Note: Descriptions are shown in the official language in which they were submitted.
CA 02284074 1999-08-03
WO 98/35115 PCT/TR97/00019
PREFABRIC FIBER REINFORCED CEMENT (GRC)
WALLPANEL
DESCRIPTION OF THE INVfNTION
The present invention relates to fiber reinforced cement (GRC)
walipanel heat isolated by foam concrete and a method for producing
this.
In terms of related field and present state of the art currently
there are 4 types of prefabric wallpanel production methods:
a) Iron reinforced concrete panel: These panels have an sq/m
weight of 400 kg, does not contain heat isolation and because of
weight create problems while transportation and mounting.
b) Heat isolated concrete panel: obtained by putting 5 cm thick
hard polystyrene foam sheet among 10 cm thick two panels and
comprises same weight and mounting problems.
c) Sandwich system panel: These panels are obtained by
covering all sides of Styropor foam blocks with Fiber reinforced
cement. It can provide heat isolation and lightness but it is not possible
to mount to concrete tabliers and creates problems as times pass by.
2o For these reasons production is abandoned.
d) Fiber reinforced cement (GRC) liningplates: They are steel
carcassed plates that have 12 mm section thickness and used to cover
general columns, present walls and to provide forms on surface. Heat
isolation is done by placing isolation plates behind them after
mounting.
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e) Since there is strict rigidity in all types of these panels they do
not have any movement freedom against building straps and building
movements.
In view of the above mentioned present state of the art, subject
of this application is the solution of the known problems.
Panels produced according to the present state of the art have a
panel thickness of 20-25 cm in order to prevent cracks and breaking of
iron mounting in the panel. In this case sq/m weight of the panel is
about 400-450 kg. And this causes problems in transporting and
Io mounting of large scale panels, also brings huge loads over building
stude frame concrete. In our invention panel thickness does not exceed
10-15 cm and panel weight is about 90-100 kg. This enables easy
transportation and mounting of the panel, weight load to building
concrete decreases to minimum and amount of iron used in building
stude frame concrete is decreased.
In the panels produced according to the present state of the art
there is a need for further heat isolation and this requires various
isolation materials and a further process, labor use and extra cost.
In our invention since cellular structure and air spaces in foam
concrete function as an isolation material there is no need for fu.rther
heat isolation process. Second advantage of heat isolation with
foamconcrete is that since it is possible to produce concrete with
requested densities while forming foam concrete, depending on the
heat values of the area that the panel is to be used, panels having
various isolation values of Lambda values 0.065 to 0.500 and K values
0.29 to 3.33.
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Panels produced according to the present state of the art can not
contain forms other than some basic shapes, because iron reinforced
concrete technology itself does not allow it. In our invention since
GRC is a material that can be molded in any form, every kind of
architectural design form can be given to the panels.
Panels produced according to the present state of the art are
heavy and rigid panels. The don't have the freedom of movement apart
from building and the ability to accommodate to the movements such
as building movements, ground movements and straps. Thus there are
cracks and openings in joint gaps among the panel in the course of
time. In our invention GRC shell which forms the outer side of panel is
fixed to the panel steel stude frame with flexible anchorage rods and
panel stude frame is fixed to the building tablier with anchorage plates.
For this reason when transition of movements of the building to the
panel body, flexible anchorage rods bend and the panel is not effected
by movements of the building.
In practice GRC panels can vary depending on the architectural
plan and subject of the application is described in more detail by the
enclosed drawings which are presented just to explain the invention
and have no intention to limit the scope of the invention. They have the
following characteristics which form the invention.
Figure 1) An outside view of a fmished window spaced monoblock
panel. On the front view there is shown (A-A) plan section and
(B-B) plan section which are going to be shown in next figures.
Figure 2) Inner detail view of panel in vertical (A-A) section.
a - building tabliers
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b - GRC shell
c - Omega sectioned steel stude frame
d - Flexible anchorage rods
e - Pets connecting flexible anchorage rods to GRC shell inner
surface
f - Foam concrete filling
g - foam concrete equipment straw steel
h - anchorage plates in four corners of panel from which panel is
going to be welded
i - brace clamp welded to anchorage plate
j- steel band screwed to building tablier
k - Joint gap isolation material (Polysulphit)
m - brace clamp on which the above panel is going to be placed.
