DE9116695U1 - Prefabricated building panel element - Google Patents

Description

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PREFABRICATED BUILDING PLATE ELEMENT

The invention relates to a prefabricated building panel element, in particular made of individual mineral panels, preferably of individual ceramic panels, which is constructed from several individual panels joined together.

Prefabricated building panel elements made of individual panels are well known. They meet different building physics requirements due to specific areas of application.

An important area of application is facings or linings of sewer pipes and sewer systems or similar made of concrete with prefabricated building panel elements made of stoneware panels, with which circular, egg-shaped, mouth-shaped or rectangular profiles of, for example, sewage pipes made of concrete are lined in order to provide corrosion protection or to repair corrosion damage. The building panel elements made of stoneware panels are prefabricated at the joints of the stoneware panels with synthetic resin mortars or putties in the factory, whereby a material is used as the joint material that resists chemical attacks and ensures sufficient mechanical strength. Protruding wire brackets are arranged on the back of the known building panel elements.

net, which can serve as anchors in the raw concrete or in a mortar layer and are intended to absorb tensile and shear forces. The well-known building panel elements are also intended to be used as permanent formwork in the production of large-format concrete profiles.

EP-A-0 242 860 summarizes the relevant state of the art and describes a method for lining pipes with ceramic plates that are arranged in a spiral. The known method is very complex. The fixing of the plates arranged in a strip to the inner wall of the pipes is not optimal.

These well-known building panel elements have not been able to establish themselves on the market because the rigidity of the prefabricated profiles severely limits their use and the manufacturing process is very complex and difficult to control.

It is an aim of the invention to create a building board element, in particular a flexible building board element made of linked, e.g. ceramic split boards, which can be installed, for example, as an inner lining in concrete sewer pipes. The installation of particularly large-area building elements should be used on the one hand as lost formwork in the production of sewer construction rings and on the other hand as a "gluable" lining shell in already laid, possibly corroded sewer networks. The building board elements should in particular have stress-specific, building physics properties, such as

Diffusion-open structure that compensates for osmotic or hydrostatic pressure peaks;

sufficient resistance to chemicals that arise as normal wastewater pollution according to the current state of technology and municipal disposal;

Resistance to temperature changes, which, for example, meets the Central European climate parameters;
sufficient flexibility at processing temperatures

of over 15 ⁰ C enables the components to be easily attached to the inner radii of the channel walls; shear- and tear-resistant adhesion of the joint compound to the interlocking surfaces of the ceramic lining. The load forces are the normal bending/tensile moments that occur when the joint is attached to the permissible inner radii. Increased abrasion resistance of the joint compound to mechanical cleaning processes (high-pressure cleaning).

A further aim of the invention are building panel elements made of pre-grouted, ceramic decorative or natural stone panels for the production of, for example, wall and facade elements as facings.

An additional object of the invention are floor slabs, preferably with a rear structure made of building panel elements made of pre-grouted coarse or fine ceramic slabs or natural stone slabs.

The object of the invention is to create prefabricated building panel elements, in particular for channel linings, which are adapted to the intended use in the joint area and preferably have anchoring means on the back.

This object is achieved by the features of the claims. Advantageous further developments of the invention are characterized in the subclaims.

The invention therefore focuses on a method for linking ceramic plates and molded parts as well as natural stone plates with different shapes to

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large-area building elements and structures, possibly stabilized and reinforced on the back, for which a specially designed work table can be used, for example, on which the panels to be linked are laid out with the visible side facing downwards - i.e. in the negative process - in a mosaic-like manner in a symmetrical or asymmetrical grid with a corresponding joint mirror and are pulled against or onto a double-walled rubber mat using freely positionable vacuum suction cups. The rubber mat is constructed in such a way that the double walls are partially vulcanized in a sensible grid so that air pockets are created in the areas of the edge zones of each individual panel. After the individual ceramic panels, ceramic components or natural stone panels have been fixed using a vacuum, the air pockets are put under pressure. This creates swelling bodies on the edges of the panels to be connected, which seal the edge zones of the panels with the rubber mat in a force-fitting manner. The sealed joint spaces are now filled with the appropriate material formulations - e.g. based on modified synthetic resins. After the curing time has ended, the double-walled rubber mat is relieved of pressure and the interconnected building board element is released for molding by switching off the vacuum. If additional stabilization of the building board element is required, a reinforcement that meets the requirements, e.g. in the form of a sandwich component, is foamed, pressed or glued onto the back in a subsequent step. Any anchoring elements required are also incorporated into the sandwich component.

