WO2006079355A1

WO2006079355A1 - Panel made from expanded plastic meterial for building slab construction, slab and construction method comprising such a panel

Info

Publication number: WO2006079355A1
Application number: PCT/EP2005/000831
Authority: WO
Inventors: Pier Giacomo Cappellano
Original assignee: DOMOPAN SpA
Current assignee: DOMOPAN SpA
Priority date: 2005-01-28
Filing date: 2005-01-28
Publication date: 2006-08-03
Anticipated expiration: 2007-07-28

Abstract

The panel (5) comprises a body (6) made from expanded plastic material, co-formed with a pair of metallic lattices (7), which is arranged with a length corresponding to the distance of the perimetric support beams, with two end portions (19) of the lattices (7) suitable for being connected with the armature of such beams. One side (17') of the panel (5) can be inclined by 45° with respect to the lattices (7), to be connected to a top beam of a hip roof slab. The panel (5) has a lower surface (9) equipped with grooves (24; 26, 27) suitable for housing ducts for building installations. Such a surface (9) can be equipped with a coating (38) made from hard plastic material. The slab (39) comprises a metallic mesh (43) for spreading loads, which is sunk in a layer (44) of concrete of the forming casting of the perimetric beams and of the rafters (42) between the adjacent panels (5) . The method for constructing the slab (39) includes the preparation steps of panels (5) with the end portions (19) of the lattices (7), the laying of the panels (5), the connection of such ends (19) with the irons of the armatures of the perimetric beams, and the casting of the concrete.

Description

PANEL MADE FROM EXPANDED PLASTIC MATERIAL FOR BUILDING SLAB CONSTRUCTION, SLAB AND CONSTRUCTION METHOD COMPRISING SUCH A PANEL

DESCRIPTION

The present invention refers to a panel made from expanded plastic material for building slab constructions , and to a slab incorporating at least such a panel .

In modern building technology, in order to lighten the weight of structures , it is becoming increasingly common to use prefabricated elements made from expanded plastic material . Panels made from expanded plastic material for the construction of building slabs are known in which the plastic material is reinforced with metallic elements with different shapes and sections , in order to give a structural rigidity, at least when it is being used to build .

In a known panel made from plastic material each reinforcing element is formed from a plate bent in a Z-shape , one wing of which is arranged at the lower surface of the panel , whereas the central core is equipped with holes both to improve the co- forming with plastic material and to lighten the weight of the structure . The panel is also co-formed with a metallic mesh, also having the function of easing the adherence with other materials of the slab, such as the concrete of the rafters and the finish or plaster of the lower surface . In particular, a central strip of such a metallic mesh is arranged adj acent to the lower surface of the panel and is welded onto the corresponding wing of the reinforcing element , whereas two side strips are arranged adj acent to two side surfaces of the panel , and partly sunk in two proj ecting wings of the panel .

This known panel has various drawbacks . Firstly, the reinforcing element , even if equipped with holes , is still relatively heavy, and complicated and expensive to build . Moreover, the metallic mesh partly sunk in the plastic material further complicates the manufacture of the panel . Such a mesh, having the aforementioned strips exposed, is subj ected to oxidation both before use and after it has been covered with concrete and plaster .

Finally, this known panel is manufactured continuously, for which reason it is supplied in segments of fixed length . In use such segments must therefore be arranged in sequence , and partially cut to achieve the length of the single span and to be connected to the perimetric beams . Therefore , the construction of the slab requires a lot of time and generates a lot of waste , for which reason it is very expensive . The purpose of the invention is that of making a panel made from expanded plastic material and a slab manufactured with such a panel , which are very reliable and low in cost , eliminating the drawbacks of the panels and slabs of the prior art .

According to the invention, this purpose is accomplished by a panel made from expanded plastic material for building slab constructions , comprising a body of said plastic material , Co-formed with at least one longitudinal reinforcing element , characterised in that said metallic element is shaped like a lattice consisting of at least two parallel longitudinal rods that are connected by a series of cross members .

