Note: Descriptions are shown in the official language in which they were submitted.
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COMPOSITE STRUCTURAL ELEMENT AND ITS METHOD OF MANUFACTURE
DES CRIPTION
Back~round of the invention
In one general aspect thereof, the present invention relates to a composite
construction
element, which has a preferred but non-exclusive use in the manufacture of
floor
structures or vertical or horizontal wall structures for living units,
warehouses, and
buildings in general, as well as in the manufacture of extern.al or partition
walls of bodies
for trucks or similar containment structures.
In the following description and in the appended claims, the expression:
composite
construction element, is used to indicate an element comprising an elongated
body made
of expanded plastic material, for example expanded polystyrene, and at least
one
reinforcing section bar at least partially incoiporated in the elongated body
itself.
In the following description and in the appended claims, the expression:
floor, is used to
indicate both a horizontal structure adapted to support the floor of each
storey of a
building (including the floor directly above the ground), and a horizontal or
slanting
covering structure adapted to close at the top the last storey of the building
itself.
P.rior art
In the manufacture of construction elements for manufacturing walls, floor
structures or
containment structures in general, and in particular in the building field, it
has long
become widespread the use of construction elements made of expanded plastic
material,
preferably expanded polystyrene, in the form of slabs or section bars of
suitable shape
and size and having the function of heat and sound insulating material.
Within the framework of several applications in the building industry and in
order to
impart suitable self-supporting characteristics to such construction elements,
the use has
become widespread of incorporating one or more suitably shaped reinforcing
section
bars in the mass of expanded plastic material. .
In the following description and in the appended claims, the tei7m: "self-
support", is used
to indicate the ability of the construction element to withstand without
structural yielding
all the stresses applied thereon during its transportation and/or
installation.
Thus, for example, European Patent EP 0 459 924 discloses a. self-supporting
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construction element of made of expanded plastic material, in particular a
floor element,
comprising a central body, substantially parallelepipedic, inside which a
reinforcing
section bar constituted by an I-shaped thin sheet is integrated during the
foimi.ng
operations.
While the construction elements of the type indicated above exhibit
characteristics of
light weight, comparative ease of installation and low cost, the Applicant has
found that
the mechanical characteristics that they possess are not always adequate for
the various
requirements which occur in practice.
The construction elements of known type, in fact, are not capable of providing
mechanical characteristics other than a simple "self-support" despite the
presence of one
or more reinforcing section bars, generally made of a metal material,
incorporated in the
expanded plastic material.
Summary of the invention
The object of the present invention therefore is that of providing a composite
construction element; which is provided on the one side with improved self-
supporting
characteristics, that is an improved ability to withstand the stresses applied
thereon
during its installation, and on the other side, provided with improved
supporting
characteristics of covering elements externally associated to the construction
element
itself.
According to a fn-st aspect thereof, the invention therefore relates to a
composite
construction element comprising:
a) at least one elongated body made of expanded plastic material provided with
opposite
faces;
b) at least one reinforcing section bar longitudinally extending in said at
least one
elongated body and having a first lateral portion protruding from a first face
of said
opposite faces of the elongated body;
wherein said first lateral portion is provided with a face extending
substantially parallel to
said first face of said at least one elongated body made of expanded plastic
material at a
predetermined distance therefrom.
In particular, the Applicant has perceived that the desired improved
characteristics of
load-bearing and of mechanical resistance of a composite consti-uction element
of the
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type indicated above can be achieved by partially incorporating in the
elongated body
made of expanded plastic material the reinforcing section bar(s)
longitudinally
extending in the latter, so as to have a first lateral portion protruding from
one of the
opposite faces of the elongated body.
In this way, the reinforcing section bar(s) advantageously carry(ies) out -
thanks to the
protruding lateral portion thereof - the function of providing a face on which
it is
possible to apply mechanical stresses greater than those which can be
withstood by the
elongated body made of expanded plastic material.
The composite construction elements of the invention therefore are capable of
autonomously withstanding any static loads applied on the protruding lateral
portion of
the reinforcing section bars.
At the same time, the expanded plastic material of the elongated body carries
out the
advantageous function of stiffening and of firmly holding in position the
reinforcing
section bar(s), preventing any deformation of the same as a consequence of the
stresses
imparted thereon.
j The Applicant has fi.irther perceived that it is possible to achieve at the
same time an
improved supporting action of covering elements extern.al to the composite
construction
element by providing in the protruding lateral portion of the reinforcing
section,bar(s)
the aforementioned face, preferably substantially planar, extendiilg
substantially parallel
to at least one face of the elongated body made of expanded plastic material
at a
predetermined distance therefrom.
In this way, the construction element of the invention is advantageously
provided with
an element having a mechanical resistance (the face of the reinforcing section
bar(s))V
extending at a precletermined distance from the elongated body made of
expanded
plastic material and capable of supporting a variety of external covering
elements, such
as -for example reinforcement metal structures, rigid panels having ornamental
or
structural function or one or more layers of covering material by means of an
interposed
supporting lath.
In a particularly preferred embodiment, the first lateral portion of the
reinforcing section
bar(s) protruding fxom the first face of the elongated body made of- expanded
plastic
material is provided with a substantially planar face, so as to obtain a more
effective
supporting action of the loads applied thereon, and to have a suitably wide
surface for
fastening an external covering element.
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In a preferred embodiment, the aforementioned at least one reinforcing section
bar of the
construction element is provided with a second lateral portion provided with a
face
extending substantially parallel to the second face of said opposite faces of
the elongated
body made of expanded plastic material.
Preferably, this second lateral portion of the reinforcing section bar(s) can
be either
entirely incorporated in the expanded plastic material, or it cah protrude
therefrom so
that the aforementioned face is extending substantially parallel to the second
face of the
elongated body made of expanded plastic material at a predetennined distance
therefrom.
In this way, the construction element is advantageously capable of
withstanding a
second external covering element - identical or different from that used for
the first face
of the elongated body made of expanded plastic material - at or at a
predetermined
distance from, the second face of said elongated body so as to easily meet the
most
varied requirements of surface finishing.
Also in this case, the second lateral portion of the reinforcing section
bar(s) protruding
from the second face of the elongated body made of expanded plastic material
is
provided with a preferably substantially planar face, so as to obtain a more
effective
supporting action of the loads applied thereon, and to have a suitably wide
surface for
fastening an external covering element.
Depending upon= the selected covering element, having or not structural
features, the
construction eleiiients of the invention may also achieve furtlier improved
load bearing
characteristics.
Preferably, the reinforcing section bar is constituted by any material having
suitable
structural characteristics and compatible with the expanded plastic material,
for example
cold-rolled and preferably galvanized steel, rigid plastic materials such as
PVC,
polyester polymers, polycarbonate, acrylonitrile-butadiene-styrene (ABS)
copolymers
and the like.
According to a preferred embodiment of the invention, the reinforcing section
bar is
transversely extending in the central body of the construction elemeiit along
substantially the entire thickness thereof.
Preferably, the reinforcing section bar is further longitudinally extending in
the central
body of the construction element along substantially the entire length
thereof.
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For obvious reasons of construction simplicity and in order to limit the
production costs,
the reinforcing section bar is preferably shaped as an L, a C, a Z or an I,
for example by
placing two C-shaped elements side by side matching the respective central
portions.
Additional preferred features of the composite construction element of the
invention are
indicated in the dependent claims 4-31, the content of which is herein
integrally
incorporated by reference.
According to a second aspect thereof, the invention relates to a method for
manufacturing a composite construction element of the type indicated above as
defined
in the attached claim 32.
Advantageously, such a method can be carried out with shearing, profiling and
molding
equipment conventionalper se and known in the art.
Additional preferred features of the method of the invention are indicated in
the
dependent claims 33-40, the content of which is herein integrally incorporated
by
reference.
According to a third aspect thereof, the invention also relates to a floor
structure for
buildings comprising at least one composite construction element of the type
illustrated
in the present description and, more preferably, comprising a plurality of
said
constru.ction elements arranged side by side.