The invention is explained in more detail below using the examples shown in the drawing. They show:

Fig. 1 shows a perspective view of the visible side of a

building panel element;
Fig. 2 shows a perspective view of the visible side of a

other building board element;
Fig. 3 shows a perspective view of the viewing and

Fig . 4a until C Fig . 5 Fig . 6 Fig . 7 Fig . 8th Fig . 9 Fig . 10 Fig . 11 Fig . 12 Fig . 13a until e

Front side of a single plate;

schematic cross-sections of joint formations between split plates of the building board element; schematically a front view of a curved suction table for producing the building board element, schematically a curved building board element; perspective and schematic a top view of another suction table;

schematically another curved building board element; schematically a cross-section through a suction table with parts of a building board element;
the detail (X) in Fig. 9;
a plan view of a suction table; schematically showing the principle of a suction table with table elements that can be angled relative to one another;

a front view of building panel elements with individual panels angled differently to each other.

A building board element 1 according to the invention consists of individual boards 2 placed next to one another, with joints 3 being provided between the individual boards 2, which are filled with a joint mortar or joint filler. The joint mortar or joint filler 4 can - as shown - frame the abutting edges of the building board elements 1 and form a joint frame 5.

In Fig. 1 and 2, rectangular individual panels 2 are shown; however, the shape of the individual panels 2 can also have other outline shapes. In Fig. 1, the individual panels 2 are arranged symmetrically next to and behind each other. Such a building panel element made of, for example, ceramic panels is primarily suitable for lining concrete channels, especially if the joint compound is flexible, or as a facing shell for cladding masonry if the joint is rigid. The configuration with individual panels 2 placed offset to one another according to Fig. 2 is particularly suitable, for example, as a floor building panel element.

According to a special embodiment of the invention (Fig. 3), the individual panels 2 are made of ceramic, in particular stoneware, and have dovetail-shaped webs 7 in cross-section on their rear surface 6 opposite the visible side 9, so that grooves 8 are formed. Such designs of the rear surface are known per se from ceramic split panel production. Within the scope of the invention, the use of such individual panels 2 has the advantage that mortar can hold better on such panels than on a smooth rear surface. It has been shown that building panel elements with the ribs 7 and the grooves 8 ensure excellent grip or anchoring in the fresh and hardened mortar on the inner surface of concrete pipes to be renovated or, when used as permanent formwork in the manufacture of, for example, concrete pipes in the cement paste and cement stone of the concrete, they provide very good adhesion and very good support forces.

According to the invention, the joint compound 11 of the building board element 1 has a concave joint groove 4a on the visible side when viewed in the cross-section of the joint (Fig. 4a to c). Due to this concave spatial shape on the visible side, the joint surface is arranged below the visible side surface of the building board element 1, which reduces abrasion, increases flexibility with flexible joint material, saves joint material and allows the joints to be adapted more effectively to the requirements of the joint material properties. In this context, it is advantageous to use individual panels 2 which are provided with a chamfer 10 in the visible side joint area, whereby - as shown - the joint compound 11 preferably only begins at the lower edge 11a of the chamfer 10. The radius of curvature of the concave arch shape of the joint grooves 4a depends on the requirements placed on the properties of the joint compounds.

The joint cross-sectional shape can be used - as shown in Fig. 4a to c, for example - to increase the adhesion surface for the

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Grooves 12 in the abutting edges 13 of the individual panels 2 filled with joint compound 11 or recesses 14 on the lower surface 6 of the individual panel 2 filled with joint compound 11 can serve this purpose.

To produce the building board elements according to the invention, the individual boards 2 are placed within a mold frame 15 of a substructure or suction table 16 with the visible side 9 facing downwards - i.e. in the so-called negative process - with a predetermined, so-called joint mirror (joint arrangement) on suction plates 17, which are arranged within the mold frame 15 at a distance in rows next to and behind one another and form a significant area of the suction table surface. Holes are made in the suction plates 17 in which funnel-shaped suction cups 17a are seated, which have suction nozzles 18 projecting downwards. The suction nozzles 18 are connected via hose lines (not shown) to a vacuum suction device (not shown) so that air can be sucked in the direction of arrow 19 and access to the free surface of the suction plate (17) is available.