In particular, the panel has a substantially rectangular section and comprises two lower wings to house a supporting rafter, and is characterised in that it comprises a pair of parallel reinforcing lattice .

For a slab comprising a series of such panels , the side wings of the panel form a recess for the casting of corresponding rafters , whereas the panels are of a length corresponding to the distance of two bearer beams and are equipped with end portions without plastic material , in which said lattices are sunk in the casting of said perimetric beams .

The method for manufacturing a slab through such panels comprises the following steps :

- firstly the panels are arranged by removing the plastic material from the end portions of the respective lattices , so that each panel is of a length corresponding to the distance of the perimetric beams of the slab ;

- after having arranged the armatures of the beams of said slab, said panels are laid next to each other, with said ends at said perimetric beams and said lattices are connected with irons of the armature of said beams ,- the armature of the rafters is arranged in the space between two adj acent panels ;

- a metallic mesh for spreading loads is arranged over said panels ; and - a concrete casting is carried out to form said beams , said rafters and an upper layer to sink said metallic mesh .

In order to better understand the invention, a preferred embodiment is described here , given as an example with the help of the attached drawings , in which :

Figure 1 is a perspective view of a panel made from expanded plastic material according to the invention;

Figure 2 is a perspective view of a reinforcing element of the panel of figure 1 ;

Figure 3 is a cross section of the panel of figure 1 ;

Figure 4 is a partial plan view of a variant of the panel of figure 1 ;

Figure 5 is a perspective view of a reinforcing element of another variant of the panel of figure 1 ;

Figure 6 is a cross section of the panel according to the variant of figure 5 ;

Figure 7 is a detail of a pair of adj acent panels ;

Figure 8 is a perspective view from below of a portion of the panel ;

Figure 9 is a perspective view of a variant of figure 8 ;

Figure 10 is a perspective view from above of a portion of slab according to the invention, with some parts removed .

As known, panel made from expanded plastic material for building have the enormous advantage of being very light and of being easy to transport . They have substantial heat insulation characteristics , for which reason they do not require other provisions or insulating materials , even for slabs in contact with the outside of the building . Moreover, they have substantial sound insulation characteristics , for which reason the inside of the building is very comfortable . With reference to figure 1 , a panel intended for building slab constructions , which is formed from a body 6 made from expanded plastic material , co- formed with one or more longitudinal metallic reinforcing elements 7 , is generically indicated with 5. In general , the body 6 of the panel 5 has a substantially rectangular section (also see figure 3 ) and comprises two lower wings 8 , which are used to house the usual reinforced concrete support rafter . Advantageously, the body 6 is co-formed with two longitudinal metallic reinforcing elements 7 , which are parallel to each other . The expanded material of the body 6 preferably consists of polystyrene expanded during the extrusion step for forming the panel 5. The body 6 has a lower surface 9 that extends to the two wings 8 and is intended to form the intrados of the slab, an upper surface 11 and two side surfaces 12 , each arranged between the corresponding wing 8 and the upper surface 11. The thickness of the panel 5 , i . e . the distance between the surfaces 9 and 11 , can vary within certain limits to define the thickness of the slab .

According to a characteristic of the invention, each metallic element 7 is in the form of a lattice consisting of at least two parallel longitudinal rods 13 connected together by a series of cross members 14 through welding points . The rods 13 and the cross members 14 are formed from corresponding profiles with a substantially circular section, for example made from steel , stainless steel or galvanized steel , preferably with a ribbed surface .

Advantageously, the cross members 14 of each lattice 7 ( figure 2 ) are formed from a single profile 15 bent in a zigzag, for example according to angles to the order of 50 ° -60 ° . The profile 15 can be welded onto the rods 13 of the lattice 7 , alternatively on the two sides , as indicated in figure 2. Alternatively, the profile 15 can also be welded onto the same side of the two rods 13. The two lattices 7 are therefore substantially flat and are arranged in the body 6 perpendicular to the lower and upper surfaces 9 , 11 ( figure 3 ) , with a rod 13 substantially flush with the lower surface 9.

