Method for manufacturing three-layer wall panel with opening

Abstract

FIELD: construction.SUBSTANCE: factory production of three-layer wall panels with an opening and with the required decorative properties, which can be used in the construction of buildings and structures for various purposes. The method for manufacturing a three-layer wall panel with an opening includes the step-by-step formation and reinforcement of layers in removable formwork, in particular a decorative layer made of concrete and formed using a removable matrix with a relief outer surface, a heat-insulating layer and a concrete layer, curing the resulting three-layer wall panel until the concrete gains strength and removing the finished product from the removable formwork, wherein a removable matrix with a relief outer surface is placed on the bottom of the removable formwork, a space divider is placed, configured to form a through opening with a quarter, outside of which a reinforcing frame of the decorative layer is installed, which is rigidly connected to the connecting elements oriented perpendicular to the layers, then the concrete mixture of the decorative layer is laid and compacted, the thickness of which is at least 6.5 cm, then a heat-insulating layer of slab material is laid, directing the connecting elements through it, the reinforcing frame of the concrete layer is mounted, which is rigidly connected to the connecting elements, after which the concrete mixture is laid and compacted.EFFECT: expanded range of three-layer wall panels, fully factory-ready and with an opening, that do not require insulation, additional processing, or finishing of the outer surface.3 cl, 3 dwg

Description

[0001] The invention relates to the field of construction, in particular to the production in factory conditions of three-layer wall panels with an opening and with the required decorative properties, which can be used in the construction of buildings and structures for various purposes.

[0002] A method for producing layered structures is known, which includes laying a volumetric reinforcement cage in prefabricated formwork, pouring a lower layer of concrete mix with subsequent compaction, forming a heat-insulating layer and pouring an upper layer of concrete mix (see USSR A.S. No. 1712188, IPC B 32 B 13 / 00, publication date 02 / 15 / 1992).

[0003] The following can be mentioned as disadvantages of the known solution:

[0004] – lack of external finishing of the finished product;

[0005] – a heat-insulating layer made of a mineral-organic elastic filling material (styrofoam concrete, peat concrete, arbolite concrete) can contribute to flammability and smoke, which are dangerous for people in the event of a fire.

[0006] The closest analogue (prototype) adopted is a method for manufacturing a three-layer wall panel, which includes the step-by-step formation and reinforcement of layers in removable formwork, in particular a decorative layer made of concrete and formed using a removable matrix with a relief outer surface, a heat-insulating layer and a concrete layer, curing the resulting three-layer wall panel until the concrete gains strength and removing the finished product from the removable formwork (see Russian Federation Patent No. 2515491, IPC E04B 1 / 02, E04C 1 / 40, publication date 10.05.2014).

[0007] The disadvantages of the prototype are:

[0008] – limited scope of application, since finished products can only be used in monolithic frame buildings;

[0009] – relatively low adhesion of layers, since the reinforcing elements are located only between the concrete and thermal insulation layers;

[0010] – placing a concrete layer between the decorative and thermal insulation layers may negatively affect the dew point position in the finished product;

[0011] – installation of windows between wall panels, which increases the labor intensity of installation work and can potentially negatively affect the thermal insulation characteristics of the building.

[0012] The problem that the claimed invention is aimed at solving is the development of a technology that mitigates the shortcomings of analogues and makes it possible to manufacture three-layer wall panels with an opening that have strength, thermal insulation and decorative properties.

[0013] The technical result that appears when solving the problem is expressed as follows.

[0014] 1. Expanding the range of three-layer wall panels, fully prefabricated and with an opening, that do not require insulation, additional processing, or finishing of the outer surface, which:

[0015] – no shrinkage due to vibration compaction in factory conditions;

[0016] – improved structural interaction between concrete layers by means of spatial reinforcement cage;

[0017] – thermal insulation characteristics have been improved by reducing heat loss through cold bridges located along the contour of the formed through opening (window or door) and by placing an intermediate thermal insulation layer;

[0018] – the possibility of modification and increase in the number of design solutions within the framework of the proposed idea is provided.

