WO2007137592A1 - Vibro-pressed micro-concrete in synthetic formwork in panels-sheets-moulded sections - Google Patents

Abstract

This invention relates to the construction sector, based on the use of vibro-pressed micro-concrete in latex formwork, through the use of inerts which are preferably screened to a size of not more than 5 mm, achieving high density and great resistance to mechanical forces and to physical and chemical actions of the environment, which as a result of the turning-out system, the water-cement ratio and the vibro-pressing can provide any shape of final component, with a turn-out time of up to 180 minutes, which accelerates works output and mould optimization. Initially its use has been envisaged for the manufacture of thermal-acoustic panels provided with tenon joints for final assembly, thin sheets of between 10 mm and 30 mm, although sheets of up to 7 mm can be obtained without the risk of cracking, and very diverse shapes required in building such as cornices, mouldings, fire walls, columns, and lintels, among others.

Description

 "VIBRO-PRESSED MICRO-CONCRETE IN SYNTHETIC FORMWORK IN

PANELS - SHEETS - FORMS "

Field of the invention:

The present invention is related to alternatives in the construction, considering the ease and versatility of the different forms that can be obtained with the vibro micro concrete pressed in latex formwork, such as membranes or sheets, panels and varied forms of construction elements that require any building, with low cost, ease of installation and reduction of execution times.

The proposed construction system, based on panels, sheets and shapes, generates a reduction in the dead load of the structural design of a building and decreases the request for floor support in any building.

Background of the invention:

Given the permanent need to find new materials, and their varied combinations, construction systems, etc. to optimize existing ones or find new ones, construction professionals resort to university education and the transmission of common experiences that become norms that are generalized at local and international level.

The proposed invention is the result of research on a stable and economical construction system, with the aim of having another construction alternative since traditional construction processes whose experiences applied to the different works carried out, have resulted in a high cost or excessive dead load on the support structure and, high request of the foundation floor.

With this invention it is intended to solve this vacuum in the construction of any building, raising the ease and versatility of the different shapes that can be obtained with the vibro micro concrete pressed in synthetic formwork, such as laminated panels and shapes characterized by various finishes such as rough or smooth provided by the mentioned formwork, obtaining the most varied construction elements that any building requires, with low cost, ease of installation and reduction of execution times. Thus, it has been possible to develop the design, development and continuous and effective application of the type of micro concrete that meets the expectations of resistance, stability, density, impermeability, economy, installation and more benefits of concrete.

The application of such characteristics in the field of construction with elements such as: walls, floating facades, lintels, inns, moldings, roofs, columns, decorative elements, and more, have shown that the characteristics achieved by this invention are of such magnitude that facilitate the efficiency of construction systems.

Currently, there are very varied alternatives for the construction of panels and other construction elements, which due to their cost and technique, make access difficult for developing countries, making it impossible for a massive application in the construction of buildings or cheap housing, which also have stability and good finishes.

It is so known of alternatives such as:

Polyurethane with external laminated steel membranes. Polystyrene expanded with micro concrete and fiberglass reinforcement (GRS system)

Polymer concrete formed by aggregates and polyester resins

Expanded styrene poly with plaster coating and plastic mesh as reinforcement.

Styrene poly plus reinforcement mesh and projected mortar.

Cellular concrete plus mortar projected.

Precast concrete panels.

Finally, a wide range of designs and constructive forms that, depending on the accessibility and cost of raw materials and the purchasing power of the beneficiary, have been adopted as practical solutions in each of the implemented regions.

Within the state of the art it is possible to find expanded polystyrene panels, which are fixed to walls and have the main function of being thermal insulators.

Document ES 2 209 669 refers to a system based on the use of prefabricated panels integrated by an expanded polystyrene core to which a resin is applied, which constitutes a resistant, layer that prevents the use of structures. reinforcement frames. In this panel the resin constitutes the exposed face, for this reason it becomes an element susceptible to deterioration by the action of external physical agents such as exposure to the sun or water, a problem that is solved by the present invention.

The PCT document WO98 / 44213 describes a roof panel produced with insulating materials that incorporate metal profiles that reinforce the panel and that would serve to provide rigidity to it, in addition to which document does not solve the problem of the construction of partitions or walls, it presents low resistance in areas where it has no reinforcements.