According to a variant of the invention, in order to rigidify the panel 5 more , each lattice 7 ' ( figures 5 and 6) comprises , as well as two rods 13 ' that are analogous to the rods 13 of figure 2 , a third longitudinal rod 16 welded onto the cross members 14 ' , preferably in a position equally spaced from the two rods 13 ' . The cross members 14 ' are also formed from a single profile 15 ' bent in a zig-zag at the rods 13 ' , and are bent in an angle at the third rod 16 , so that the lattice 7 ' takes on an angled section at the third rod 16. According to the thickness of the body 6 , the angle of the lattice 7 ' at the rod 16 can vary within certain limits . Preferably, the rods 13 ' are welded with the profile 15 ' on the outer side of such an angle , whereas the rod 16 is welded to the inside of the angle . Each lattice 7 ' is arranged in the body 6 with the two rods 13 ' substantially- flush with the lower surface 9 of the body 6 and with the third rod 16 arranged above .

In both of the variants of lattices 7 , 7 ' described above , the rods 13 , 13 ' adj acent to the lower surface 9 of the body 6 can easily be used for the attachment of fastening devices of suspended bodies , for example lighting bodies , or for the attachment of a false ceiling .

The panel 5 is arranged to rest on two perimetric beams , for which reason it has a length corresponding to the distance between such beams . Normally, each panel 5 terminates with two end sides 17 ( figure 1) perpendicular to the side surfaces 12. At each of such sides 17 , the panel 5 is arranged with a layer 18 of the plastic material of the body 6 , having a thickness substantially equal to that of the wings 8 , for which reason the rods 13 , 13 ' flush with the surface 9 of the body remain totally incorporated in such a layer 18. In the case of a slab that is a shape other than rectangular, therefore with a side with a different angle to a right angle with respect to the laying direction of the panels 5 , the relative end side 17 is arranged according to such an angle . In particular, should the slab concern a support structure of a hip roof , the panels 5 that terminate on an inclined ridge are arranged with an end side 17 ' ( figure 4 ) and a corresponding layer 18 ' inclined by 45 ° in one direction or the other with respect to the rods 13 , 13 ' , 16 , i . e . with respect to the laying direction of the panels 5. The layer 18 , 18 ' of plastic material ensures that the intrados of the perimetric beams remains coated by the layer 18 , 18 ' of the panels 5 , avoiding the effect of condensation at such an intrados .

In any case , each panel 5 has two extreme portions 19 of each lattice 7 , 7 ' , which proj ect from the ends 17 , 17 ' of the panel 5 , i . e . they are substantially uncovered by the expanded plastic material . The extreme portions 19 of the lattices I ₁ T can be used for fastening with loading and unloading means 5 for transportation . The portions 19 are also suitable for being incorporated in the concrete cast of the perimetric beams , and can be suitably connected to the irons of the armature of such beams . Therefore , the panels 5 are arranged to size based upon the design requirements of the building, eliminating waste and enormously reducing the laying time of the slab .

In the case of particularly long panels 5 , each panel 5 can also be equipped with section-breaking portions 21 , in which the plastic material of the body 6 for a thickness such as to uncover an intermediate part 22 of the lattice 7 , 7 ' , leaving a layer 23 of the body 6 , analogous to the layer 18. The layer 23 thus also incorporates the rods 13 , 13 ' adj acent to the lower surface 9. The section-breaking portions 21 can be arranged at a predetermined distance , for example 2 metres , and can be incorporated in the concrete of corresponding intermediate beams . According to another characteristic of the invention, the lower surface 9 of each panel 5 is equipped with a series of grooves 24 , in which ducts can be housed for electric , telephone and television installations , and even ducts of water and air-conditioning installations . The grooves 24 can be entirely parallel to each other as in figure 8 , or else they can be formed from rectilinear segments 26 connected by curved sections 27 , especially in the case in which one wants to house air-conditioning coils 25 in them.

