WO2013061344A1

WO2013061344A1 - Prefabricated panel

Info

Publication number: WO2013061344A1
Application number: PCT/IT2011/000363
Authority: WO
Inventors: Francesco Bodini
Original assignee: PENSERINI COSTRUZIONI Srl
Current assignee: PENSERINI COSTRUZIONI Srl
Priority date: 2011-10-28
Filing date: 2011-10-28
Publication date: 2013-05-02
Anticipated expiration: 2014-04-28

Abstract

The present invention relates to prefabricated panels for the manufacturing of prefabricated-type structures, and to a process of manufacturing such panels. The prefabricated structure according to the present invention comprises panels, fabricated by casting concrete into formworks, having metal elements anchored thereto which make the assembling of the raw structure extremely quick and safe.

Description

PREFABRICATED PANEL

DESCRIPTION

The present invention relates to prefabricated panels for the manufacturing of prefabricated-type structures, and to a process of manufacturing such panels. History of the Technology

The methodology of building construction by prefabrication is well known in the current state of the art. In such methodology the structural elements of the construction, in most cases made of concrete, are individually produced on site or in a factory and then subsequently transported on the building site and assembled thereat.

Description of the Prior Art

In general, the assembling of prefabricated panels placed on site envisages the casting of binder materials, like e.g. cement grout, to ensure interconnection between the panels and the bed of the underlying foundations, in order to provide the construction with the required stability.

Drawbacks of the Prior Art

The above-described technique entails the remarkable drawback of having just to perform grout casting on the structure. Such an operation in fact proves remarkably awkward, as the grout, or other binder materials, have to be provided in suitable mixers. On top of that, there is the fact that binder casting operations entail an unavoidable increase of the time required to carry out the assembling operations, as well as an increase of associated costs.

Objects of the Invention

Object of the present invention is to solve the above-mentioned drawbacks by providing a panel as substantially defined in claim 1 , a floor panel as substantially defined in claim 9 and a prefabricated structure as substantially defined in the scope of claim 21.

A further object of the present invention is to provide a production process of a panel and of a floor panel as substantially defined respectively in claims 12 and 15. Further features of the invention are defined in the corresponding dependent claims thereof.

Advantages of the Invention

The present invention, by overcoming the mentioned problems of the known art, entails several evident advantages.

The prefabricated structure according to the present invention provides, as will be made evident by a detailed description of a preferred embodiment thereof, the fabrication of panels, by casting concrete into formworks, having metal elements anchored thereto which make the assembling of the raw structure extremely quick and safe.

By way of example and without limitative purposes, when the prefabricated structure subject of the present invention comprises eight apartments, it could be easily assembled by the operating sequence of the assembling of sixty prefabricated panels, in which it is divided.

Advantageously, the various panels are numbered in increasing order; when in place, said panels form resistant and self-constraining cores, in order to make assembling operations quicker. Since the assembling of a panel according to the present invention by a team of three/four operators requires about ten minutes, six panels/hour could be assembled, and therefore the entire building in ten hours, therefore forming the raw structure of no less than eight apartments.

Finally, according to an aspect of the invention, the prefabricated structure is suitable for receiving thermal and acoustic shields, both with plastic inserts and with internal and external plating (polystyrene and/or rock wool), remarkably improving the thermoacoustic features of the constructions.

Brief Description of the Drawings

Yet further advantages, as well as the features and operation steps of the present invention will be made evident by the following detailed description of a preferred embodiment thereof, given by way of example and not for limitative purposes. Reference will be made to the figures of the annexed drawings, wherein:

Figures 1 , 3 and 5 show perspective views of panels accordin g to the present invention, laid in place;

Figures 2A-2C show a detail of Figure 1 ;

Figures 4A-4C show a detail of Figure 3;

Figures 6A-6B show, in a side view, a detail of Figure 5;

Figure 7 shows, in several views, details of Figure 6.