In the patent US 4 019 297 a characteristic panel is protected that serves to integrate the structure of buildings, comprised of a structure in the form of a frame and horizontal and vertical crossbars joined by nails between which the polystyrene is located, all this being reinforced by means of a metal or plastic mesh to successively add a cement clad (micro concrete or projected mortar).

US 4 019 297 and PCT WO98 / 44213 generate high construction costs due to the fact of carrying out additional work not contemplated in the present invention such as assembling the self-supporting panels, coating the faces by projected micro concrete or adding mortar and finally their smoothing prior to the paint treatment.

US 5 765 330 relates to a prefabricated panel composed of a wooden frame composed of stringers and vertical uprights with rectangular cavities filled with polyurethane and polystyrene.

This document cannot have a great application in humid or tropical areas due to the high incidence of microbiological agents that would accelerate its deterioration, in addition it should be considered that the cost of wood would substantially increase the final value of the building.

Document ES 2 188 303 refers to a process for the manufacture of an insulating panel for façades and enclosures covered by cold-profiled metal sheets, provided in its interior loads with an adhesive to hold the internal polystyrene membrane, then pressed and cut to the desired extent. ES 2 188 303 does not provide versatility in the design of the finishes of a building, in addition there is an imminent risk of oxidation in wet areas and an increase in the final cost by requiring interior and exterior finishes, aspects overcome by the present invention.

Description of the invention

In a construction there are problems of all kinds such as: exaggerated loads provided by elements that do not support structural stresses (walls, countertops, decorative elements), high soil demands, high costs and execution times.

There are approximate weights that we could exemplify:

- Approximate weight of masonry brick masonry 172 Kg./m2

- Approximate masonry brick masonry weight 122 Kg./m2

- Approximate weight of medium brick masonry 111 Kg./m2

- Approximate weight of structural brick masonry 101 Kg Jm2

- Approximate weight of decorative brick masonry 92 Kg./m2

- Approximate weight of relieved block masonry e = 10 cm. 78 Kg./m2

To these charges, the one generated by its coating and finish must be added, which, except for that of the decorative brick, requires protection on both of its exposed faces.

In the course of its useful life, the final coatings generally due to their high porosity, allow water infiltrations that, when combined with salts existing in the sands or those containing the same cement, are transformed into sulfates that are totally detrimental to the stability of the coatings and some concrete, causing its deterioration and bad presence in both exterior and interior facades.

Regarding the existing panels in the market, they present higher costs of commissioning due to the requirement of final finishes or low physical stability over time.

The present construction system guarantees low weight (around 58 Kg / m ² ), easy installation, great stability over time due to its impermeability guaranteed by the high density of the micro concrete, avoiding the annoying efflorescence on walls and elements built with coated mortars or projected. A constructive solution using existing materials of great abundance in any country in the world, plus a polystyrene membrane that is very stable, low weight, and that its production is relatively easy with minimal contaminating effects, but with high thermo acoustic properties.

Its final finish in work basically consists of a resanado of joints and a minimum of general treatment for the almost smooth provision of their faces, or of any finish other than their paint when the final surface has a rough texture.

With the use of panels, sheets and forms of micro concrete in synthetic formwork, the design loads in both the upper structure and the foundation structure would be substantially reduced by the large difference between the weights per square meter.

The panels provide easy installation for your tongue and groove system, reducing installation and acquisition costs. The sheets or membranes, as well as the forms require minimum installation times because they are elements that only need to be cut as if it were a wooden sheet but with a disc (grinder), then welded into their iron piece (pieces of iron cast in the sheets, and shapes) of which are provided or secured by a concrete adhesive.

The danger of efflorescence is completely eliminated by the high impermeability obtained by the high density provided and the cleaning of the material from which they are constructed, presenting a better image throughout its useful life.

The vibro-pressed micro concrete in synthetic formwork is the result of a process of elaboration and optimization of the aggregate of aggregates in high density conditions, provided by its particle size, the mechanical action incorporated into the mixture, complemented by a forced water ratio - cement and, the use of synthetic forms to obtain surfaces with textures and finishes provided, substantially reduces the formwork times, obtaining minimum thicknesses in the construction elements and maintaining properties such as high mechanical resistance, stability over time and impermeability.