In both of the variants according to figures 3 and 6 , the upper surface 11 of the body 6 has a flat central portion 28 , equipped with two curved side fittings 29 (see also figure I ) ₁ which form two depressed edges 30 of the surface 11. The two side surfaces 12 of the body 6 each comprise at least one strip 31 , having a curved and hollow section, to allow the formation of rafters with rounded sides . In the case - of panels 5 of substantial thickness , the side surfaces 12 can also comprise another flat strip 32 perpendicular to the lower surface 9 , as indicated in figure 3.

The two wings 8 of the body 6 are equipped with two edges 33 and 34 ( figure 7 ) having matching profiles . Each edge 33 , 34 comprises a ribbing 35 , 36 substantially without sharp edges , so as to make it easier to bring them together . In order to ease the laying of the panels 5 , the upper surface 11 of the body 6 ( figures 3 , 4 and 6) is equipped with indication elements 37 of the laying position, arranged at a predetermined distance and each formed from a raised arrow . In particular, two lines of indication elements 37 can be foreseen .

The grooves 24 , 26 , 27 of the lower surface 9 of the panel 5 , in any case , also have the function of easing the fastening or adherence of a finishing coating 38 ( figure 9) , for example a chalk, lime or expanded perlite-based mortar . However, to improve such adherence an anti -shrink mesh made from plastic material , not indicated in the drawings , can be used, which is fixed by adherence in any known way, on the entire lower surface 9 of the panel 6. The finishing coating 38 can also be obtained in plasterboard, in which the sheets of plasterboard are fixed to the rafters of the slab and/or to the rods 13 , 13 ' of the lattices 7 , 7 ' of the panels 5. The finishing coating can also be obtained with a layer 40 (figure 8 ) of polyurethane resin, coating the surface 9 of the body 6 with a rigid synthesis polymer, at the time of its manufacture . The polymer gives the intrados a pleasant finish, for example for commercial or industrial buildings , and it can be of a colour selected from amongst a range of available colours . Moreover, the polymer gives the panel 5 an additional rigidity with respect to that achieved by the lattices 7 , 7 ' .

In addition, the other surfaces 11 and 12 of the panel 5 can also be coated with such a polymer, obtaining a protection of the panel 5 against possible local breaking before being laid, even greater strength of the panel 5 and great fire resistance . Since the outer surface of the polymer can be obtained rough and partially porous , the adherence of the concrete of the rafters and of the cement at the casting step of the slab, and of a possible finishing plaster of the ceiling, for example in civil buildings , is improved . In figure 10 a portion of a slab is illustrated, generically indicated with 39 , manufactured with panels 5 according to the invention . For such a purpose , in building yards the single panels 5 ( see also figures 1 and 4 ) arranged to size are laid with the ends 19 of the lattices 7 , 7 ' at the perimetric beams , and possibly at the top beam. The uncovered rod portions 13 and 16 are connected with the irons of the armature of such perimetric and top beams , and possibly with those of the armature of possible section-breaking beams . Moreover, in each space between the side surfaces 12 of two adj acent panels , the usual irons 41 of the corresponding rafters 42 are arranged . Thanks to the curved shape of the portion 31 of the surfaces 12 , a larger space is obtained for housing such an armature 41 , and therefore a greater thickness of iron-covering concrete is obtained . On the intrados of the slab 39 , before the casting of the concrete , a metallic mesh 43 for spreading loads , for example of the electrowelded type , can possibly be arranged . Finally, the casting of concrete is carried out , which, as well as the peripheral and section-breaking beams , forms the rafters 42 and an upper layer 44 , in which the metallic mesh 43 remains sunk . Therefore , the method for manufacturing a slab 39 through the panels 5 according to the invention comprises the following steps :

- firstly the panels 5 are arranged by removing the plastic material from the end portions 19 of the respective lattices 7 , 7 ' , so that each panel is of a length corresponding to the distance of the perimetric beams of the slab 39 ;

- after having arranged the armatures of the beams of the slab 39 , the panels 5 are laid next to each other, with the ends 19 at said perimetric beams and the lattices 7 , 7 ' are connected with irons of the armature of the beams ,-

- the armature 41 of a rafter 42 is arranged in each space between two adj acent panels 5 ;

- a metallic mesh 43 for spreading loads is arranged over the panels 5 ; and

- a concrete casting is carried out to form the beams , the rafters 42 and an upper layer 44 to sink the metallic mesh 43.