[0019] 2. Expansion of the scope of application of finished products, since the claimed technology:

[0020] – can be used for the production of load-bearing walls for panel buildings;

[0021] – reduces the complexity and labor intensity of installation, thereby shortening the construction time and expanding the geography of construction due to the high degree of product readiness and the minimization of concrete work on the construction site.

[0022] The stated problem is solved in that the method for manufacturing a three-layer wall panel with an opening, including the step-by-step formation and reinforcement of layers in removable formwork, in particular a decorative layer made of concrete and formed using a removable matrix with a relief outer surface, a heat-insulating layer and a concrete layer, curing the resulting three-layer wall panel until the concrete gains strength and removing the finished product from the removable formwork is characterized in that a removable matrix with a relief outer surface is placed on the bottom of the removable formwork, a space divider is placed, made with the possibility of forming a through opening with a quarter, outside of which a reinforcing frame of the decorative layer is installed, which is rigidly connected to connecting elements oriented perpendicular to the layers, then the concrete mixture of the decorative layer is laid and compacted, the thickness of which is not less than 6.5 cm,then a heat-insulating layer of slab material is laid, directing the connecting elements through it, a reinforcing frame of the concrete layer is installed, which is rigidly connected to the connecting elements, after which the concrete mixture is laid and compacted.

[0023] In addition, polystyrene foam is used as a slab material.

[0024] In addition, mineral wool is used as a slab material.

[0025] A comparative analysis of the features of the claimed invention with the features of the prototype and analogues indicates that the claimed solution meets the criterion of “novelty”.

[0026] At the same time, the distinctive features of the invention formula provide a solution to the following functional problems.

[0027] The features “a removable matrix with a relief outer surface is placed on the bottom of the removable formwork, a space divider is placed” allow for a through opening to be precisely and hermetically formed inside the space divider and at the same time to form the outer surface of the decorative layer outside the said divider, which does not require subsequent processing or finishing.

[0028] A feature indicating that “the space divider is designed with the ability to form a through opening with a rebate” helps to reduce heat loss through cold bridges located along the contour of the formed through opening (window or door).

[0029] The features “a reinforcing frame of the decorative layer is installed outside the space divider” and “a reinforcing frame of the concrete layer is mounted” make it possible to increase the strength of the specified layers to withstand tensile loads.

[0030] Signs indicating that “the reinforcement cages of the decorative and concrete layers are rigidly connected to each other by means of connecting elements oriented perpendicular to the layers” ensure:

[0031] 1. formation of a spatial reinforcement frame, which helps to improve the structural interaction between the specified layers;

[0032] 2. More efficient perception of loads and displacements, which most often occur in the structure due to the following effects:

[0033] – lifting and transportation;

[0034] – the own weight of the concrete layer;

[0035] – deformation shrinkage;

[0036] – wind load;

[0037] – temperature deformation.

[0038] The feature “the thickness of the decorative layer is not less than 6.5 cm” describes the minimum thickness of the decorative layer, which, while ensuring the required strength, allows for the formation of a relief in the body of the concrete and thus preserves the original appearance of the outer surface of the finished product for a long time.

[0039] The features indicating that “the thermal insulation layer is made of a slab material,” as well as the features of the dependent claims of the formula, describe the type of finished thermal insulation layer material that has stable and known characteristics.

[0040] Signs indicating that after compaction of the concrete mixture of the decorative layer, “a heat-insulating layer is laid, directing the binding elements through it” allow the integration of a spatial reinforcement frame into the body of the heat-insulating layer.

[0041] Concrete mix compaction allows:

[0042] – to prevent shrinkage of the finished product during the operation of the building;

[0043] – minimize the formation of air voids;

[0044] Other distinctive features and advantages of the invention are clearly evident from the description given below for illustration and not as limiting, with reference to the accompanying drawings:

[0045] Fig. 1 shows removable formwork before laying the concrete mixture of the decorative layer;

[0046] Fig. 2 shows a variant of the outer surface of the decorative layer, imitating brickwork;

[0047] Fig. 3 shows a variant of the outer surface of the decorative layer, made with vertical recesses.