According to a fourth aspect thereof, the invention also relates to a wall
structure for
'buildings comprising at least one composite construction element of the type
illustrated
in the present description and, more preferably, comprising a plurality of
said
construction elements arranged side by side.
Brief description of the drawings
Additional features and advantages of the invention will become more readily
apparent
from the description of some preferred embodiments of a composite construction
element, of a floor structure and of a wall structure according to the
invention, made
hereinafter by way of a non-limiting example with reference to the annexed
drawings.
In the drawings:
- Fig. 1 shows a perspective view of a first embodiment of a composite
construction
- element according to the invention;
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- Fig. 2 shows a perspective view, in enlarged scale, of some details of a
second
embodiment of the composite construction element of the invention;
- Fig. 3 shows a perspective view, in enlarged scale, of an alternative
preferred
embodiment of the reinforcing section bar extending in the composite
construction
element of the invention;
- Fig. 4 shows a perspective view, in enlarged scale, of a further preferred
embodiment
of the reinforcing section bar extending in the composite construction element
of the
invention;
- Fig. 5 shows a perspective view, in partial cross-section, of a portion of a
floor
structure obtainable by placing a plurality of composite construction elements
of the
invention side by side; -
- Fig. 6 shows a perspective view, in enlarged scale and in partial cross-
section, of an
alternative preferred embodiment of a floor structure obtainable by placing a
plurality of
composite construction elements of the invention side by side;
- Fig. 7 shows a perspective view, in enlarged scale, of some details of the
floor
structure of Fig. 6;
- Figs. 8-10 show perspective views of some details of alternative preferred
embodiments of the composite construction element of the invention;
- Fig. 11 shows a perspective view, in enlarged scale, of an alternative
preferred
embodiment of the reinforcing section bar extending 'in the composite
construction
element of the invention;
- Figs. 12-13 show perspective views of a portion of a wall structure
obtainable by
placing a plurality of composite construction elements of the invention side
by side.
Detailed description of the preferred embodiments
With reference to Figs. 1-13, a composite construction element made of
expanded
plastic material, for example expanded polystyrene, according to a first
preferred
embodiment of t h e p r e s e n t i n v e n t i o n , is generally indicated
at 1.
The construction element 1 of the illustrated example, can be
usefullyremployed for
manufacturing load-bearing and partition walls or for manufacturing floor
structures of a
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building.
Alternatively, the construction element 1 of the illustrated example can also
be usefully
employed for manufacturing bodies for trucks or similar structures.
The composite construction element 1 comprises an elongated body 2 made of
expanded
plastic material, preferably substantially parallelepipedic in' shape,
provided with
opposite faces, both preferably substantially planar, respectively indicated
at 2a and 2b.
While in the illustrated example the faces 2a, 2b are substantially planar, it
should be
understood that their shape is not critical for the purposes of the invention;
such a shape,
in fact, can assume any other geometrical configuration useful for the
intended purpose.
Preferably, the elongated body 2 has the following dimensions, determined at
the design
stage: a thickness comprised between about 40 and about 120 mm and, more
preferably,
comprised between about 60 and about 80 mm, a width comprised between about
500
and about 1200 mm and, more preferably, comprised between about 600 and about
1000
mm and a length greater than about 500 mm, the maximum length being determined
by
the design specifications at values substantially selectable, as desired.
By way of a non-limiting example, the length of the elongated body 2 can be
equal to
about 13000 mm.
Within the framework of the present description and in the following claims,
except
where otherwise indicated, all numbers expressing amounts, quantities,
percentages, and
so forth, are to be understood as being modified in all instances by the term
"about".
Also, all ranges include any combination of the maximum and miniinum points
disclosed and include any intermediate ranges therein, which may or may not be
specifically enumerated herein.
In a way known per se, the body 2 is also laterally provided with opposite
sides 3, 4
respectively provided with a groove 5 and, respectively, with a rib 6,
preferably having a
mating shape; longitudinally extending along the entire length of the
construction
element 1.
In this way, a plurality of construction elements 1 arranged side by side can
be firml.y
connected to one another by means of a substantially joint-wise coupling.
The composite construction element 1 fiuther comprises at least one
reinforcing section
bar, preferably at least two reinforcing section bars 7, 8, preferably
substantially
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identical to each other, longitudinally extending in the elongated body 2 and
parallel to
one another.
In the preferred embodiment illustrated, the reinforcing section bars 7, 8 are
longitudinally extending in the elongated body 2 of the composite construction
element
1 along substantially the entire length thereof.
Preferably, the reinforcing section bars 7, 8 are longitudinally extending in
the elongated
body 2 made of expanded plastic material at opposite parts of the longitudinal
center
plane of said body along a direction substantially parallel to said center
plane.
Still more preferably, the reinforcing section bars 7, 8 are symmetrically
arranged in the
elongated body 2 with respect to said longitudinal center plane thereof.
Thanks to this arrangement of the reinforcing section bars 7, 8, it is
advantageously
possible to achieve balanced and symmetrical reinforcement characteristics of
the
elongated body at opposite parts of the longitudinal center plane thereof.
Preferably, the reinforcing section bars 7, 8 are made of a material having
suitable
structural characteristics, such as for example cold-rolled and preferably
galvanized
steel, shaped in a suitable manner.
In a preferred embodiment, the reinforcing section bars 7, 8 are coated at
least in part
and, still more preferably, entirely coated with a fire resistant film, for
example obtained
from a paint selected from the group comprising intumescent paints and
antifire paints.
The composite construction element 1 of the invention is in this case
advantageously
capable of achieving suitable characteristics of fire resistance in case of
fire thanks to
the presence of the aforementioned film.
By way of example, the reinforcing section bars 7, 8 can be obtained from a
sheet
having a width comprised between about 100 mm and about 300 mm and, still more
preferably, comprised between about 120 mrn and about 250 mm and a thickness
preferably comprised between about 0.4 mm and about 1.2 mm and still more
preferably, comprised between about 0.5 mm and about 0.8 mm.
The reinforcing section bars 7, 8 are provided with a central body 7a, 8a,
with a first
lateral portion 7b, 8b protruding from the face 2a of. the elongated body 2
made of
expanded plastic material and with a second lateral portion 7c, 8c essentialiy
incorporated in the elongated body 2.
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The first lateral portions 7b, 8b of the reinforcing section bars 7, 8 are
provided with .
respective faces 9, 10, preferably substantially planar, extending
substantially parallel to
the face 2a of the elongated body 2 made of expanded plastic material at a
predetermined distance therefrom.
Advantageously, the faces 9, 10 define a surface for supporting a finishing
element, for
example a rigid panel of plasterboard, wood, rigid plastic material or other
suitable
material indicated at 11 in Fig. 1, or for supporting a substantially
reticular metal
structure for reinforcing a concrete casting, as illustrated in more detail
hereinafter.
The rigid panel 11 can be fastened to the faces 9, 10 in a way knownper se,
for example
by means of screws knownper se and not shown,.
In a preferred embodiment, the rigid panel 11 can incorporate at least one
suitable fire
retardant material, preferably in powder, granules or fibers, adapted to
impart an
improved fire resistance to the panel itself and, consequently, to the
composite
construction element 1 which iricludes the same.
Pre,ferably, such a fire retardant material is selected from mineral fibers,
such as fiber
glass, mineral wool, inert materials such as perlite, glass spheres, expanded
clay
granules or other materials suitable for the purpose and known to those
skilled in the art.
In an alternative preferred embodiment, the. rigid panel 11 can be coated at
least in part
with a fire resistant film, for example obtained from a paint selected from
the group
comprising intumescent paints and antifire paints.
Preferably, the distance between the upper faces 9, 10 of the first lateral
portions 7b, 8b
of the reinforcing section bars 7, 8 and the face 2a of the elongated body 2
made of
expanded plastic material is comprised between about 10 mm and about 60 mm
and,
still more preferably, is comprised between about 20 mm and about 40 mm.