The relieved panels are made with two thin sheets of vibro-pressed micro-concrete with mesh and synthetic fiber to eliminate the effects of setting contraction, with a thermo-acoustic central body that will basically consist of a sheet of poly styrene, or product of the recycling of waste elements of the same material, joined by a binder, and optionally one or two electro-welded meshes to provide greater security to the panel, not requiring a support structure.

The presentation of the panel is conditioned to the height required in the work from 1.00 by 1.00 meters to 1.00 by 2.00 meters, its assembly is carried out between sheets by a tongue and groove provided at its edges to which it is supplied an adhesive that is strong enough to permanently immobilize this coupling so that the assembly is easy and efficient and without the presence of cracks per joint.

- Panels

The panels obtained with this micro concrete, are formed by an expanded polystyrene plate of 15 Kg./m3 of variable thickness between 25 to 50mm. Ie provides the thermo acoustic properties, provided with perpendicular grooves to each other, to accommodate micro concrete in them (see drawing 3). This plate in turn is wrapped with two faces of 10 to 15 mm. each one of them, reinforced by a steel mesh with a diameter of not more than 2 mm and with a pitch of not less than 1 mm as a contraction steel and in its perimeter which is that of union with other panels or with the support structure, the same micro concrete in the form of a tongue and groove to facilitate assembly between them, until forming an entire wall (see drawing 1).

As an option in the construction of these panels, and to provide security to the sector where they will be located, one or two electro-welded meshes will be housed, in the slots supplied to the polystyrene sheet on each of its sides (see drawing 1 ), and that generate greater rigidity to the panel under normal conditions, being embedded in a mixture without presenting wall effects that would be negative to the stability of the exposed iron.

The polystyrene layer, also called accommodation, facilitates the placement of construction pieces such as electrical, sanitary and any other type of installation, as long as one of the dimensions does not exceed 5.00 cm, which is the thickness of the membrane (see drawing 3).

- Sheets or membranes

Foils or membranes, optimal for spatial facades, porches of the most capricious forms, firewalls, counters and other applications, with thicknesses between 10 and 15 mm, with a metal mesh embedded to avoid contraction effects, which depending on the thickness will be additionally accompanied by a 50 x 50 mm square mesh with 2 mm diameter wire, which will absorb small efforts that this element requires on site, 1000 x 1000 mm sizes will be available. at 1000 x 1500 mm., the shape of the membranes may be flat, concave (dome), vaulted, with the most convenient or most frequently used radii of curvature, these membranes will have strategic iron short distances greater than 4 mm at strategic distances , to weld the sheet to a support structure.

- Shapes

The most varied, among them, lintels, cornices, moldings, window frames, columns that to relieve will also keep embedded apart from the metal mesh with a diameter of no more than 2 mm. and step not less than 10 mm. and in its most robust part an expanded polystyrene sheet. For its installation on site, an adhesive and the support of welded screws or binches will be required to guarantee its stability.

features

The vibro-pressed micro-concrete in synthetic formwork, used in the manufacture of infinity of elements, is on the guidelines specified for a normal concrete, since its physical and mechanical characteristics easily exceed the specific strengths and weights of the common elements of a Traditional system construction.

Specific gravity: 2,300 - 2,450 Kg ./m3

Compressive strength 400 - 450 Kg./cm2

Flexural strength 85 - 90 Kg./cm2

Components

All the materials used in the manufacture of the elements of the vibro-pressed micro-concrete in synthetic formwork have inert characteristics, in a natural state, with aggregate cleaning control and quality control of each of the materials used in its manufacture.

• Water.- Free of clay particles, oil, basically clean.

• Sand.- Used in the elaboration of the mortar with varied granulometry of dimensions between 0 and 5 mm. • Cement.- Existing material in the market, especially type I.

• Additives for concrete. - Those existing in the market and those developed for this purpose as plasticizer, adhesive between old concrete.

• Synthetic Fiber.- The one that is on the market as a setting cracking reducer.

Manufacturing equipment:

The equipment used in the process of manufacturing the vibro-pressed micro-concrete in synthetic formwork, is basically the existing one in the market with adaptations, modifications and even with the total transformation of its elements and functions, with specific characteristics achieved for the different phases of elaboration; This is how:

• Electronic scale

• Helical mechanical mixer

• Stands,

• Formwork,

• Release agents,

• Vibro compactors,

• Vibrating rasanteadoras,

• Vibrating rollers,

• Vibrating polisher,

• knitted vibrators, boards, fasteners, tensioners, etc.