Detailed Description of the Drawings

Referring to Figure 1A, a prefabricated panel 1 according to a preferred embodiment of the present invention is shown in a perspective view. The panel 1 , preferably made of concrete, has front walls 11 and 12, opposite to each other, and two side walls 13 and 14, them also opposite to each other. In particular, in the preferred embodiment described by way of example and not for limitative purposes, the panel 1 has a parallelepiped shape. It will be appreciated that other shapes of panel could be used in an entirely equivalent manner, like, e.g. panels having a C- like or an L-like shape. For this purpose, it is generally defined a side wall of the panel, the wall apt to be connected to a side wall of a subsequent panel, whereas the front walls are those together defining the perimeter of the prefabricated structure.

Always referring to Figure 1A, the panel 1 is laid in place along a vertical direction. According to the present invention, the panel 1 comprises a bottom recess 2 obtained on the front wall 1 1 at a bottom edge thereof. Into the bottom recess 2 it is obtained first connecting means 20 for connecting with a foundation bed, denoted in the figure by reference number 100. The first connecting means 20 comprises a first beam 21 of substantially L-shaped section. As can be seen in the Figure, the beam 21 is anchored to the panel by a pair of forks 22, each connected at a respective end of the beam 21 and buried internally to the panel 1. The selection of anchors by fork-shaped rods proved extremely advantageous, as said shape results to be non-deformable when buried into the concrete of the panel. Therefore, beam sliding is prevented, thereby ensuring structure stability. In fact, at the bottom of the panel the stresses are greater than those recorded at the top, therefore greater resistance and static safety are required.

In the preferred embodiment described herein, the bottom recesses obtained in the panel are two, arranged according to the geometry indicated. It will be appreciated that the number of bottom recesses provided will depend on the rigidity with which the structure is to be provided; as a lower limit, only one recess could be provided, preferably placed onto the center line of the panel.

Referring to Figure 1 B, the first beam 21 has a portion apt to be arranged on the foundation bed, and connected thereat. For this purpose, said portion has a through bore, by which it is anchored to the bed 100 by means of, e.g., a screw anchor or other equivalent systems known in the art. Therefore, it will be appreciated how the presence of the bottom recess be necessary in order to allow the maneuver of connecting the panel to the bed, as it enables to manually access the beam portion arranged on the foundation bed so as to operate just the connection.

Referring to Figures 2A, 2B and 2C it is depicted the first beam 21 , having the through bore now visible and denoted by reference number 23, respectively in side, top and front views thereof.

Referring to next Figure 3, again the panel 1 is shown. For simplicity's sake, the bottom recesses of which at Figure 1 are not shown in Figure 3.

The panel 1 further comprises a top recess 3, obtained on the side wall 14, into which it is positioned a second connecting means 30 with a subsequent panel, the latter denoted in Figure by reference 1 '. Referring to Figure 3B, showing an enlargement of the panel 1 in the neighborhood of the top recess, the second connecting means 30 comprises a substantially L-shaped second beam 31 comprising a portion arranged substantially on a plane defined by the side wall 14. Said portion has a through slot. Moreover, the second beam 31 is anchored to the panel 1 by a pair of rectilinear rods 32, connected each at a respective end of the second beam, and buried internally to the panel.

In the example in figure, the panel 1 has a top recess on each of its side walls. It will be appreciated that there could be panels even with a single top recess; this if, by virtue of the structure to be manufactured, the panel should be connected to a single subsequent panel, therefore at a single vertical wall.

Referring to Figures 4A-4C, the second L-shaped beam 31 is shown, respectively in a side, a front and a top view, anchored to the panel (not depicted) by the two rectilinear rods 32. In particular, Figure AC shows the beam portion arranged along the plane of the side wall, portion which comprises a through slot, denoted in figure by reference number 33. The subsequent panel (not depicted) in turn has a top recess into which a respective second L-shaped beam is obtained, having a portion arranged substantially along the plane of the side wall and a through slot. The two slots are then placed the one in front of the other, and preferably have tilts opposite to each other, so as to define an intersection area that is then intercepted, e.g., by a bolt fitted between the two slots and locked at its end by a bushing. Thus, the two beams and therefore the panels are connected. Such a top connection between two panels, which in the preferred embodiment shown herein enables also to adjust the distance between the two by acting on the bolt reachable through the area for maneuvering made accessible to the operator by the same recess, is necessary; that is so since even ever-present small shifting motions between subsequent panels, which are recorded at the bottom, are remarkably amplified at the top of the panels.