[0048] The drawings show removable formwork 1, decorative layer 2, removable matrix 3, space divider 4, reinforcement cage 5 of decorative layer 2, connecting elements 6, embedded parts 7.

[0049] The drawings additionally indicate G, the direction of acceleration due to gravity, and indicate a coordinate system in space with axes x, y, and z, the origin of which is located at the conditional intersection of the walls of removable formwork 1, wherein the x-axis is oriented along the width of the three-layer wall panel, the y-axis is oriented along the height of the three-layer wall panel, and the z-axis is perpendicular to the bottom of removable formwork 1.

[0050] Decorative layer 2 is made of concrete and its thickness is not less than 6.5 cm.

[0051] Removable matrix 3 is provided with a relief outer surface.

[0052] Space divider 4 is designed with the possibility of forming a through opening with a rebate.

[0053] Connecting Elements 6:

[0054] – oriented perpendicular to the layers (along the z-axis);

[0055] – pass through the thermal insulation layer (not shown in the drawings);

[0056] – rigidly connect the reinforcement frame 5 of the decorative layer 2 with the reinforcement frame of the concrete layer (not shown in the drawings).

[0057] The thermal insulation layer is made of a slab material, which may include, but is not limited to, expanded polystyrene or mineral wool.

[0058] The claimed method is carried out on standard equipment in several stages.

[0059] The design and operating characteristics of a three-layer wall panel are preliminarily determined using known methods, including:

[0060] type of finished product depending on the load-bearing capacity (load-bearing wall or self-supporting);

[0061] dimensions of the finished product, including the thickness of the layers;

[0062] location and dimensions of the through opening;

[0063] Material and characteristics of thermal insulation layer;

[0064] configuration, composition, dimensions and strength of the spatial reinforcement cage;

[0065] composition and characteristics of concrete mixture;

[0066] Method and parameters of concrete mixture compaction;

[0067] Curing time and design strength of three-layer wall panel, etc.

[0068] At the first stage, a volumetric removable formwork 1 is prepared, the surface of which is cleaned and lubricated with a known lubricant or fat phase.

[0069] In subsequent stages, layers are formed face down.

[0070] At the second stage, decorative layer 2 is formed.

[0071] For this purpose, at the bottom of the removable formwork 1 (oriented in the x and y axes) according to the design, a removable matrix 3 with a relief outer surface is installed, and a space divider 4 is placed.

[0072] In this case, the space divider 4 can rest on the removable matrix 3, as shown in Fig. 1, or pass through the corresponding through hole in the removable matrix 3 and rest on the bottom of the removable formwork 1.

[0073] The designs of space dividers 4 are standard and well-known, for example, it is possible to use removable dividing inserts, or permanent internal formwork, which is then included in a single work together with the surrounding material.

[0074] Next, on special supports (not indicated in the drawings, they help to organize the protective layer of concrete), a reinforcement frame 5 of the decorative layer 2 is placed, which is rigidly connected to the connecting elements 6.

[0075] The concrete mixture of the decorative layer 2, the thickness of which is not less than 6.5 cm, is placed into the removable formwork 1.

[0076] Then the concrete is compacted by vibration using a vibrating table or internal vibrators.

[0077] At the third stage, a heat-insulating layer is formed.

[0078] To do this, a heat-insulating layer (not shown in the drawings) is laid on top of the decorative layer 2, directing the connecting elements 6 through it.

[0079] At the fourth stage, the reinforcement frame of the concrete layer is installed (not shown in the drawings), which is rigidly connected to the connecting elements 6.

[0080] If necessary, install embedded parts 7.

[0081] At the fifth stage, a concrete layer is formed.

[0082] To do this, concrete mixture is placed in removable formwork 1 on top of the heat-insulating layer and then compacted by vibration.

[0083] At the sixth stage, the resulting three-layer wall panel is cured until it reaches at least 70% of its design strength.

[0084] At the seventh stage, the finished product is removed from the removable formwork 1.