From that which has been seen above the advantages of the panels made from plastic material for slabs according to the invention with respect to known panels are clear . In particular, the lattices 7 , 7 ' and the body 6 without holes ease the manufacture of the panels 5. Moreover, the arrangement of the panels 5 of a length corresponding to the distance between the perimetric beams eases the laying of the panels 5. The cutting of the plastic material of the body 6 at the ends 19 of the lattices I ₁ T eases the relative loading and unloading for transportation for use . The grooves 24 on the lower surface 9 of the panels 5 ease the laying of possible ducts and the sticking of the subsequent finishing coating 38. Finally, the layer 40 of hard resin on the surfaces of the body 6 increases the rigidity of the panel 5 and eases the sticking of the subsequent plaster . It is intended that various modifications can be brought to the panel and to the slab described above without departing from the scope of the claims . For example , the lattices 7 , 7 ' can be equipped with cross-members 14 , 14 ' arranged individually and/or in a different way . An end side 17 , 17 ' of the panel 5 can also be inclined with respect to the lower and upper surfaces 9 , 11. Moreover, the body 6 of the panel 5 can be obtained with other light or expanded plastic materials .

Claims

1. Panel made from expanded plastic material for building slab constructions , comprising a body ( 6 ) of said plastic material , co- formed with at least one longitudinal reinforcing element ( 7 , 7 ' ) , characterised in that said metallic element is shaped like a lattice ( 7 , 7 ' ) consisting of at least two parallel longitudinal rods (13 , 13 ' ) that are connected by a series of cross members ( 14 , 14 ' ) .

2. Panel according to claim 1 , wherein said body ( 6 ) has a substantially rectangular section and comprises two lower wings (8 ) to house corresponding supporting rafters (42 ) , characterised in that it comprises a pair of parallel reinforcing lattices (7 , 7 ' ) .

3. Panel according to claim 1 or 2 , characterised in that said rods ( 13 , 13 ' ) and said cross members ( 14 , 14 ' ) are formed from corresponding profiles with a substantially circular section, the cross members ( 14 , 14 ' ) of each lattice (7 , 7 ' ) being formed from a profile ( 15 , 15 ' ) bent in a zigzag and welded onto said two rods ( 13 , 13 ' ) .

4. Panel according to claim 3 , characterised in that the cross members ( 14 ' ) of each lattice ( 7 ' ) are also welded onto a third longitudinal rod ( 16) equally spaced from said two rods ( 13 ' ) , said cross members ( 14 ' ) being bent at an angle at said third rod ( 16) .

5. Panel according to claim 4 , characterised in that said two rods ( 13 ' ) are arranged below and are welded onto said profile ( 15 ' ) bent at the outside by said angle , said third rod ( 16) being arranged above the inside of said angle .

6. Panel according to claim 2 and 5 , characterised in that it is arranged to rest on at least two perimetric beams and in that it has a length corresponding to the distance of said beams , each of said lattices (7 , 7 ' ) having two extreme portions ( 19 ) proj ecting from said body ( 6 ) and suitable for being incorporated in said beams .

7. Panel according to claim 6 , characterised in that said length is defined by two end sides ( 17 , 17 ' ) of said body ( 6 ) , at least one of said end sides ( 17 ' ) forming an angle different to a right angle with said rods ( 13 , 13 ' ) .

8. Panel according to claim 6 or 7 , characterised in that between said extreme portions ( 19) section-breaking portions

(21 ) are foreseen comprising intermediate parts (22 ) of said lattices ( 7 , 7 ' ) without said plastic material , said intermediate parts (22 ) being suitable for being incorporated in corresponding section-breaking beams .

9. Panel according to claim 8 , characterised in that at least one of said rods ( 13 , 13 ' ) is arranged at a lower surface of said body (6 ) , said body (6) comprising a layer ( 18 , 18 ' , 23 ) of said plastic material arranged at at least one of said extreme portions ( 19) and/or at said intermediate parts (22 ) and incorporating said rod ( 13 , 13 ' ) thus arranged .