The suction cups 17a are positioned so that they do not protrude beyond the free surface of the suction plate 17. An individual plate 2 placed with its visible side 9 on the suction plate 17 can thus be held or fixed on the suction plate 17 by suction force (Fig. 9). An individual plate 2 can also extend over two or more suction plates 17 (Fig. 11). The outline dimension of a suction plate 17 is expediently smaller than the outline dimension of an individual plate 2 to be fixed.

The suction plates 17 are arranged in corresponding recesses 20 of a double-walled rubber mat 21, whereby the free surface of the suction plates 17 is flush with the free surface of the rubber mat 21. The two-layered rubber mat 21 is partially vulcanized together according to a grid corresponding to the joint pattern, so that in the area of the joint zones of the individual

2 swelling bodies 22 and next to them a sealing bed 23 are formed under each individual panel. The swelling bodies 22 are connected to a compressed air connection 24 through which air can be pressed into the cavity 26 of the swelling bodies 22 in the direction of the arrow 25. These swelling bodies 22 are inflated with compressed air after the individual panels have been fixed. This creates bulges 27 on the panel edges and in the joint areas, which seal the panel edges on the visible side. The level of the air pressure applied influences the formation and groove depth of the joint shape.

By means of a practical division of slide rails beneath the working surface of the suction table 16, the individual vacuum suction plates 17 are arranged so that they can be adjusted so that they can be positioned depending on the position and size of the individual plates 2. The double-walled rubber mat 21 is mounted so that it can be replaced, so that changing the joint surface is easy and straightforward.

After fixing the individual panels 2 and sealing the panel edges through the bulges 27, the joints are filled on the back using, for example, the known injection method with, for example, appropriate synthetic resin formulations. If necessary, fabric strips are worked into prepared recesses on the individual panels 2 in strips to increase stability and flexibility.

According to the invention, preformed, curved facing shells or building board elements la with semi-rigid or rigid joints are also produced. Such curved segments serve, for example, in the manufacture of concrete pipes or gutters as facing shells.

It is advisable to use rectangular ceramic split plates, which are preferably positioned with their long edges in the longitudinal direction of the pipe, so that the pipe or gutter inner circle is formed in a chord-like polygon by the narrow edges.

It is advantageous to arrange fabric strips on the back of the longitudinal joints of the building panel linkage to improve strength and elasticity.

The production of curved facing shells or building board elements la (Fig. 6,8) takes place on a curved suction table 16a with suction plates 17 and rubber mat 21 arranged in a correspondingly curved manner on the suction table 16a (Fig. 5) or on a flat suction table 16, above which the suction plates 17 and the rubber mat 21 are arranged in a curved manner (Fig. 7).

For example, a

A curved suction table 16b is used (Fig. 12), with which curved building board segments la with different radii of curvature can be produced, as shown, for example, in Fig. 13a to 13f. The suction table 16b consists of table top segments 29 connected by joints 28. The joint axis 30 of the joints 28 extends parallel to the longitudinal arch axis 31 of the curved building board segments la. The rubber mat 21 and the suction plates 17 are arranged in such a way (not shown) that they can follow the pivoting of the joints 28 accordingly. With such a suction table, the joint compound can be curved or the curvature can be changed during curing.

According to the invention, facing shells

made of chemical-resistant and abrasion-resistant ceramic split panels as lining elements for sewer pipes and sewer systems. For better anchoring of the split panels and optimal fastening of the facing shells to the concrete structure, special anchoring elements in the form of ribs and grooves are provided on the back of the split panels. The type of installation of the facing shell determines the structure and shape of the linking joint and influences the selection of the material formulations of the joint. When making new sewer pipes or

For sewer components such as access and inspection shafts or similar, the facing layers are installed directly in the form of pre-formed individual segments or self-contained pipe sections, during the casting and compaction process as so-called lost formwork. The use of rigid jointing is advisable for this area of application.