The reinforcing section bars 7 and 8 therefore carry out the following
advantageous
functions:
- they impart adequate load-bearing characteristics to the composite
construction
element 1;
- they support a covering element of the elongated body 2 made of expanded
plastic material at a predetermined distance from its face 2a creating a gap
that
can be either left substantially empty or filled with a suitable filling
material
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optionally incorporating at least one fire retardant material adapted to
impart an
improved fire resistance to said material. In the first case, the composite
construction element 1 exhibits improved sound insulation characteristics
(thanks to the presence of air in the gap) and advantageously allows to house
hydraulic pipes or electrical raceways, whereas in the second case the
composite
construction element 1 can exhibit improved characteristics of heat
insulation, of
finishing, of mechanical resistance or of fire resistance depending upon the
type
of material arranged between the covering element and the face 2a of the
elongated body 2;
- they impart improved characteristics of fire resistance to the composite
construction element 1 if they are partly or entirely coated with a fire
resistant
fihn, for example obtained from a paint selected from the group comprising
intumescent paints and antifire paints.
Preferably, the first lateral portion 7b, 8b of the reinforcing section bars
7, 8 is
substantially hook-shaped and has in this preferred embodiment a substantially
C-
shaped end portion.
4 '
In this case, the aforementioned end portion constitutes a substantially box-
shaped
structure the back of which defines the aforementioned upper faces 9, 10
intended in
this case to support the rigid panel 11.
20. Preferably, the central portion 7a, 8a of the reinforcing section bars 7,
8 has a height
comprised between about 60 mm and about 320 mm.
In the preferred embodiment illustrated in Fig. 1, the second lateral portion
7c, 8c of the
reinforcing section bars 7, 8 is for example constituted by a fin projecting
in a
cantilevered fashion from the central portion 7a, 8a of the reinfo'rcing
section bars.
The fins 7c, 8c of the reinforcing section bars 7, 8 carry out the function of
providing a
suitable supporting surface which an additional suitable covering element of
the face 2b
of the composite construction element 1 can be fastened to, such as for
example a
second rigid panel of plasterboard, wood, rigid plastic material, or other
suitable
material indicated at 12 in Fig. 1 or, alternatively, a stretched lath for
supporting at least
one covering layer (not shown in such figure).
The rigid panel 12 can be fastened to the fms 7c, 8-c in a way knownper se,
for example
by means of screws knownper se and not shown.
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In this case, the construction element 1 of the invention is capable of
achieving
advantageous load-bearing characteristics, i.e. it is capable of autonomously
withstanding any static loads applied thereon.
Also in this case, it is possible to impart improved characteristics of fire
resistance to the
composite construction element 1 by using a rigid panel 12 incorporating at
least one,
fire retardant material adapted to impart an improved fire resistance to the
panel itself or
by coating at least in part the rigid panel 12 with a fire resistant film for
example
obtained from a paint selected from the group comprising intumescent paints
and
antifire paints.
If the covering element of the face 2b of the composite construction element 1
is
constituted by a covering layer supported by a stretched lath, such
advantageous
characteristics can be achieved by incorporating in the material used for
forining the
layer (for example plaster or cement) at least one suitable fire retardant
material, for
example one of the materials indicated hereinbefore, adapted to impart
improved fire
resistance properties.
In the preferred embodiment illustrated in Fig. 1, the fins 7c, 8c of the
reinforcing
section bars 7, 8 are provided with an initial portion extending flush with
and
substantially parallel to the face 2b of the elongated body 2 and with an end
portion
forming with respect to the aforementioned initial portion an angle comprised
between
40 and 120 and, still more preferably, equal to about 90 .
Preferably, the initial portion of the fms 7c, 8c of the reinforcing section
bars 7, 8 is
provided with a face 13, 14 preferably substantially planar.
Preferably, fiu-thermore, such initial portion of the fms 7c, 8c of the
reinforcing section
bars 7, 8 has a length comprised between about 15 mm and about 40 mm and,
still more
preferably, comprised between about 20 inrn and about 30 mm.
Advantageously, such initial portion carries out the function of providing a
suitable
supporting surface which a covering element can be fastened to; for example
the
aforementioned rigid panel 12 or a lath for supporting at least one covering
layer, for
example of plaster, whereas the end portion increases the reinforcing action
carried out
by the reinforcing section bars 7, 8 under bending loads.
Tests carried out by the Applicant, furthermore, have shown that such a
configuration of
the fins 7c, 8c contributes to fiu-tlier stiffen the reinforcing section bars
7, 8, thus further
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increasing the self-supporting and compression resistance characteristics. of
the
composite construction element 1.
In this preferred embodiment, the substantially planar faces 9, 10 of the
first lateral
portion 7b, 8b and the substantially planar faces 13, 14 of the fins (second
lateral
portions) 7c, 8c of the reinforcing section bars 7, 8 are both substantially
perpendicular
to the central portion 7a, 8a of the latter.
In this preferred embodiment, furthermore, the reinforcing section bars 7, 8
of the
aforementioned pair are preferably spaced apart from one another by a
predetermined
distance, so as to suitably distribute the reinforcing section bars 7, 8 in
the elongated
body 2, achieving in this way some advantageous technical effects: possibility
of
homogeneously distributing the reinforcing action exerted by them; possibility
of
homogeneously distributing the loads applied to the reinforcing section bars
7, 8 and
fmally, possibility of arranging in a krlown and reproducible manner the fins
7c, 8c of
the reinforcing section bars 7, 8 so as to know their position even when such
fins are
completely embedded in the mass of expanded plastic material and as such, are
not
visible from the outside.
In the preferred embodiment illustrated in Fig. 1, the reinforcing section
bars 7, 8 are
arranged in the elongated body 2 at a predetermined distance from one another;
preferably, the distance d between the centre line of the fins 7c, 8c -
measured along a
direction substantially perpendicular to the longitudinal axis of the
elongated body 2 - is
equal to about 300 mm.
From the preceding description, the features and the technical effects that
can be
achieved by the composite construction element 1 of the invention are
immediately
clear.
Firstly, the composite construction element 1 is provided with improved load-
bearing
characteristics thanks to the presence of the first protruding lateral
portions 7b, 8b of the
reinforcing section bars 7, 8, both provided with faces 9, 10 preferably
substantially
planar on which it is possible to apply mechanical stresses greater than those
that can be
withstood by the elongated body 2 made of expanded plastic material.
Secondly, the expanded plastic material of the elongated body 2 carries out
the
advantageous function of stiffening and firml.y holding in position the
reinforcing
section bars 7, 8, preventing that the same could be deformed as a consequence
of the
stresses imparted thereon.
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Thirdly, the composite construction element 1 allows to easily support
external covering
elements thanks both to the substantially _planar faces 9, 10 extending
substantially
parallel to the face 2a of the elongated body 2 made of expanded plastic
material at a
predetennined distance therefrom, and to the fms 7c, 8c extending flush with
the face 2b
of the elongated body 2 made of expanded plastic material.
Fourthly, the composite construction element 1 allows to achieve improved
characteristics of fire resistance thanks to the partial or total coating of
the reinforcing
section bars 7, 8 with a fire resistant film for example obtained from a paint
selected
from the group comprising intumescent paints and antifire paints and/or thanks
to the.
use of a covering element incorporating at least one fire retardant material
adapted to
impart an improved fire resistance, =or of a covering element at least
partially coated with
a fire resistant film.
Figs. 2-13 schematically illustrate additional embodiments of the composite
construction ' element 1 according to the present invention. These additional
embodiments essentially achieve both the technical effects and the advantages
of the
preferred embodiment illustrated above and tlie fin-ther technical effects and
advantages
described hereinafter.
In the following description and in such figures, the components of the
construction
element 1 structurally or functionally equivalent to those illustrated with
reference to the
previous embodiment shall be indicated with the same reference numerals and
will not
be fu.rther described.
According to the embodiment illustrated in Fig. 2, the reinforcing section
bars 7, 8
comprise respective second lateral portions 7c, 8c substantially fm-shaped and
provided
with a substantially planar face 13, 14.
The fins 7c, 8c are in this case entirely incorporated in the elongated body 2
made of
expanded plastic material and are arranged at a predetennined distance from
the face 2b
of such elongated body 2.
Preferably, the fins 7c, 8c are arranged at a distance d' preferably comprised
between
about 5 mm and about 15 mm from the face 2b of the elongated body 2.