10. Panel according to one of claims 2 to 9 , characterised in that it comprises a lower surface ( 9) equipped with grooves (24 ; 26 , 27) suitable for easing the sticking with a finishing material .

11. Panel according to claim 10 , characterised in that said grooves (24 ; 26 , 27) are arranged at least in part substantially parallel to said rods ( 13 , 13 ' ) and are suitable for housing ducts for an electric or water installation, or air-conditioning coils (25 ) .

12. Panel according to one of claims 10 or 11 , wherein said wings (8) are equipped with two edges (33 , 34) having matching profiles , characterised in that each of said edges

( 33 , 34 ) comprises a ribbing (35 , 36 ) without sharp edges .

13. Panel according to claim 12 , characterised in that it comprises an upper surface ( 11) equipped with indicator elements (37 ) of the laying directions of said panel (5 ) .

14. Panel according to claim 13 , characterised in that said upper surface ( 11 ) has a flat central portion (28 ) and two curved side fittings (29 ) connected to two depressed edges (30 ) , said indicator elements (37 ) being raised on said central portion (28 ) .

15. Panel according to claim 13 or 14 , characterised in that it comprises two side surfaces ( 12 ) each having at least one strip (31 ) with a hollow curved section, to allow the formation of rounded rafters (42 ) .

16. Panel according to one of claims 10 to 15 , characterised in that at least one of the surfaces ( 9 , 11 , 12 ) of said body ( 6 ) is equipped with a coating or finishing layer (40 ) made from hard plastic material .

17. Building slab comprising a series of panels (5 ) according to one of claims 2 to 16 , wherein said side wings ( 8 ) form a recess for the casting of corresponding rafters (42 ) , characterised in that said panels (5) have a length corresponding to the distance of the two perimetric beams and are equipped with end portions (19) of said lattices (7 , 7 ' ) without plastic material and sunk in the casting of said perimetric beams .

18. Slab according to claim 17 , for supporting a hip roof cover, characterised in that an end side ( 18) of each panel is inclined at 45 ° with respect to said rods ( 13 , 13 ' ) to allow the formation of an inclined top of said roof .

19. Slab according to claim 17 or 18 , characterised in that a surface (9) of said panels (5) is equipped with grooves (24 ; 26 , 27) in which ducts for installations of the building are housed .

20. Slab according to one of claims 17 to 19 , characterised in that said surface (9) equipped with grooves (24 ; 26 , 27) forms the intrados of the slab, an upper surface ( 11) of said panels ( 5) being coated in use by a metallic mesh (43 ) suitable for being sunk in a layer of concrete (44) of the slab .

21. Slab according to claim 19 or 20 , characterised in that said surface (9) equipped with grooves (24 ; 26 , 27) is coated with a layer of plaster (38) .

22. Method for manufacturing a slab (39) according to one of claims 17 to 21 , characterised in that it comprises the following steps :

- firstly the panels (5) are arranged, removing the plastic material from two end portions ( 19) of the respective lattices ( 7 , T ) , so that each panel (5) is of a length corresponding to the distance of the perimetric beams of the slab ( 39) ;

- after having arranged the armatures of the beams of the slab (39 ) , said panels (5) are laid with said ends ( 19 ) at said perimetric beams and said lattices (7 , T ) are connected with the irons of the armature of said perimetric beams ;

- an armature (41) of a rafter (42 ) is arranged in a space between two adj acent panels ( 5 ) ;

- a metallic mesh (43 ) for spreading loads is arranged over said panels ( 5 ) ; and

- a concrete casting is carried out to form said perimetric beams , said rafters (42 ) and an upper layer (44 ) to sink said metallic mesh (43 ) .

23. Method according to claim 22 , characterised in that it comprises the following other steps : installation ducts are arranged in a series of grooves (24 ; 26 , 27 ) of a lower surface ( 9 ) of said panels ( 5) , and a finishing coating (38 ) is applied onto said lower surface ( 9) .