METHOD FOR PRODUCING PREFABRICATED BUILDING ELEMENTS, AND ELEMENTS THUS OBTAINED

Abstract

The invention relates to a method for producing prefabricated structural elements, particularly for building structures such as walls, partitions, or roof sections, as well as the prefabricated elements obtained by implementing this method. The method according to the invention includes a step of pre-cutting an insulating material to form anchoring elements (5) which will hold these elements on a pre-cast concrete base (1), without the need for additional fastening means once said insulating material panel (4) is pressed against the concrete base. Application: construction of residential or commercial premises (Figure 2).

Description

Title of the invention: METHOD FOR PRODUCING PREFABRICATED BUILDING ELEMENTS, AND ELEMENTS THUS OBTAINED

[0001] The present invention relates to a method for producing prefabricated structural elements, more particularly intended for the construction of building structures, such as walls, partitions or roof sections.

[0002] The invention also relates to prefabricated elements obtained by implementing the process.

[0003] The evolution of modern building construction techniques, particularly for residential or professional use, has prompted various research aimed at both accelerating and simplifying construction operations, while reducing costs, without compromising the insulation qualities and modularity of buildings.

[0004] The concept of prefabricated construction has thus experienced a certain boom in the field of building over the past several years.

[0005] According to this design, to erect the planned building, whether it is a premises for professional or residential use, elements or sets of elements are manufactured in a factory and assembled on site to form the complete structure of the building.

[0006] This design has obvious advantages in terms of cost, since it will be possible to pre-produce the various constituent elements of the building structure in the factory from the plans previously drawn up.

[0007] It will therefore no longer be necessary to assemble these different elements separately, gradually and on site, which sometimes led to delays due in particular to the need to allow waiting or setting times, or to interrupt operations due to external parameters such as weather.

[0008] It is quite obvious that it is both much faster and easier to erect a wall by assembling factory-made elements than to use the classic technique requiring formwork, pouring concrete or building the wall in brick or classic masonry, the result being moreover totally raw and subsequently requiring finishing, cladding or other work.

[0009] A typical example of prefabricated elements intended for the construction of a structure is described for example in document FR 2 116 622.

[0010] This older document describes a prefabricated facade panel, comprising an outer facing and an inner facing on either side of an intermediate space containing a filling material, these two facings being made of plates of stone and being connected to each other by clips which pass through said space and which are embedded at their ends in the joints of the stones, the panel comprising two beams arranged respectively under the lower edge and on the upper edge of the whole of the two facings, these two beams receiving and distributing a prestressing pressure.

[0011] This construction technique is now tried and tested and recognized. However, it still presents various problems, such as insulation.

[0012] Indeed, in the case of a wall built using conventional masonry techniques or by using prefabricated elements, it remains necessary, in order to ensure the insulation of the room, to provide for the installation of additional elements on the surfaces forming the exterior walls of the building, which entails additional operations, therefore additional time and costs.

[0013] It may therefore also be interesting to propose a solution allowing the integration or association of elements fulfilling an insulation function with prefabricated structural elements, from the stage of their manufacture in the factory, in order to avoid subsequent interventions on site.

[0014] Document EP 1 235 037 describes a prefabricated thermoregulatory element intended for the construction of building walls, consisting of a cast concrete core, in which through holes have been made to allow the passage of pipes, and against which layers of insulating material are simultaneously placed.

[0015] To secure the assembly before its use on site, retaining rods are provided at regular intervals which pass through the assembly formed by the concrete element and the corresponding layer of insulating material.

[0016] This method is not entirely satisfactory. Indeed, while it appears to produce a prefabricated element combining structural blocks and layers of insulating materials, the long-term durability of walls or partitions made using these elements clearly leaves much to be desired.

[0017] The insulating layers are not integrated into the structural elements, but simply plated on, and their retention in position depends on additional fixing elements that are pre-installed.

[0018] The integrity of the assembly formed from such elements is therefore likely to be called into question in the event of wear, breakage or defect of one of these fastening elements.

[0019] The present invention aims to remedy these various drawbacks by proposing a method for producing prefabricated panels for the construction of walls or structural elements, in which a layer of insulating material is integrated into a concrete base, the whole being ready to install without the need to provide external chemical or mechanical means to ensure its stability.

[0020] The method according to the invention is characterized in that it includes a pre-cutting step of an insulating material to form anchoring elements which will allow the latter to be held on a pre-cast concrete base, without recourse to additional fixing means.

[0021] The invention will be better understood through the following description of an embodiment, and with reference to the accompanying drawings, in which:

[0022] [Fig. 1] is a diagram representing the different stages of the process according to the invention, and

[0023] [Fig.2] is a cross-sectional view of a prefabricated element obtained by implementing the process according to the invention.

[0024] With reference to the attached figures, and in particular [Fig.1], the production of a prefabricated building element according to the invention involves the implementation of a process comprising the following steps.

[0025] In a first step, a flat concrete slab is poured on a metal bench, providing from this stage for the openings desired, such as doors or windows, as well as for the various networks that will supply the building, such as electrical outlets or connections to cable or telephone networks or even to seismic pillars.

[0026] From this stage, a heating mat is placed in the lower part of the concrete, i.e. over a maximum height of lm20 measured from the lower limit of the concrete base, which will be integrated so as to be positioned about 4 centimeters from the outer edge of the inner wall of the element.

[0027] In a second step, after pouring the fresh concrete, pre-formed plates of insulating material, preferably polystyrene, of corresponding dimensions, with pre-cuts forming extensions or tenons, will be placed on the concrete bases.