In this way, it is possible to fasten suitable covering elements of the face
2b of the
elongated body 2 of the composite construction element 1 for example the
aforementioned panel 12 made of plasterboard - to the fms 7c, 8c of the
reinforcing
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section bars 7, 8 by using fastening elements (not shown) of limited length.
Since the fins 7c, 8c of the reinforcing section bars 7, 8 are not visible
from the outside,
in order to fasten the covering elements it is necessary in this case to know
in advance
the position of such fins in.side,the mass of expanded plastic material with
respect to a
reference element, such as for example with respect to the sides 3, 4 or with
respect to
the longitudinal center plane of the elongated body 2 made of expanded plastic
material.
With reference to Figs. 3 and 4, some additional preferred embodiments of the
reinforcing section bars 7, 8 will ri.ow be illustrated:
According to the embodiment illustrated in Fig. 3, the reinforcing section
bars 7, 8 of
the composite construction elemezits 1(of which only the reinforcing section
bar 7 is
shown in Fig. 3 for simplicity) are provided with respective first 'portions
7b, 8b
substantially similar to those of the embodiment illustrated with reference to
Figs. 1 and
2.
In this case, the reinforcing section bars 7, 8 of the composite construction
elements 1
are advantageously provided with a plurality of openings 15, preferably of
circular
shape, formed in the central portion 7a, 8a thereof comprised between the
aforementioned first and second lateral portions 7b, 8b and 7c, 8c.
The openings 15 carry out the dual advantageous function of lightening the
reinforcing
section bars 7, 8 and of allowing an even more intimate integration thereof in
the mass
of expanded plastic material.
Thanks to the presence of the openings 15, in fact, the mass of expanded
plastic matexial
is capable of interpenetrating with the reinforcing section bars 7, 8 during
the molding
operation, integrating and firm.ly holding in place the reinforcing section
bars 7, 8 within
the elongated body 2 of the composite construction element 1.
This intimate integration of the reinforcing section bars 7, 8 in the mass of
expanded
plastic material, furthermore, prevents any deforrnation or bending along the
transversal
direction of the reinforcing section bars 7, 8 even though they are
essentially constituted
by a fairly thin metal sheet.
Preferably, the openings 15 have a total area comprised between about 5% and
about
50% of the total area of each reinforcing section bar 7, 8, where the
expression: total
area of each reinforcing section bar, is used to indicate the area of the
overall surface of
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the section bar including that of the opposite lateral portions 7b, 7c .and
8b, 8c (that is,
the area of the total lateral surface before forming such portions and the
openings 15).
Still more preferably, the openings 15 formed in the central portion 7a, 8a of
the
reinforcing section bars 7, 8 have a total area comprised between about 20%
and about
30% of the total area thereof.
The openings 15 have a diameter preferably comprised between about 15 mm and
about
100 mm and, more preferably, comprised between about 40 mm and about 70 mm.
In a preferred embodiment, the openings 15 are pitchwise arranged in the
central portion
7a, 8a of the reinforcing section bars 7, 8 along the center plane of the
section bars
themselves.
Preferably, the pitch of the openings 15 is comprised between about 50 and
about 100
mm and, still more preferably, is equal to about 75 mm.
According to the embodiment illustrated in Fig. 4, the reinforcing section
bars 7, 8 of
the composite construction elements 1 (of which only the reinforcing section
bar 7 is
shown in Fig. 4 for simplicity) are provided with openings 15 entirely
similar'to those of
the reinforcing section bars of Fig. 3 and with a first substantially hook-
shaped lateral
portion 7b, 8b having a shape substantially resembling an upturned U.
Thanks to this feature, the first-lateral portion 7b, 8b of the reinforcing
section bars 7, 8 -
preferably essentially constituted by a fairly thin sheet - substantially acts
as a spring
whenever it engages suitably grooved covering elements connectable in a snap-
wise
fashion in such first lateral portion 7b, Sb.
Preferably, such first lateral portion of the reinforcing section =bars 7, 8
is provided in
this case with lateral portions, indicated at 16 and 17, which are
substantially tapered so
as to increase the spring effect achieved by this substantially hook-wise
configuration.
With reference to Fig.' 5, a floor structure 18 that can be manufactured by
means of a
plurality of composite construction elements 1 according to the invention, for
example
each incorporating a pair of reinforcing section bars 7, 8 according to the
embodiment of
Fig. 4, will now be described.
According to this embodiment, the floor structure 18 is especially suitable
for
constructing the so-called "wide span" floors.
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The floor structure 18 comprises a plurality of composite construction
elements 1
arranged side by side, a plurality of floor elements 19 made of expanded
plastic material
supported by the composite construction elements 1 and a substantially
reticular metal
structure 20 for reinforcing a concrete casting, schematically indicated at 21
in Fig. 5,
arranged between the floor elements 19.
In the following description and in the appended claims, the expression:
substantially
reticular metal structure, is used to indicate a reinforcement metal structure
comprising a
plurality of longitudinal reinforcing elements and a plurality of transversal
reinforcing
elements of the casting crossed with one another so as to form a grid
extending
substantially along the entire extension of the floor structure to be
manufactured.
The latter is defined in the field as a floor structure provided with "crossed
reinforcement rods" and allows to manufacture floors having a length greater
than those
that can be achieved by floor structures having the same thickness but not
provided with
substantially reticular reinforcement metal structures.
Advantageously, the composite construction elements 1 are laying at the
opposite ends
thereof on respective supporting structures of a building (not shown), such as
for
example beams and/or load-bearing walls.
In this way, the composite construction elements 1 form in this case as many
supporting
elements adapted to define a base of the floor structure 18 adapted to support
the floor
elements 19 and the reinforcement metal structure 20 and adapted to receive
the
concrete casting 21.
In this embodiment, the reinforcing section bars 7, 8 of the composite
construction
elements 1 carry out the following advantageous functions:
- they impart suitable self-supporting characteristics to the composite
construction elements 1;
- they support the floor elements 19 and firmly hold the same in place;
they support the reinforcement metal structure 20 of the casting at a
predetermined distance from the upper face 2a of the elongated body 2 of the
composite construction elements 1;
- they impart improved characteristics of fire resistance to the composite
construction elements 1 whenever they are partially or entirely coated with a
fire
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resistant film, for example obtained from a paint. selected from the group
comprising intumescent paints and antifire paints.
Since the reinforcement metal structure 20 of the casting is supported at a
predetermined
distance from the upper face 2a of the elongated body 2 of the composite
construction
elements 1, it is advantageously ensured in a simple and effective manner that
the
concrete casting 21 can easily fill the spaces below the reinforcement metal
structure 20
as required by the building regulations currently in force.
Advantageously, furthermore, the first lateral portions 7b, 8b of the
reinforcing section
bars 7, 8 - preferably essentially constituted by a fairly thin metal sheet -
substantially
act as springs upon their engagement with the floor elements 19.
In the preferred embodiment of the floor structure 18 illustrated in Fig. 5,
the
reinforcement metal structure 20 can be advantageously firmly associated to
the
reinforcing section bars 7, 8 by means of a plurality of staples 3 8 having a
central body
38a substantially shaped as an upturned U and having opposite free ends 38b,
38c
projecting in a cantilevered fashion from the central body 38a and adapted to
engage the
lateral portions 7b, 8b of the reinforcing section bars 7, 8.
Preferably, the staples 38 are constituted by a wire of a suitable structural
material, for
example metal, so as to constitute substantially spring-wise connecting means
thanks to
the elasticity of the material.
Thanks to the ensuing stable association of the reinforcing section bars 7, 8
to the
reinforcement metal structure 20, the composite construction element 1
advantageously
allows to achieve improved characteristics of fire resistance, since the
covering
elements, in this case the rigid panels 12 associated to the face 2b of the
elongated body
2, are firmly held by the reinforcement metal structure 20 embedded in the
concrete
casting 21 by means of the reinforcing section bars 7, 8.
In case of fire, therefore, the rigid panels 12 do not detach from the
composite
construction element 1 even in the presence of a complete collapse of the
elongated
body 2 made of expanded plastic material.