For the bottom and top recesses L-shaped beams have been selected, as such a shape is self-stiffening. In other words, with said configuration is possible to distribute load on the concrete more evenly than with other beam types, like e.g. the flat one. A flat beam would require a large thickness, and therefore drilling would become extremely complex. Hence, thus the costs of machining, which otherwise would have to be carried out by drill and cutter, are reduced. Finally, L-shaped beams are easily available everywhere.

Referring to Figure 5, panel 1 is shown, from which for simplicity's sake bottom and top recesses are omitted. With reference to said figure, the panel 1 subject of the present invention further comprises a face recess 4, in the example in figure obtained on the front wall 11. The face recess 4 has a bearing plane 41 apt to support a floor panel (not depicted), as will be detailed hereinafter.

Preferably, referring to the detail of Figure 5B, along the bearing plane 41 a beam having a substantially U-shaped section is arranged, anchored to the panel 1 by, by way of example, a pair of cramps 412, them also buried into the panel.

The number of face recesses obtained on the panel 1 could vary and will depend on the specific structure that is to be manufactured. For instance, the envisaged number of face recesses will be associated, e.g., to the weight of the floor panel that will have to be supported.

Referring now to next Figure 6A, the panel 1 is shown in a side view, in which are evident the face recess 4 and the bearing plane 41 on which the U- shaped beam 411 is arranged, anchored to the panel 1 by the cramps 412. By means of the bearing plane 41 the panel 1 supports a floor panel, now depicted and denoted by reference number 50.

The floor panel 10, it also preferably made of concrete, in turn has a top wall 51 and a bottom wall 52, opposite to each other, and is laid in place along a horizontal direction, transversally with respect to the panel 1. In the example in figure the face recess 4 is obtained centrally on the panel 1 , since in the preferred embodiment the panel 1 has a height H such as to cover two floors of the structure, and therefore the bottom wall 52 of the floor panel will form the ceiling of the lower floor, whereas the top wall 51 will form the floor of the top wall.

Analogously to the panel 1 , also the floor panel 50 has a first side recess 53, obtained onto the bottom wall 52 at a first side edge thereof. Likewise, the floor panel 50 comprises a second recess (not depicted), obtained on the bottom wall 52 at a second side edge thereof, opposite to the first one. At said recess, the floor panel 50 is supported by a panel (not depicted) opposite to the panel 1 in figure. Into the recess 53 it is preferably positioned a respective beam 531 , having an U- shaped section, anchored to the floor panel by a pair of cramps 54 (of which only one is visible in the figure).

Always referring to Figure 6A, the panel 1 supports the floor panel 50 by interposition of a connecting element 60 comprising a substantially S-shaped plate, having a central rectilinear region 61 and two hook-like curved portions 62 and 63 opposed to each other.

The portion 62 rests on the beam 411 , whereas the portion 63 supports the floor panel 50 by resting on the beam 531. The arrangement in figure is repeated in a wholly equivalent manner at the second recess of the floor panel (not depicted). Preferably, the element 60 comprises a threaded bushing 64 connected, e.g. by welding or other known techniques, along an external surface of the hook-like curved portion 62 so as to be aligned with the rectilinear central region 61.

Thus, by fitting a threaded bolt into the recess 4 and in particular into the bushing 64, it is possible to adjust the height of the floor panel 50 by setting the bolt in rotation, so that the two threadings by cooperating with each other produce a sliding along the vertical direction of the connecting element 60, and therefore of the panel 50, to the desired height. Therefore the face recess 4, besides allowing interposition of the connecting element 60, allows also adjustment of the height thereof, as it is configured so as to make available an operator-accessible space for maneuvering.