The elasticity in the joint area required to adapt to the technically induced change in the shape of the concrete structure (shrinkage) can be compensated for by the basic elasticity of the joint materials used. If the basic elasticity is not sufficient due to the choice of material, too great a change in the shape of the concrete structure or tectonic loads expected later, the linking of the individual split panels to one another is ensured by a semi-flexible joint. The shape of the semi-flexible joint is characterized by the fact that, in addition to the material's own elasticity, additional resilience is achieved through tensile bending moments due to the enlargement of the joint surface and, preferably, also due to the installation of a fiber belt on the back.

When using the facing shells according to the invention for the purpose of renovating defective sewer systems, the use of a fully flexible joint is advisable.

Facing shells made of ceramic decorative or natural stone panels for the production of wall and facade elements for high-end construction needs can have the same jointing as the facing shells for sewer construction. However, a rigid or semi-flexible joint is usually chosen for this area of use. In this context, it is also advisable to build a suitable stabilizing layer on the back. If shaped structures are to be clad, a fully flexible joint can also be chosen.

Due to the specific areas of application, the building physics requirements for the elements of the individual product groups are very broad. For sewer construction, good resistance to acidic and basic media from the industrial and municipal sector, sufficient resistance to solvents, detergents or other chemical additives from the municipal sector, good resistance to drastic temperature changes and sufficient abrasion resistance are required. For cladding elements, good resistance to commercially available cleaning agents, sufficient abrasion resistance, good dimensional stability, good resistance to UV radiation (color fastness), good resistance to drastic temperature changes are required. Finally, floor panels must have sufficient resistance to aggressive media, good abrasion resistance, good resistance to UV radiation (color fastness), good dimensional stability and, if necessary, sufficient protection against fire and electrical conductivity.

In sewer construction, the building board elements according to the invention are suitable as lining elements in the form of segments or pipe sections for equipping concrete pipes, as lining elements for sewer shafts, branches and other molded parts, as facing shells in rigid or semi-flexible joints in industrial construction, as protective linings in chemical construction, as prefabricated drainage and collection shafts, drainage channels, pipelines or the like and as lining elements in the municipal construction sector (floor trays, collecting containers, sewage treatment plants or the like).

The cladding elements according to the invention are used expediently as facings, as visible surfaces in interior construction, as cladding elements, as visible surfaces of light room partition systems, as cladding elements in the sanitary area, as linings of prefabricated or finished wet areas and as wall and

Facade surfaces in exterior architecture. Floor panels according to the invention are used in particular as elements for raised floor surfaces in the areas of computer rooms, control rooms, industrial plants, security zones, laboratory and clinical facilities, sewer covers, office, business and residential spaces, roof gardens, balconies, terraces or the like.

With regard to the choice of materials for grouting, epoxy resins, polyester resins, vinyl esters, polyurethanes, polysulfide polymers have proven to be suitable for sewer construction; epoxy resins, polyester resins, polyurethanes, phenolic resins for cladding elements; and epoxy resins, polyester resins, polyurethanes and phenolic resins for floor slabs. The grouting materials can be combined with a known bonding agent, particularly when producing elastic joints.

Claims (10)

EXPECTATIONS 1. Prefabricated building panel element, in particular made of individual mineral panels, preferably of rectangular, ceramic individual panels, which is constructed from several individual panels that are jointed together, with the joints being filled with a synthetic resin mass or a synthetic resin putty, characterized in that the joint compound (11) has a concave joint groove (4a) on the side of the visible side (9) of the building board element. 2. Building panel element according to claim 1,
characterized in that the joint surface is arranged below the surface of the visible side (9). 3. Building board element according to claim 1 and/or 2, characterized in that the joint compound is rigid. 4. Building board element according to claim 1 and/or 2, characterized in that the joint compound is flexible. 5. Building panel element according to one or more of claims 1 to 3, characterized in that it is curved. 6. Building panel element according to one or more of claims 1 to 5, characterized in that the individual panels (2) have a chamfer (10) in the visible joint area. 7. Building panel element according to claim 6,
characterized in that the joint compound (11) only begins at the lowest edge (Ha) of the chamfers (10). 8. Building panel element according to one or more of claims 1 to 7, marked by Grooves (12) filled with joint compound (11) in the abutting edges (13) of the individual panels (2). 9. Building panel element according to one or more of claims 1 to 8, marked by Recesses (14) filled with joint compound (11) on the underside (6) of the individual panels (2). 10. Building panel element according to one or more of claims 1 to 9, characterized in that the individual plates (2) have webs (7) with grooves (8) on their rear side.