Advantageously, fiu-thermore, the characteristics of fire resistance of the
floor structure
18 can be further improved if the rigid panels 12 incorporate at least one
fire retardant
material adapted to impart an iinproved fire resistance or are coated at least
in part with
a fire resistant film.
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Preferably, the floor elements 1.9 made of expanded plastic material supported
by the
composite construction elements 1 are arranged at a predetermined distance
from one
another along the floor structure 18 - both along a longitudinal and along a
transversal
direction - so as to define a plurality of transversal channels 22 and a
plurality of
longitudinal channels 23 adapted to house the concrete casting 21.
In this preferred embodiment, the floor elements 19 are arranged astride of
the
composite construction elements 1.
Thanks to this arrangement, it is advantageously possible to increase the
characteristics
of mechanical resistance of the floor structure 18 since the stresses imparted
to the
structure by the concrete casting 21 do not concern the projecting portions of
the
elongated bodies 2 made of expanded plastic material (the portion of plastic
material
extending between the reinforcing section bars 7, 8 and the sides 3, 4 of the
elongated
bodies 2).
In the illustrated example, each' floor element 19 comprises a central body
19a
substantially parallelepipedic, in which a plurality of parallel cavities 24
is
longitudinally defined. '
Advantageously, the floor elements 19 made of expanded plastic material can be
realized with any desired height, so as to regulate as desired the thickness
of the floor
structure 18 and, therefore, the maximum length of the final floor.
Preferably, the floor elements 19 have a thickness comprised between about 160
mm
and about 500 mm and, still more preferably, comprised between about 180 mm
and
about 300 mm.
Preferably, the floor elements 19 have the following further dimensions,
determined at
the design stage: a width comprised between about 450 and about 500 mm and a
length
greater than about 300 mm, the maximum length being determined by the design
specifications at values substantially selectable as desired.
By way of a non-limiting example, the length of the floor elements 19 can be
comprised
between 300 mm and 13000 mm.
Preferably, the floor elements 19 are arranged on the cornposite construction
elements 1
so as to form a grid of transversal channels 22 and longitudinal channels 23
substantially
perpendicular to one another.
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Advantageously, the width of the channels 22 and 23 can be determined by a man
skilled in the art on the basis of the design specifications. By way of an
example only,
such a width may be comprised between about 100 and about 200 mm.
In this preferred embodiment of the floor structure 18, the composite
construction
elements 1 thus constitute as many joists on which the floor elements 19 rest
to form a
so-called "panelled" floor structure.
Within the framework of this preferred embodiment, the . floor elements 19 are
preferably provided at a lower side with at least one and preferably a pair of
longitudinal
grooves 25 adapted to house the first lateral portions 7b, 8b of the
reinforcing section
bars 7, 8, so as to have a firni connection between the floor elements 19 and
the
composite construction elements 1 of the floor structure 18.
Preferably, the longitudinal grooves 25 are configured so as to have a shape
substantially mating the shape of the first lateral portions 7b, 8b of the
reinforcing
section bars 7, 8 projecting from the composite construction elements 1, so as
to
increase the stability of the connection between the reinforcing section bars
7, 8 and the
floor elements 19.
Thus, for example, in the preferred embodiment illustrated in Fig. 5, the
longitudinal
grooves 25 are substantially dovetail-shaped with opposite lateral walls
tapered in such
a way as to firmly hold in the grooves 25, with a substantially snap-wise
connection, the
first lateral portions 7b, 8b of the reinforcing section bars 7, 8, having in
turn tapered
lateral portions 16, 17 as bette'r illustrated in Fig. 4.
According to the invention and as described above, the reinforcement metal
structure 20
of the concrete casting 21 is supported by the first lateral portions 7b, 8b
of the
reinforcing section bars 7, 8 at a predetermined distance from the upper face
2a of the
elongated body 2 made of expanded plastic material.
Within the framework of this preferred embodiment, the reinforcement metal
structure
20 of the casting comprises a plurality of transversal reinforcement elements
of the
casting 21, generally indicated at 26, and a plurality of'longitudirial
reinforcement
elements of the casting, generally indicated at 27, respectively housed in the
aforementioned transversal and longitudinal channels 22, 23.
In this way, it is advantageously possible to realize, within the framework of
the
aforementioned "panelled" floor structure, zones of reinforced concrete
arranged only
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where needed on the basis of the design parameters, with a reduction of the
weight and
of the costs for manufacturi.ng the final floor.
Preferably, the transversal reinforcement elements 26 of the casting lay on
the first
lateral portions 7b, 8b of the reinforcing section bars 7, 8 and in
particular, lay on the
substantially planar faces 9, 10 of such first lateral portions 7b, 8b and are
fiimly
associated to the reinforcing section bars 7, 8 in way conventional per se,
for example
by means of the staples 38 described hereinbefore.
In this preferred embodiment, the longitudinal reinforcement elements 27 of
the casting
21 lay on the transversal reinforcement elements 26 and are firrnly
'associated to the
same in way conventionalper se, for example by means of strings 39 of
conventional
type and constituted by the conventional iron wires used to this end in the
art.
Thanks to the aforementioned supporting configuration of the transversal and
of the
longitudinal reinforcement elements 26, 27 of the casting 21 provided by the
composite
construction elements 1 of the invention, it is advantageously possible to
arrange the
lower portion thereof - the portion which is subjected to the tensile stresses
- near the
lower portion of the floor structure 18 with an increase of the
characteristics of
resistance to external loads of the final floor.
For the purposes of the invention, the specific shape and structure of the
transversal. and
of the longitudinal reinforcement elements 26, 27 of the reinforcement metal
structure
20 is not critical, provided that they supply the necessary amount of metal
according to
the design specifications. Thus, for example, the transversal and the
longitudinal
reinforcement elements 26, 27 of the reinforcement metal structure 20 can be
constituted by a plurality of iron rods suitably spaced from one another or
they can be
constituted by substantially trestle-shaped structures according to what is
known to a
man skilled in the art.
From the foregoing description, the features and the technical effects that
can be
achieved by the floor structure 18 of the invention are immediately clear.
Thanks to the structural characteristics of the composite constru.ction
elements 1 and, in
particular, to their self-supporting characteristics and to their ability of
supporting the
reinforcement metal structure 20, it is possible in the first place to
minimize the labor
required to manufacture the fmal floor at the yard.
The operations required to manufacture the fmal floor, in fact, essentially
comprise the
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steps of laying a plurality of composite construction elements 1 on the load-
bearing
structures of the building being erected, of arranging thereon the floor
elements 19 and
the reinforcement metal . structure 20 and then, of casting the concrete on
the floor
structure 18 thus assembled.
Once the floor structure 18 has been assembled, 'the function of containing
the concrete
casting 21 is ensured by the transversal and by the longitudinal channels 22,
23 defmed
between the floor elements 19 and the composite construction elements l.
Advantageously, the aforementioned operating steps can be carried out without
using
temporary supports for lengths of the floor structure 18 up to about 2 meters
or using a
limited number thereof for greater lengths.
Advantageously, firrthermore, the aforementioned laying step of the composite
construction elements 1 can be readily carried out with a minimum labor,
thanks to the
compactness, lightness and handiness of the elements themselves.
Finally, the floor structure 18 according to the invention achieves ilnproved
characteristics of fire resistance in case of fire thanks to one or more of
the following
features:
- to the fact that the covering elements associated to the face 2b of the
elongated
body 2, in this case constituted by the rigid panels 12, are fi.r.mly held by
the
reinforcement metal structure 20 embedded in the concrete casting 21 by means
of the reinforcing section bars 7, 8;
- to the fact that the reinforcing section bars 7, 8 can be coated at least in
part
with a fire resistant fihn;
- to the fact that the covering elements associated to the face 2b of the
elongated
body 2 can incorporate at least one fire retardant material adapted to impart
an
improved fire resistance or to the fact that the covering elements can be
coated at
least in part with a fire resistant film.
According to an another preferred embodiment of the floor structure 18
illustrated in
Figs. 6 and 7, the elongated body 2 of the composite construction elements 1
is provided
with a plurality of cavities 40 substantially parallel to one another and
longitudinally
extending in a central portion of the elongated body 2 between the reinforcing
section
bars 7, 8.