Referring to Figure 6B, it is depicted the panel 1 when in it the recess 4, as described above, and a recess 4' contiguous to the recess 4 are obtained. Such an embodiment is needed in case the pair of recesses thus arranged be required for the supporting of two floor panels resting on opposite front walls of the same panel. Therefore, the pair of recesses 4, 4' is such as to form on the panel a through opening.

Referring to Figures 7A, 7B and 7C, the above-described connecting element 6 is depicted respectively in the side, front and plan views.

Figure 7D shows the bolt for adjustment of the above-mentioned floor panel.

Figure 7E shows instead the detail of the U beam placed in the bearing plane of the face recess.

The above-described panel 1 is manufactured by the production process described hereinafter.

The panel 1 for prefabricated structure is fabricated by casting concrete into a formwork. Prior to the carrying out of the casting, the above-described beams are introduced into the formwork, in particular the L-shaped beams for the bottom and top recesses, and the U-shaped beams for the face recesses.

It will be appreciated that the number of beams provided and their position on the panel will depend on the specific design of the prefabricated structure. Each beam is made integral, e.g. by gluing, to a respective insert of extractable material, which insert is introduced into the formwork prior to the casting in order to form a respective recess into the panel.

In case no U-shaped beam is used for the bearing plane, an insert such as to form the face recess will be positioned into the panel.

Upon carrying out the casting of concrete, and subsequently to the material setting stage, inserts are removed so as to form the recesses having thereinside the connecting means for structure assembling, as described in detail above.

Preferably, such inserts are made of polystyrene, so as to be easily removed by burning after concrete has set.

Alternatively, to make the inserts, by way of example foamed materials or recycled rubber can be used.

The process described above applies likewise also for the production of the floor panel, therefore a detailed description of said process will be omitted.

As to the floor panel, besides the polystyrene inserts for the forming of the side recesses, also force linkages are introduced to enable crane hoisting, in order to be able to position it in place on the connecting elements.

Moreover, upon manufacturing the prefabricated structure, having connected panels to each other by the top recesses, said panels being anchored to the foundation bed by the bottom recesses and connected to the floor panels by the face recesses, the recesses may be preferably filled with a grout casting, so as to block and stabilize the prefabricated structure thus formed.

Finally, it will be appreciated that the prefabricated structure, owing to its modular nature in which the modules are just comprised of the prefabricated panels described in detail above, could also be provided as an assembly kit.

The present invention has been hereto described with reference to a preferred embodiment thereof. It is understood that other embodiments might exist, all falling within the concept of the same invention, and all comprised within the protective scope of the claims reported hereinafter.

Claims

1. A panel (1 ) for prefabricated structure, having two front walls (11 , 12) opposite to each other and two side walls (13, 14), arranged, when in place, along a vertical direction, comprising:

· at least one bottom recess (2) obtained on said front wall (11) at a bottom edge thereof, into which it is positioned first connecting means (20) for connecting to a foundation bed (100);

• at least one top recess (3) obtained on at least one of said side walls (14), into which it is positioned second connecting means (30) for connecting with a subsequent panel (1 ');

• at least one face recess (4) obtained on at least one of said front walls (1 1), said face recess (4) having an internal bearing plane (41) apt to support a floor panel (50).

2. The panel (1 ) according to the preceding claim, wherein said first connecting means (20) comprises a first beam (21 ) of substantially L-shaped section, anchored to the panel (1 ) and having a portion apt to be arranged on the foundation bed (100), said portion having a through bore (23).

3. The panel (1) according to the preceding claim, wherein said first L-shaped beam (21 ) is anchored to the panel (1 ) by a pair of forks (22), each connected to a respective end of said first beam (21 ), said pair of forks (22) being buried internally to the panel (1).

4. The panel (1 ) according to any one of the preceding claims, wherein said second connecting means (30) comprises a substantially L-shaped second beam (31) anchored to the panel (1) and comprising a portion arranged substantially along a plane defined by the side wall (14), said portion having a through slot (33).

5. The panel (1 ) according to the preceding claim, wherein said second beam (31) is anchored to the panel (1) by a pair of rectilinear rods (32), each connected to a respective end of said second profile (31), said pair of rectilinear rods (32) being buried internally to the panel (1).

