPa - Conductivity: 0.57 W / mK 4a.- GRC sandwich panel with thermal break for modular construction according to claim 1 and characterized in that the 200mm thick thermal insulation layer (19) used as insulating material is expanded polystyrene or EPS. 5a.- GRC sandwich panel with thermal break for modular construction according to claim 1 and characterized in that the double "T" shaped profile (14),It is made of low conductivity material to facilitate the thermal break of the panel when joining both GRC layers (10) and (11). 6a.- GRC sandwich panel with thermal break for modular construction according to claim 1 and characterized in that, to modify the appearance of the outer face of the outer panel (10), the chosen elements are placed at the bottom of the formwork, such as screen prints, drawings, a relief engraving, photovoltaic cells for the production of electrical energy or recessed LED lights; over which a layer of GRC of 10 / 14mm thickness is spread, which will form the outer face (10) of the panel. 7a.- GRC sandwich panel with thermal break for modular construction according to claim 1 and characterized in that the advantages of using these GRC panels for the manufacture of building modules can be summarized as follows: they are lightweight products,which can have different appearances on their visible side, are inexpensive to manufacture, corrosion and rot resistant, and are also fireproof.

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