[0085] There are two options for installing three-layer wall panels:

[0086] – with a locking connection of embedded parts followed by monolithic casting;

[0087] – with connection of embedded parts by welding.

[0088] The claimed invention is illustrated by the following examples.

[0089] Example 1 – load-bearing three-layer wall panel with the following characteristics:

[0090] 1. Overall dimensions – length 8 m, floor height 4 m;

[0091] type of through opening – window and door;

[0092] 2. decorative layer, the outer surface of which imitates brickwork (see Fig. 2):

[0093] material – heavy concrete B25 F200 W6;

[0094] thickness – 8 cm;

[0095] relief depth of the outer surface – 1.5 cm;

[0096] compacting concrete mix – using deep vibrators with a frequency range of 50-100 Hz and an amplitude of 0.3-0.7 mm;

[0097] 3. Thermal insulation layer:

[0098] material – rigid thermal insulation boards EPS grade 25;

[0099] thickness – 15 cm;

[0100] 4. Concrete layer:

[0101] material – heavy concrete B25 F200 W4;

[0102] thickness – 12 cm;

[0103] compacting concrete mix – using deep vibrators with a frequency range of 50-100 Hz and an amplitude of 0.3-0.7 mm.

[0104] Example 2 – Self-supporting three-layer wall panel with the following characteristics:

[0105] 1. Overall dimensions – length 8 m, floor height 4 m;

[0106] through opening type – window;

[0107] 2. decorative layer, the outer surface of which is made with vertical recesses (see Fig. 3):

[0108] material – heavy concrete B25 F200 W6;

[0109] thickness – 6.5 cm;

[0110] relief depth of the outer surface – 2 cm;

[0111] compacting concrete mix – on a vibrating table;

[0112] 3. Thermal insulation layer:

[0113] Material – mineral wool based on basalt fiber with a density of 120 kg / m3 3 ;

[0114] thickness – 15 cm;

[0115] 4. Concrete layer:

[0116] material – heavy concrete B25 F200 W4;

[0117] thickness – 8 cm;

[0118] compacting concrete mix – on a vibrating table.

[0119] Example 3 – Self-supporting three-layer wall panel with the following characteristics:

[0120] 1. Overall dimensions – length 8 m, floor height 4 m;

[0121] type of through opening – door;

[0122] 2. decorative layer, the outer surface of which imitates brickwork (see Fig. 2):

[0123] material – heavy concrete B25 F200 W6;

[0124] thickness – 8 cm;

[0125] relief depth of the outer surface – 1.5 cm;

[0126] compacting concrete mix – using deep vibrators with a frequency range of 50-100 Hz and an amplitude of 0.3-0.7 mm;

[0127] 3. Thermal insulation layer:

[0128] Material – mineral wool based on basalt fiber with a density of 100 kg / m3 3 ;

[0129] thickness – 15 cm;

[0130] 4. Concrete layer:

[0131] material – heavy concrete B25 F200 W4;

[0132] thickness – 8 cm;

[0133] compacting concrete mix – on a vibrating table.

Claims

1. A method for manufacturing a three-layer wall panel with an opening, which includes the step-by-step formation and reinforcement of layers in removable formwork, in particular a decorative layer made of concrete and formed using a removable matrix with a relief outer surface, a heat-insulating layer and a concrete layer, curing the resulting three-layer wall panel until the concrete gains strength and removing the finished product from the removable formwork, characterized in that a removable matrix is ​​placed on the bottom of the removable formwork, a space divider is placed, made with the possibility of forming a through opening with a quarter, outside of which a reinforcing frame of the decorative layer is installed, which is rigidly connected to connecting elements oriented perpendicular to the layers, then the concrete mixture of the decorative layer is laid and compacted, the thickness of which is at least 6.5 cm, then a heat-insulating layer of slab material is laid,by directing the connecting elements through it, they install a reinforcing frame of the concrete layer, which is rigidly connected to the connecting elements, after which the concrete mixture is laid and compacted.

2. The method according to paragraph 1, characterized in that expanded polystyrene is used as the plate material.

3. The method according to paragraph 1, characterized in that mineral wool is used as the slab material.

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