6. The panel (1 ) according to any one of the preceding claims, wherein along said bearing plane (41 ) a beam (411 ) having a substantially U-shaped section is arranged, said beam (41 1 ) being anchored to the panel (1).

7. The panel (1) according to any one of the preceding claims, comprising a pair of face recesses (4, 4'), each recess being obtained on a respective front wall of the panel (1 1 , 2) and in positions contiguous to each other, so as to form on the panel a through opening.

8. The panel (1) according to any one of the preceding claims, made of concrete.

9. A floor panel (50) for prefabricated structure, having a top wall (51) and a bottom wall (52), opposite to each other, arranged in place along a horizontal direction, comprising:

• a first side recess (53), obtained on said bottom wall (52) at a first side edge thereof;

• a second side recess, obtained on said bottom wall (52) at a second side edge, opposite to said first edge.

10. The floor panel (50) according to the preceding claim, wherein into each of said first and second recess a respective beam having a substantially U-shaped section is arranged, anchored to the floor panel (50).

11. The floor panel (50) according to claims 9 or 10, made of concrete.

12. A production process of a panel ( 1) for prefabricated structure by casting concrete into a formwork, the panel (1) having two front walls (11 , 12) opposite to each other e due side walls (13, 14), the process comprising the steps of:

· positioning into the formwork at least one substantially L-shaped first beam

(21) connected to a pair of anchoring forks (22), each fork being connected to a respective end of said first beam (21), said at least one first beam (21) being integral to a first insert of extractable material;

• positioning into the formwork at least one substantially L-shaped second beam (31) connected to a pair of rectilinear anchoring rods (32), each rod

(32) being connected to a respective end of said second beam (31), said second beam (31) being integral to a second insert of extractable material;

• positioning into the formwork at least one third insert of extractable material;

• carrying out the casting of concrete;

· removing said first, second and third insert;

said first, second and third insert being positioned into the formwork so that, when removed, be such as to form into the panel (1) respectively a bottom recess (2) obtained on said front wall (11) at a bottom edge thereof, a top recess (3) obtained on at least one of said side walls (14), and a face recess (4) obtained on at least one of said front walls (11).

13. The production process of a panel (1) according to the preceding claim, wherein said extractable material is polystyrene.

14. The production process of a panel (1) according to the preceding claim, wherein said step of removing said first, second and third insert occurs by burning the polystyrene.

15. The production process of a floor panel (50) for prefabricated structure by casting concrete into a formwork, the floor panel (50) having a top wall (51) and a bottom wall (52) opposite to each other, the process comprising the steps of:

• positioning into the formwork a first and a second insert of extractable material;

• casting the concrete;

• removing said first and second inserts;

wherein said first and second inserts are positioned into the formwork so that, when removed, are such as to form respectively a first side recess (53), obtained on said bottom wall (52) at a first side edge thereof, and a second side recess, obtained on said bottom wall (52) at a second side edge, opposite to said first edge.

16. The production process of a floor panel (50) according to the preceding claim, wherein said extractable material is polystyrene.

17. The production process of a floor panel (50) according to the preceding claim, wherein said step of removing said first and second inserts occurs by burning the polystyrene.

18. A connecting element (6) for prefabricated structure, comprising a substantially S-shaped plate having a central rectilinear region (60) and two hook-like curved portions (62, 63) opposed to each other, said connecting element (6) comprising a threaded bushing (64) connected to one of said curved portions (62) so as to be aligned with said central rectilinear region (60).

19. The connecting element (6) according to the preceding claim, wherein said threaded bushing (64) is connected to said curved portion (62) by welding.

20. The connecting element (6) according to claims 17 or 18, wherein said threaded bushing (64) is connected to said curved portion (62) at an external surface of the latter.

21. A prefabricated structure, characterized in that it comprises a plurality of panels (1 , 1 ') according to any one of the claims 1 to 8 connected to each other in sequence, and a plurality of floor panels (50) according to one of the claims 9 to 11 connected to said panels (1 , 1').

22. The prefabricated structure according to the preceding claim, which is provided in the form of an assembly kit.