Figure 3) Inner detail view of panel in (B-B) vertical section:
a - building tabliers
b - GRC shell
c - Omega sectioned steel stude frame
d - Flexible anchorage rods
e - Pets connecting flexible anchorage rods to GRC shell inner
surface
f - Foam concrete filling
g - foam concrete equipment straw steel
h - anchorage plates in four corners of panel from which panel is
going to be welded
i - brace clamp welded to anchorage plate
j - steel band screwed to building tablier
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k - Joint gap isolation material (Polysulphit)
m - brace clamp on which the above panel is going to be placed
Figure 4) Section of panels connection section to building tablier.
a - building tabliers
5 b - GRC shell
c - Omega sectioned steel stude frame
d - Flexible anchorage rods
e - Pets connecting flexible anchorage rods to GRC shell inner
surface
f - Foam concrete filling
g - foam concrete equipment straw steel
h - anchorage plates in four corners of panel from which panel is
going to be welded
i - brace clamp welded to anchorage plate
j - steel band screwed to building tablier
k - Joint gap isolation material (Polysuiphit)
m - brace clamp on which the above panel is going to be placed
Figure 5) Flexible anchorage detail
a - Steel stude frame
b - Flexible rod
d - GRCpet
e - GRC shell
c - the part which is going to provide flexibility by inclinations
Figure 6) View of steel stude frame on which there is flexible
anchorage rods and anchorage plates on 4 corners:
c - Omega sectioned steel stude frame
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d - Flexible anchorage rods
h - steel plates by which stude frame is going to be connected to
building tablier.
The subjeq tif ~is app~ication is explained below.
In GRC p4}9j of c iuvention obtained by providing a
composite produ~l py joi:p}r}g two different elements which have
different charaq?qs~~~s qqq se, advantages are obtained which are
formed by joining characteristics of two elements and thus there is
1o obtained novel self heat isolated, light, monoblock prefabric GRC
wallpanel.
In known state of the art Fiber reinforced cement is a type of
cement which is formed by alkali resistant glass fiber and has the
strength of reinforced cement-sand mortar, can be molded and can be
casted in section thickness of 10-12 mm. On the other hand, foam
concrete is a type of air foamed concrete that is obtained by foaming a
foamer liquid chemical by an air generator and mixing this foam with
cement mortar. Because of the air bubbles contained it provides perfect
heat isolation, moreover it is light.
The present invention relates to a self heating isolated light,
monoblock GRC prefabric wallpanel obtained by joining these two
material in a form of a panel and a method for producing this.
10-12 mm thick GRC shell is formed (Figure 2,3-b) by spraying
GRC mortar inside steel or glass fiber reinforced plastic (CTP) panel
mold prepared according to the requested architectural form. Spraying
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of GRC mortar is done by concrete pump and spray guns built for this
purpose.
Steel stude frame (Figure 2,3-c) (Figure 6) designed to provide
wind load, essential weight etc. mechanic characteristics is going to be
placed inside the formed GRC shell. On this stude frame there is
placed flexible anchorage rods with 50 cm distance from each other.
Also there is provided steel anchorage plates (Figure 2,3-h)(Figure 6-h)
on four corners of steel stude frame which are going to be fixed to steel
straps on the building. Thus, it is displaced inside steel stude frame
1 o GRC shell (b) which both carries the GRC and also the panel by fixing
to building tablier. After this process flexible anchorage rods are
padded to steel stude frame by GRC mortar (Figure 2,3,4-e)(Figure 5-
e). One end of these 6-10 mm section thick , 1-15 long flexible
anchorage rods are fixed to steel stude frame and the other end is fixed
to GRC shell. There is a 6-8 cm free section in between (Figure 5-c).
This free section on the rod provides the flexibility. When there is a
movement in the building and panel these flexible rods bend and
prevent the movement from transmitting to the rigid section. As a
result this causes the ground movements, building movements and
tasmans from being transmitted to the panel.
After placing flexible anchorage rods (Figure 6-d) and steel
stude frame (Figure 6) containing mounting plates (Figure 6-h) into
GRC shell and after each flexible anchorage rod is padded to GRC
shell (Figure 2,3,4-e), a layer of straw steel is placed in order to
function as a filling to the foam which will be poured into shell and
prevent cracks and openings that may happen there, and is fixed from a
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few points to the steel stude frame (c). After this stage, panel is formed
by putting foam concrete into GRC shell (Figure 2,3,5-f).
Panel is sent to curing chamber together with its mold, is taken
out of the mold after the curing period and sent to construction area
where it is going to be mounted.
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