[0028] The insulating polystyrene plates are arranged on the concrete bases in such a way that the protruding tenons of the inner wall of the insulating plate come into contact with the outer surface of the concrete base.

[0029] The aim is thus to ensure perfect retention, without any possibility of withdrawal, of the insulating plate once the concrete has completely set and will retain the protruding tenons of the insulating plate, preventing any subsequent release.

[0030] In a third step, a classic operation of vibrating the concrete is carried out.

[0031] Then, in a fourth step, the polystyrene plate is pressed against the base in concrete to cause a penetration of approximately 15 mm of the internal wall of the insulating element into the fresh concrete.

[0032] Thus, a solid and natural fixing will be achieved which will not require the use of other fixing elements for its maintenance.

[0033] A hot wire is then passed over the outer surface of the polystyrene to recalibrate the thickness of the wall and compensate for any twisting movements that may have occurred during the installation and pressing of the insulating panel against the concrete base.

[0034] Finally, in a last step, the insulating plate will be cut in relation to the predefined openings in the concrete base in order to obtain a prefabricated element ready for use.

[0035] Figure [Fig.2] illustrates in cross-section a prefabricated element obtained by means of the process according to the invention.

[0036] The concrete base (1) has one or more pre-formed openings corresponding for example to doors or windows (2).

[0037] The heating mat (3) is located near the inner wall of the base. It is controlled by a room thermostat with gradual heating (not shown).

[0038] A probe embedded in the concrete wall makes it possible not to exceed the maximum temperature of 26°C in the concrete panel.

[0039] By inner wall, we mean the wall of the element which will be located towards the interior of the building to be constructed.

[0040] The tablecloth (3) is limited in height, to a maximum of lm20 from the lower limit of the concrete base, in order to avoid any risk of deterioration if the users or inhabitants subsequently wish to make perforations in the walls, for example to hang decorative elements.

[0041] A plate of insulating material (4) is arranged against the inner surface of the concrete base (1).

[0042] The dimensions of the plate (4) are predefined according to those of the concrete base (1) so that they can very precisely overlap one another.

[0043] The insulating plate (4) has lateral extensions forming a corner formwork.

[0044] The insulating plate (4) is pre-cut so as to have various protrusions (5) of various shapes defining tenons when said plate (4) is placed on the concrete base (1) which has just been poured.

[0045] As the concrete is still fresh, the tenons (5) penetrate the base until the gaps (6) which separate each of the tenons (5) are completely filled with fresh concrete.

[0046] The insulating plate (4) is thus glued against the concrete base and the setting of the concrete will result in trapping the tenons (5) inside said base (1).

[0047] To ensure that the insulation adheres perfectly to the concrete base, pressure is applied to the plate (4) so ​​that it penetrates the surface of said concrete base. (1) over a distance (x) of a few centimeters.

[0048] Thus, the plate (4) is perfectly inseparable from the prefabricated element when the concrete of the base (1) has set and dried.

Claims

Claims

1. Method for producing prefabricated structural elements, characterized in that it comprises a step of pre-cutting an insulating material to form anchoring elements which will make it possible to maintain said anchoring elements on a pre-cast concrete base, without recourse to additional fixing means.

2. Method according to claim 1, characterized in that it comprises the following successive steps: - a concrete sheet is poured flat, - a preformed plate of insulating material (4) of corresponding dimensions is placed on the concrete base (1) obtained, comprising pre-cuts forming anchoring elements (5), - the concrete is vibrated, - the plate of insulating material (4) is pressed against the concrete base (1) to cause a penetration of the order of 15 mm of the internal wall of the insulator into the fresh concrete. - the plate of insulating material (4) is cut according to the concrete base (1).

3. Method according to claim 2, characterized in that a heating mat (3) positioned approximately 4 centimeters from the outer edge of the inner wall of the concrete base (1) is placed in the lower part of the concrete base (1) at a maximum height of 1 m20 measured from its lower limit.

4. Method according to one of the preceding claims, characterized in that the insulating material is polystyrene.

5. Method according to one of the preceding claims, characterized in that the concrete base (1) comprises at least one preformed opening (2).

6. Method according to one of the preceding claims, characterized in that the dimensions of the insulating material plate (4) are predefined according to those of the concrete base (1) so that they can very precisely overlap one another.

7. Method according to one of the preceding claims, characterized in that the anchoring elements (5) of the pre-cut insulating material plate (4) consist of protrusions of various shapes defining tenons separated by gaps (6).

8. Method according to claim 7, characterized in that the plate is placed of insulating material (4) on the concrete base (1) so that the tenons (5) penetrate the concrete until the gaps (6) which separate each of the tenons (5) are completely filled with fresh concrete.

9. Prefabricated structural element, characterized in that it is obtained by implementing the following steps: - a concrete sheet is poured flat, - a preformed plate of insulating material (4) of corresponding dimensions comprising pre-cutouts forming anchoring elements (5) is placed on the concrete base (1) obtained, - the concrete is vibrated, - the plate of insulating material (4) is pressed against the concrete base (1) to cause a penetration of the order of 15 mm of the internal wall of the insulator into the fresh concrete, - the plate of insulating material (4) is cut according to the concrete base (1).

10. Structural element according to claim 9, characterized in that it is composed of a concrete base (1) and a plate of insulating material (4) comprising lateral extensions forming an angle formwork, and anchoring elements (5) provided to penetrate the fresh concrete when said plate is placed on said base.

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