Integral prefabricated panels for the construction of floors and roofs for buildings in general

Abstract

The present invention relates to a prefabricated panel for the construction of floors and roofs in buildings, which comprises a central element formed from a folded metal sheet (2), wherein said sheet (2) is folded semi-hexagonally along the panel (1) and on itself at the ends. The prefabricated panel also comprises a plurality of round structural steel bars (3) in the form of a mesh arranged at the corners of the folds of the sheet (2); a polished concrete finish (4) for the upper face (6); a coating (5) for the lower face (7); and thermal and acoustic insulation elements between the sheet (2) and the lower face (7).

Description

[0001] INTEGRAL PREFABRICATED PANELS FOR THE CONSTRUCTION OF SLABS AND ROOFS FOR BUILDINGS IN GENERAL

[0002] DESCRIPTION

[0003] OBJECT OF THE INVENTION

[0004] The present invention discloses a prefabricated panel that can be adapted to specific needs, depending on the project to be executed. The panels that form part of this invention are composed of a resistant central element formed from a folded metal sheet (steel, lacquered or baked iron, etc.). This sheet is folded in a semi-hexagonal shape along the panel. This element is reinforced with the placement of steel rounds as a mesh for the subsequent on-site pouring of dosed concrete according to the specifications of the project management. The interior is coated with a layer of polyurethane with an outer layer of galvanized steel.

[0005] BACKGROUND OF THE INVENTION

[0006] One of the most important structural components in construction is the floor, as it supports existing loads and transmits them to the ground through beams, pillars, walls, and foundations. Considering various variables, there are different types of floor.

[0007] One-way slabs require supports at both ends to transmit the loads from the slab through the slab to the pillars and from there to the building's foundation. Joist and vault slabs are the most widely used type of slab in our country, transmitting the load to the beams at opposite ends. Cast-in-place joist slabs are a variant of the former and can be assembled at the time of slab construction, which is an advantage when working on more complex structures.

[0008] Two-way slabs do not require end support, as they transmit loads in two main, generally orthogonal, directions, creating a framework or grid. For this reason, they are also called waffle slabs. The elements of this framework are called caissons. Panel-based building construction is currently well-known, where panels can be used to form the walls, ceiling, or floor of a building to be constructed and can be provided with different materials and structures to suit their purpose.

[0009] In the state of the art, there are forging panels, as described in Spanish utility model U9101237, which refers to a forging panel used for the manufacture of homes in which prefabricated panels are used that cooperate together with the panel of the invention in the construction of prefabricated houses. According to the invention, the quadrangular panel is made up of parallel "C" structural profiles facing each other, since the parallel branches of each "C" face the parallel branches of the other profile. The vertical branches of the structural profiles are joined by a horizontal, quadrangular, frame-shaped structured panel that has stiffening rounds on one of its sides, on which a perforated and ribbed metal sheet is arranged, on which the compression layer of the forging is formed, once projected.

[0010] The Spanish utility model U200401362 reveals a panel for forming formwork, of the type intended to be intercoupled coplanarly with others to form a flat and continuous formwork surface, for which purpose said panels have a rectangular outline, where said panel is constituted by means of a single-piece body in which a plate of reduced thickness is defined, in correspondence with what must be its upper face in working condition, plate from which a perimeter partition and a plurality of interior partitions determining a reticular structure emerge inferiorly and vertically, the height of said partitions determining the thickness of the panel, said partitions also configuring a plurality of alveoli, open internally, with the special particularity that within said alveoli crossed partitions are established, in a diagonal arrangement,which also emerge from the base plate but whose height is considerably lower than that of the previously mentioned partitions.

[0011] Utility model U201530266 discloses a panel comprising a metal structural frame incorporating an upper profile, a lower profile and two side profiles, which are arranged to frame a central body comprising an insulating layer intended to configure the inner face of the panel and another opposing layer of reinforced concrete intended to configure the outer face of the panel, such that the assembled panel offers the outer face configured by the reinforced concrete layer to the outside environment, and the inner face, configured by the insulating layer, towards the interior of the building, then providing a lining on the inside of the building that hides this inner face and gives a finish to the wall. The panel ideally includes metal crossbars on its interior that connect opposite profiles, which are embedded in the concrete layer, cooperating in its reinforcement, achieving a perfect union with the concrete.The panel described above can be concreted on-site. The frame, reinforcements, and insulation layer are pre-assembled in the factory and transported to the site at minimal cost. Once on site, the pre-assembled assembly is laid down with the insulation layer facing down, and the reinforced concrete layer, which will encase the reinforcements, is poured and poured using a vibrating screed. Once the panel has set, it can be handled with a crane, and all on-site operations can be performed by just two people, offering great productivity and cost savings.

[0012] One of the problems with this technique is that current prefabricated panels cannot be adapted to the specific needs of each situation, limiting their application. Therefore, the builder on the job site must make unforeseen changes, costing them time and personnel.

[0013] The present invention is based on a "base" panel adapted for installation as a horizontal support base in prefabricated buildings. The dimensions of each panel can be adapted to the needs of each project. The panels that form part of this invention are composed of a strong central element formed from a folded metal sheet (steel, lacquered or baked iron, etc.). This sheet is folded in a semi-hexagonal shape along the panel and on itself at the ends, generating a larger resistant section at the ends of the panels. Steel rounds arranged in a grid are attached to this sheet to reinforce the concrete that will be poured onto the panel after assembly to create a compression layer that gives it the final strength for use as a floor.

[0014] The purpose of the panel of the invention is to facilitate the horizontal construction of all types of buildings, since its dynamic nature allows for the simplification of the installation, connection, and completion of the panels on-site. The placement of the panel after assembly must be complemented by the pouring and setting of concrete, dosed according to the length chosen for the panel by the project management.