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Advantageously, the cavities 40 contribute to lighten the elongated body 2
making the
same easier to handle during the installation.
The elongated body 2 made of expanded plastic material is fi.u-ther provided
with a
plurality of longitudinalribs 41, 42 made of expanded plastic material,
substantially
parallel to one another, projecting in a cantilevered fashion from the upper
face 2a of the
elongated body 2. at opposite parts of the longitudinal center plane thereof.
In this preferred embodiment, the elongated body 2 made of expanded plastic
material is
also provided with a pair of projections 43, 44 laterally and longitudinally
extending at
opposite parts of the longitudinal ribs 41, 42 towards the opposite sides 3
and 4 of the
elongated body 3 in which the groove 5 and, respectively, the rib 6 are
formed.
Preferably, the longitudinal ribs 41, 42 integrally extend substantially
perpendicularly to
the upper face 2a of the elongated body 3 and are preferably obtained at the
molding
stage of the elongated body 2.
In this preferred embodiment, the reinforcing section bars 7, 8 of the
composite
construction elements 1 are substantially Z-shaped and each of them comprises
respective first lateral portions 7b, 8b substantially fm-shaped associated to
the
longitudinal ribs 41, 42 made of expanded plastic material projecting in a
cantilevered
fashion from the upper face 2a of the elongated body 2.
In this preferred embodiment, the second lateral portions 7c, 8c of the
reinforcing
section bars 7, 8 are constituted .by respective fins perpendicularly
extending from the
ends of the central portion 7a, 8a opposite to that of the fins 7b, 8b and at
opposite side
of the central portion 7a, 8a.
Preferably, fu.rthermore, the upper face 9, 10 of the first fins 7b, 8b of the
reinforcing
section bars 7, 8 is extending at least in part substantially flush with an
upper face 41a,
42a of the longitudinal ribs 41, 42 of the elongated body 2 made of expanded
plastic
material.
In this way, the assembly constituted by the longitudinal ribs 41, 42 and by
the fiirst fins
7b, 8b forms a rigid structure adapted to effectively support the
reinforcement metal
structure 20.
Similarly to what has been described hereinabove with reference to the
previous
embodiment of the floor structure 18, the floor elements 19 are provided with
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longitudinal grooves 25. having a shape substantially mating the shape of the
longitudinal ribs 41, 42 incorporating the first fms 7b, 8b of the reinforcing
section bars
7, 8 and are engageable with a substantially snap-wise connection on such
ribs.
In this preferred embodiment, the fins 7b, Sb and 7c, 8c comprise a first
portion
substantially rectilinear and substantially perpendicular to the central
portion 7a, 8a of
the reinforcing section bars 7, 8 and an second portion, or end portion,
inclined and
forming an angle of predeterrnined value with the first portion.
Preferably, the first portion of the fins 7b, 8b and 7c, 8c has a width equal
to about 40
mm, whereas the end portion has a width equal to about 5 mm and forms with
respect to
the first portion an angle equal to about 90 in the case of the second fins
7c, 8c and
equal to about 45 in the case of the first fiins 7b, 8b.
In an additional embodiment, the end portion of the first fins 7b, 8b can be
radiused to
the first portion by means of a substantially curvilinear j oining zone.
Preferably, the reinforcing section bars 7, 8 are arranged in a mirror fashion
at opposite
parts of the longitudinal center plane of the elongated body 2 so as to impart
optimum
characteristics of load resistance to the composite construction element 1 as
a whole.
Thanks to this arrangement, the reinforcing section bars 7, 8 are provided
with second
fms 7c, 8c extending at opposite parts of the longitudinal center plane of the
elongated
body 2 made of expanded plastic material so as to form a configuration that
advantageously improves the characteristics of resistance to the bending loads
of the
composite construction element 1, in particular those to the loads applied to
the
projections 43, 44 of the elongated body 2 made of expanded plastic material
arranged
between the reinforcing section bars 7, 8 and the opposite sides 3, 4 of the
aforementioned body.
In the preferred embodiment illustrated in Figs. 6 and 7, the first fins 7b,
8b and the
second fms 7c, 8c of the reinforcing section bars 7, 8 are provided with
respective
longitudinal ribs 45, 46 adapted to stiffen the structure thereof, and in the
case of the
second fms 7c, 8c, adapted to form a notoh for the introduction of the tip of
fastening
means, for example screws, for anchoring a rigid covering element, for exan-
lple the
panel 12 made of plasterboard, to the reinforcing section bars 7, 8.
Similarly to the embodiments illustrated hereinabove, furthermore, the
reinforcing
section bars 7, 8 are provided with a plurality of openings 15, preferably of
circular
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shape, formed in the central portion 7a, 8a comprised between the first fins
7b, 8b and
the second fins 7c, 8c.
Also in this case, the openings 15 carry out the dual advantageous function of
lightening
the reinforcing section bars 7, 8 and of allowing a still more intimate
integration thereof
within the mass of expanded plastic material.
In this preferred embodiment, furthermore, the staples 38 engage at their ends
3 8b, 38c
the lower portion of the longitudinal ribs 41,'42 which forms an undercut
which is
hooked by the aforementioned ends of the staples 3 8.
Unlike what is illustrated in Fig. 5, the floor elements 19 are arranged so
that each
longitudinal row of floor elements 19 is supported by one and the same
composite
construction element 1.
In this case, it is therefore advantageously possible to pre-assemble at the
factory a
plurality of floor elements 19 longitudinally aligned on one and the same
composite -
construction element 1 with an additional simplification of the laying
operations of the
floor structure 18 carried out at the yard.
In an additional embodiment, not shown, the composite construction elements 1
of the
invention can be provided with longitudinal ribs projecting in a cantilevered
fashion
from both faces 2a, 2b of the elongated body 2 made of expanded plastic
material, in
which case the second lateral portions 7c, 8c of the reinforcing section bars
7, 8 will
assume a configuration sirimilar to that of the first lateral portions 7b, 8b
illustrated with
reference to Figs. 6 and 7.
According to the preferred embodiment illustrated in Fig. 8, the reinforcing
section bars
7, 8 of the construction element 1 are substantially Z-shaped and each of them
comprises a plurality of openings 15 pitchwise formed in the central portion
7a, 8a
thereof as described hereinbefore.
In this preferred embodiment, the second lateral portion 7c of the reinforcing
section bar
7 protrudes from the face 2b of the elongated body 2 made of expanded plastic
material
and is provided with a face 13, preferably substantially planar, extending
substantially
parallel to the face 2b at a predetermined distance therefrom.
Preferably, the distance between the face 13 of the second lateral portion 7c
of the
reinforcing section bar 7 and the face 2b of the elongated body 2 made of
expanded
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plastic material is comprised between about 10 mm and about 60 mrn and, still
more
preferably, comprised between about 20 mm and about 40 mm.
The first lateral portion 7b of the reinforcing section bar 7 is on the other
hand
substantially incorporated, in the expanded plastic material, so that the face
9 is
extending flush with the face 2a of the elongated body 2 made of expanded
plastic
material.
Conversely, the first lateral portion 8b of the reinforcing section bar 8
protrudes from
the face 2a of the elongated body 2 made of expanded plastic material and is
provided
with a face 10, preferably substantially planar, extending substantially
parallel to the
face 2a at a predetermined distance therefrom, preferably at a distance
similar to that
indicated above for the face 13 of the lateral portion 7c.
The second lateral portion 8c of the reinforcing section bar 8 is on the other
hand
substantially incorporated in the expanded plastic material, so that the face
14 is
extending flush with the face 2b of the elongated body 2 made of expanded'
plastic
material.
In this preferred embodimen"t, the first and the second lateral portions 7b,
8b and 7c, 8c
of the reinforcing section bars 7, 8 are for example constituted by respective
fins
extending perpendicularly from the ends of the central portion 7a, 8a of the
section bars
7, 8 at opposite sides thereof.