[0015] DESCRIPTION OF THE DRAWINGS To complement the description being made and in order to help better understand the characteristics of the invention, in accordance with a preferred example of its practical implementation, a set of drawings is attached as an integral part of said description, in which the following has been represented for illustrative and non-limiting purposes:

[0016] FIG 1a.- General view of a base panel (1).

[0017] FIG 1b.- Horizontal cross section of a base panel (1).

[0018] FIG 2.- View of the longitudinal horizontal section of a base panel (1).

[0019] FIG 3.- View of the horizontal section of the panel (1), showing the elements that compose it, a folded metal sheet (2), which can be made of steel, lacquered iron, or baked, where said sheet (2) is folded in a semi-hexagonal shape along the panel (1). A plurality of structural steel rounds (3) arranged in the corners of the folds of the sheet (2) in a vertical and horizontal arrangement in the form of a mesh, which improves the resistance to bending and compression of the panel (1). A concrete filling (4) for the upper face (6) and a coating (5) for the outer face (7).

[0020] PREFERRED EMBODIMENT OF THE INVENTION

[0021] The present invention reveals a dynamic panel (1) which has the advantage of adapting to the specific needs of each project, being able to incorporate the electrical energy or water installations on its lower face to the steel core, in addition, it allows to be coupled to other panels (1) horizontally by means of the execution after the assembly of a concrete compression layer. The object of the panel of the invention is to facilitate the construction of buildings of all types, since due to its dynamic nature it allows the simplification of the installation, connection and completion of the panels on site.

[0022] The integrated horizontal prefabricated panel (1) comprises a central resistant element formed from a folded metal sheet (2), which can be made of steel, lacquered iron, or baked, where said sheet (2) is folded in a semi-hexagonal shape along the panel (1); a plurality of structural steel rounds (3) arranged in the corners of the folds of the sheet (2) in a vertical and horizontal arrangement in the form of a mesh, which allows improving the resistance to bending and compression of the panel (1) in particular, to use the maximum length of the panel, raise more floors or for areas requiring reinforcements due to earthquakes, according to the needs of each design or project.

[0023] The external part of the panel (1) has a concrete filling (4) for the upper face (6) and a coating (5) for the outer face (7), in addition, between the metal sheet (2) and the inner face (6) thermal and acoustic insulation elements are placed, as well as between the sheet (2) and the outer face (7), in such a way that it maintains soundproofing and thermal insulation in the building.

[0024] The union between two panels (1) is carried out by means of the execution of a concrete compression layer, joining all the horizontal panels that make up the slab or the inclined roof by means of its setting.

[0025] The union of the panels (1) with the roof or upper slab is carried out through a perimeter strap (10) consisting of a quadrangular metal profile to which the roof structure allows to be screwed or welded, according to the determinations of each project.

[0026] The materials used for thermal and acoustic insulation are selected from PVC, expanded polystyrene, rock wool, materials derived from natural or recycled elements, or a combination of these. Different materials can be placed on each side to achieve the properties required for each location or project.

[0027] The final coating or finish (7) (plaster mortar, plaster, single-layer, etc.) is placed over the insulating materials on the lower face. The upper face is formed by a concrete compression layer with a polished finish and optional flooring. A mesh is placed between the insulating materials and the finish to improve the adhesion and durability of the finishes.

[0028] The panel (1) of the invention allows the incorporation of installations for electrical energy or water in the lower layer of the building, where the installations will generally run under the roof or slab and will be connected to the taps or demand points by means of downpipes coupled in the existing gaps in the folded sheet metal. In the event that the distribution of installations (generally water and electrical energy) along several coupled panels (1) is necessary, the panels (1) will have holes in the oblique parts that allow the horizontal passage of the installations between the panels (1). The application of the panels (1) described has the objective of facilitating the construction of floors and roofs of buildings (generally homes, but not exclusively).To achieve this goal, the panels were designed with the aim of simplifying the installation, connection, and completion of the panels on-site.

Claims

CLAIMS 1- Prefabricated panels for the construction of floors and roofs in buildings, characterized in that it comprises a central element formed from a folded metal sheet (2), where said sheet (2) is folded in a semi-hexagonal shape along the panel (1) and on itself at the ends; a plurality of structural steel rounds (3) in the form of a mesh arranged at the corners of the folds of the sheet (2); a polished concrete finish (4) for the upper face (6); a coating (5) for the lower face (7); and thermal and acoustic insulation elements between the sheet (2) and the lower face (7). 2- Prefabricated panels for the construction of floors and roofs in buildings according to claim 1, characterized in that the materials used for thermal and acoustic insulation are selected from PVC, expanded polystyrene, rock wool, materials from natural or recycled elements or a combination thereof. 3- Prefabricated panels for the construction of floors and roofs in buildings according to claim 1, characterized in that the final coating or finish is placed on the insulating materials, both for the upper face (6) and for the lower face (7). 4- Prefabricated panels for the construction of floors and roofs in buildings according to claim 1, characterized in that a mesh is placed between the insulating materials and the finish. 5- Prefabricated panels for the construction of floors and roofs in buildings according to claim 1, characterized in that the panel (1) allows the incorporation of installations for electrical energy or water which will generally run under the roof or floor and will be connected to the taps or places of demand by means of downpipes coupled in the existing gaps in the folded sheet. 6- Prefabricated panels for the construction of floors and roofs in buildings according to claim 1, characterized in that when 2 or more panels (1) are coupled, they have holes in the oblique parts that allow the horizontal passage of water and electrical energy installations between said panels (1).

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