Similarly to the embodiments illustrated hereinabove, the fun.s 7b, 8b and 7c,
8c
comprise also in this case a first portion rectilinear and substantially
perpendicular to the
central portion 7a and 8a of the reinforcing section bars 7, 8 and a second
end portion
inclined and forming an angle of predetermined value with the first portion.
Preferably,
such an angle is equal to about 900.
This additional embodiment of the composite construction elements 1
advantageously
allows both to have improved characteristics of resistance to the bending
loads and to
support external covering elements (for example rigid panels made of
plasterboard
andlor laths supporting plaster layers, not shown) at opposite parts of the
elongated body
2 made of expanded plastic material and at a predetermined distance from both
faces 2a,
2b of said body.
This additional embodiment of the composite construction elements 1 further
allows to
achieve improved characteristics of fire resistance in case of fire, either by
coating at
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least in part the. reinforcing section bars 7, 8 with a fire resistant film,
or by arranging a
suitable filling material incorporating at least one fire retardant material
adapted to
impart an improved fire resistance in the gap defmed between the rigid
covering element
(where present) and the face(s) 2a, 2b of the elongated body 2 made of
expanded plastic
material.
According to the preferred embodiment illustrated in Fig. 9, the reinforcing
section bars
7, 8 of the construction element 1 are substantially Z-shaped in a manner
entirely similar
to what has been illustrated in Fig. 8.
In this preferred embodiment, however, the reinforcing section bars 7, 8 are
provided
with opposite first and second lateral portions 7b, 8b and 7c, 8c respectively
protruding
from the opposite faces 2a, 2b of the elongated body 2 made of expanded
plastic
material.
The substantially planar faces 9,. 10, 13 and 14, therefore, are extending
substantially
parallel to the faces 2a and 2b at a predetermined distance therefrom,
preferably at a
distance similar to that described above with reference to Fig. 8 (10-60 mm).
This additional embodiment of the composite construction elements 1,
therefore,
advantageously allows both to have improved characteristics of resistance to
the
bending loads and to support external covering elements (for example panels
made of
plasterboard and/or laths supporting plaster layers, not shown) at opposite
parts of the
elongated body 2 made of expanded plastic material and at a predetermined
distance
from both faces 2a, 2b of said body.
Also this additional embodiment of the composite construction elements 1
allows to
achieve improved characteristics of fire resistance in case of fire, either by
coating at
least in part the reinforcing section bars 7, 8 with a fire resistant film, or
by arranging a
suitable filling material incorporating at least one fire retardant material
adapted to
impart an improved fire resistance in the gap defined between the rigid
covering element
(where present) and the face(s) 2a, 2b of the elongated body 2 made of
expanded plastic
material.
According to the preferred embodiment illustrated in Fig. 10, the reinforcing
section
bars 7, 8 of the construction element 1 are substantially Z-shaped in a manner
entirely
similar to what has been illustrated in Fig. 8.
In this preferred embodiment, however, the arrangement of the planar faces of
the first
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and of the second lateral portions 7b, 8b and 7c, 8c of the reinforcing
section bars 7, 8 is
similar to that of Fig. 1, that is, with only the substantially planar faces
9, 10 protruding
from the elongated body 2 made of expanded plastic material at a predetermined
distance therefrom.
This additional embodiment of the composite construction elements 1,
therefore, allows
to have improved characteristics of resistance to the bending loads in
addition to the
technical effects already described above with reference to Figs. 1, 8 and 9.
According to the preferred embodiment illustrated in Fig. 11, the reinforcing
section
bars 7 and 8 of the composite construction elements 1(of which only the
reinforci.ng
section bar 7 is illustrated in Fig. 11 for simplicity) are substantially C-
shaped and each
of them comprises respective first portions 7b, 8b and respective second
portions 7c, 8c
substantially fin-shaped and provided with faces 9, 10 and 13, 14, preferably
substantially planar, projecting in a cantilevered fashion from the central
portion 7a, 8a
of the section bars themselves.
In the preferred embodiment illustrated, the fms 7b, 8b and 7c, 8c are
extending
substantially perpendicular to the central portion 7a, 8a.
With reference to Figs. 12 and 13, some preferred embodiments of a wall
structure 28
will now be described by way of a non-limiting example, which wall structure
may be
realized;by means= of a plurality of composite construction elements =1
according to the
invention, for = example each incorporating a pair of substantially C-shaped
reinforcing
section bars 7, 8 according to the embodiment of Fig. 11.
= Y
According to the preferred embodiment of Fig. 12, the wall structure 28
comprises a
plurality of composite construction elements 1 arranged side by side and each
of which
is provided with a pair of reinforcing section bars 7, 8 having respective
first lateral
portions 7b, 8b protruding from the face 2a of the elongated body 2 made of
expanded
plastic material and provided with respective substantially planar faces 9, 10
extending
substantially parallel to the face 2a at a predetermined distance therefrom.
In this case,
the lateral portions 7b, 8b are substantially fin-shaped and are projecting in
a
cantilevered fashion from the central portion 7a, 8a of the section bars
themselves.
The reinforcing section bars 7, 8 are also provided with respective second
lateral
portions 7c, 8c - also substantially fin-shaped - incorporated in the mass of
expanded
plastic material and provided with respective faces 13, 14, preferably
substantially
planar, extending substantially flush with the face 2b of the elongated body
2.
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Similarly to what has been described above with reference to the preferred
embodiment
of Fig. 1, the composite construction elements 1 of the wall structure 28
support a
plurality of rigid covering elements, for example matchboarded wood panels
indicated
at 29 and a plurality of plasterboard panels indicated at 30, at opposite
parts of the
elongated body 2 made of expanded plastic material.
The panels 29 arid 30 are fastened in a way known per se to the substantially
planar
faces 9, 10 and, respectively, 13, 14'of the reinforcing section bars 7, 8 for
example by
means of screws not shown.
Thanks to the configuration of the composite construction elements 1, a gap 31
is
defined in this case between the panels 29 and the face 2a of the elongated
body 2 made
of expanded plastic material, which is filled in this case with a suitable
heat and sound-
proofmg filling material M, such as glass wool, mineral wool or a foamed
polyurethane
material.
The composite construction elements 1 of this embodiment advantageously
achieve
improved supporting and heat and sound insulation characteristics.
Ffiially, the wall structure 28 according to the invention can achieve
improved
characteristics of fire resistance in case of fire thanks to one or more of
the following
features:
- to the fact that the reinforcing section bars 7, 8 can be coated at least in
part
with a fire resistant film;
- to the fact that the rigid covering elements associated to the reinforcing
section
bars 7, 8 can incorporate at least one fire retardant material adapted to
impart an
improved fire resistance or to the fact that they can be coated at least in
part with
a fire resistant fi1m;
- to the fact that the filling material M can incorporate at least one fire
retardant
material adapted to impart an improved fire resistance.
According to the preferred embodiment of Fig. 13, the wall structure 28
comprises a
plurality of composite construction elements 1 arranged side by side, each of
which is
provided with a pair of reinforcing section bars 7, 8 substantially C-shaped
and having
respective first and second lateral portions 7b, 8b and 7c, 8c protruding from
the faces
2a and 2b of the elongated body 2 made of expanded plastic material.
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The aforementioned lateral portions 7b, Sb and 7c, 8c are provided with
respective faces
9, 10 and 13, 14, preferably substantially planar, extending substantially
parallel to the
face'2a and, respectively, 2b at a predetermined distance therefrom, for
example at a
distance similar to that described above with reference to Fig. 8 (10-60 mm).
Similarly to the previous embodiment illustrated in Fig. 12, the lateral
portions 7b, 8b
and 7c, 8c of the reinforcing section . bars 7, 8 are substantially fin-shaped
and are
projecting in a cantilevered fashion from the central portion 7a, 8a of the
section bars
themselves.
In this preferred embodiment, the faces 9, 10 and 13, 14 of the opposite
lateral portions
7b, 8b and 7c, 8c of the reinforcing section bars 7, 8 support a pair of laths
32, 33 at a
predetermined distance from the faces 2a, 2b of the elongated body 2 made of
expanded
plastic material so as to define two gaps 34, 35 between the laths 32, 33 and
the
aforementioned faces 2a, 2b. In this case, these gaps are not filled with any
material and
defme respective air chambers which improve the sound insulation properties of
the
wall structure 28.
In the following description and in the subsequent claims, the ' expression:
lath for
supporting at least one covering layer, is used to indicate not only
conventional laths
having a mesh structure - either smooth or provided with protruding ribs -
obtained by
stretching a suitably notched metal sheet, but also any sheet-like member
adapted to
support a suitable covering material.
Preferably, each of the laths 32, 33 is a stretched metal lath essentially
formed by a
rhomb-shaped mesh having a length-to-height rhomb ratio of 2:1.
Preferably, the rhomb length varies between about 20 and about 60 mm, while
the
rhomb width varies between about 10 and about 30 mm.
Preferably, fixrthermore, such stretched laths have a thickness comprised
between about
0:4 mm and about 1.0 mm and, still more preferably, comprised between about
0.4 mm
and about 0.8 mm.
The laths 32, 33 support in turn at least one layer 36, 37 of a suitable
covering material,
such as for example plaster or cement, optionally incorporating at least one
material
selected from reinforcing fibers of a suitable material and at least one fire
retardant
material adapted to impart an improved fire resistance to the covering
material, which
can be applied after laying the wall structure 28.
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The. composite construction .elements 1 of this embodiment advantageously
achieve
improved load-bearing characteristics, improved heat and sound insulation -
characteristics and improved characteristics of fire resistance thanks to the
firm
connection of the laths 32, 33 and of the covering material supported thereby
to the
reinforcing section bars 7, 8.
In an additional embodiment, not shown, the faces 9, 10 and 13, 14 of the
opposite
lateral portions 7b, 8b and 7c, 8c of the reinforcing section bars 7, 8 can
support a pair
of arc welded meshes constituted by metal reinforcement rods of a concrete
casting
applied outside the composite construction elements 1.
The, composite construction element 1 illustrated hereinabove in some of the
possible
embodiments thereof, can be advantageously obtained by means of known
operations
for manufacturing the reinforcing section bars 7, 8 and known equipment for
the
continuous or discontinuous molding of the elongated body 2 made of expanded
plastic
material incorporating such section bars.
With reference to the preferred embodiments described above of the
construction
element 1, a preferred embodiment of a method according to the invention will
now be
described.
In a preliminary step, carried out in a way lmownper se, at least one sheet -
preferably a
pair' of sheets ,- made of a structural rigid material, for example galvanized
steel,
intended to form the reinforcing section bars 7, 8, are provided.
Advantageously, the aforementioned sheets have a predetermined thickness and a
width
comprised, for example, between about 0.4 and 1.5 mm and, respectively,
between
about 140 and about 340 mm.
The sheets further comprise a central portion and a pair of lateral portions
extending
from axially opposite parts with respect to the central portion, which
portions are
intended to constitute, as it will appear more clearly hereinafter, the
central portion 7a,
8a and, respectively, the lateral portions 7b, 8b and 7c, 8c of the
reinforcing section bars
7, 8 being manufactLired.
In a subsequent step, the sheets are bent in a way knownper se - for example
by means
of"a forming machine - along a pair of longitudinal bending lines
substantially parallel
to one another so as to form the reinforoing section bars 7, 8 comprising the
first lateral
portions 7b, 8b provided with the faces 9, 10, preferably substantially
planar, extending
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substantially perpendicular to the central portions 7a, 8a of the section bars
being
manufactured.
Preferably, the bending step is carried out so as to form at the same time
also the second
lateral portions 7c, 8c provided with the faces 13, 14, also preferably
substantially planar
and extending substantially perpendicular to the central portions 7a, 8a of
the section
bars being manufactured.
In a variant of this embodiment, the faces 9, 10 and 13, 14 of the first and
of the second
lateral portions 7b, 8b and 7c, 8c of the reinforcing section bars 7, 8 are
both extending
above or both below the lying plane of the sheet.
Preferably, the bending step is carried out so that the faces 9, 10 and 13, 14
of the first
and of the second lateral portions 7b, 8b and 7c, 8c of the reinforcing
section bars 7, 8
form an angle of about 90 with respect to the lying plane of the sheet
central portion.
Preferably, furthermore, the sheet bending step can be carried out, still
using equipment
knownper se, so as to fi.irther bend for example at an angle equal to about 90
, the faces
9, 10 and 13, 14 so as to obtain the aforementioned first, portion
substantially
perpendicular to the central portion 7a, 8a of the reinforcing section bars 7,
8 and the
second end portion inclined and forming an angle of predetermined value with
the
aforementioned first portion.
According to additional preferred embodiments, the aforementioned bending step
can be
carried out by bending the sheets along at least two longitudinal bending
lines
substantially parallel to one another, so as to fonn a pair of first and
second lateral
portions 7b, 8b and 7c, 8c, provided with respective faces 9, 10 and 13, 14
extending at
opposite parts with respect to the central portions 7a, 8a of the section bars
being
manufactured, in order to obtain the structures of the reinforcing section
bars 7, 8
illustrated in Figs. 8, 9 and 10.
In a subsequent step, the reinforcing section bars 7, 8 thus obtained are
arranged in a
molding seat of a suitable equipment for molding plastics, conventionalper se
and not
shown.
Once the reinforcing section bars 7, 8 have been arranged in the molding seat,
the steps
of feeding expandable plastics granules into said molding seat and of
expanding and
then bonding together the plastics granules in the molding seat, so as to form
the
elongated body 2 of the construction element 1 incorporating the reinforcing
section
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bars 7, 8, are carried out.
In a first embodiment, the step of molding the elongated body 2 made of
expanded
plastic material is carried out in such a way that the faces 9, 10 of the
first lateral
portions 7b, 8b of the reinforcing section bars 7, 8 protrude from the face 2a
of the
elongated body 2 and extend substantially parallel to- said face at a
predetermined
distance therefrom.
According to additional preferred embodiments, the aforementioned step of
molding the
elongated body 2 made of expanded plastic material is carried out in such a
way that the
opposite faces 13, 14 of the lateral portions 7c, 8c of the reinforcing
section bars 7, 8 are
essentially incorporated in the mass of expanded plastic material and, as
such, are
extending parallel to and substailtially flush with the opposite face 2b of
the elongated
body 2 or, alternatively, protrude from the face 2b and extend substantially
parallel to
said face at a predetermined distance therefrom.
In a preferred embodiment, the method of the invention fiirther comprises the
step of
forming a plurality of openings 15 in the central portion of the sheet or of
the sheets
from which the reinforcing section bars 7, 8 are obtained.
Preferably, such, openings have a circular shape and are extending in
longitudinal
direction along the sheet preferably astride of the longitudinal axis of the
sheet itself.
The operation of forming the openings 15 can be carried out in a way
conventionalper
se, for example by punching.
In a preferred embodiment, the method of the invention further comprises tlie
step of
providing a fire resistant film on at least a portion of the sheet or sheets
from which the
reinforcing section bars 7, 8 are obtained.
Preferably, the aforementioned film is provided by means of the steps of:
a) applying a paint selected from the group comprising intumescent paints and
antifire paints on at least a portion of the sheet or sheets from which the
reinforcing section bars 7, 8 are obtained; and
b) drying said paint.
The steps a) and b) are carried out with methods and equipment known to those
skilled
in the art.
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In an additional embodiment of the method of the invention, it is also
possible to begin
the manufacture of the construction element 1 starting from a pre-drilled
sheet,
optionally already incorporating a fire resistant film on at least a portion
of the external
surface thereof, wound on a reel and arranged upstream of the bending station.
If the manufacture of the construction element 1 is carried out continuously,
the method
fmally provides for. a fmal step, also carried out by means of equipment
knownpef; se, in
which the body 2 is cut to size so as to obtain a construction element having
the desired
lengtli.
In this way, it is possible to obtain the structures of construction element 1
illustrated iri
.10 Figs. 1-13.
Clearly, a man skilled in the art may introduce modifications and variants to
the
invention described hereinbefore in order to meet specific and contingent
application
requirements, variants and modifications. which anyway fall within the scope
of
protection as defmed in the attached claims.