Construction Steps.-

• Selection and provision of materials.

• Granulometry

• Determination of the content of clays and silts

• Determination of humidity levels

• Granulometry correction

• Addition of cement, additives, synthetic fiber

• Mixed

• Adding water • Formwork

• Reinforcement location

• Casting of elements

• Vibro process - pressing

• decoupling

• Cured

• Storage

1. Selection and provision of materials: In order to guarantee the stability of the entire construction system, aggregates must have the best stability characteristics, such as hardness and resistance to abrasion, they will preferably be (with their predominant mineral components in quartz) free of materials such as muscovite that reacts with the cement in a negative way, being also preferably obtained from the crushing process.

2. Granulometry: The granulometry will be determined from the design obtained from the density tests carried out with the passing materials, the # 4 sieve that will be called coarse, the # 8 that will be called media, and # 40 including the fines that reach the bottom that will be called fine, and that are located in the triangle of FÉRET (see drawing 4), obtaining the area of greatest density, which will provide us with the content of each of these materials in our mixture. Through materials, the 3/8 "sieve can be used to obtain shapes, the thickness of which exceeds 20 mm.

3. Determination of the content of clays and silts: By means of known analyzes of content the clays and silts will be determined, not being able to contain more than 1% of the total fines, since these must be the product of the same crushing.

4. Determination of moisture content: The design moisture content will be determined by the water - cement ratio, equivalent to the multiplication of the factor 0.40 to 0.45, by the amount of cement; This implies that the percentage of water will reach approximately 11.25% of the total materials that make up the mixture. 5. Granulometry correction: With the adopted design of the alternatives that the range of densities of the FEREET ₇ triangle provides, it is generally necessary to correct the granulometries obtained from crushing stone in the plant.

6. Addition of cement, additives, synthetic fiber: The amount of cement that should be added to the mixture will be equivalent to the multiplication of the volume of voids determined according to FAURY, by the specific weight of the cement 3,100 Kg./m ³ ; The result of this operation (cement weight) must replace the same proportion of fine aggregates (through sieve # 40) of the percentage obtained according to the density triangle of FÉRET, which is not normally considered as part of the FAURY mixture, since This author works with clean aggregates to determine the percentage of voids.

The use of additives and synthetic fiber or nylon, will be provided by replacing water or fines respectively, in the same proportion of manufacturer specification or requirement of the element to be manufactured.

7. Mixing: The mixing process will be carried out in a mixer whose shaft will rotate at approximately 500 revolutions per minute with a spiral blade system, so that it raises the bottom material, and rotates no less than 10 revolutions per minute around of the mixing pot, until homogeneity is obtained.

8. Water addition: The amount of water and additive will be supplied to this mixture, resulting in a mixture of homogeneous "Wet Earth" (FAURY) characteristics.

9. Formwork: Prior to the placement of the mixture, all molds, forms or formwork must be ready, whose walls that will come into contact with said mixture will be covered with a synthetic rubber membrane (which can be latex) not less than 3 mm thick, whose texture can be smooth, rough or any other shape which will determine the appearance of the formwork surface. The membrane will be sufficiently resistant to the stress of the pressed vibro, as well as to the weight of the lodged material.

10. Location of reinforcements: Once the formwork has been located, the thermo-acoustic reinforcements or parts will be arranged in each of the parts, which in the case of the panels will be as follows:

- Super reinforced wall: In the channels that the thermo acoustic part (polystyrene) will maintain, an electro-welded mesh of the requested diameter 4 - 6 mm will be housed. on each side, regardless of the contraction mesh, which will generally be the metal mesh mesh with a diameter of no more than 2 mm. and step not less than 10 mm. and that will be embedded in the micro concrete on all its sides.

- Mediumly reinforced wall: only one electro-welded mesh will be available on one of its sides, always maintaining the metal mesh mesh with a diameter of no more than 2 mm. and step not less than 10 mm. in each of them.

- Wall without reinforcement (Interiors): All its faces will have the electro-welded mesh as a support element for contraction effects.

- Sheets and membranes: The reinforcement in the sheets apart from the contraction, will be characterized by its dimensions and diameters, which are determined to withstand small solicitations, since its design is mainly aimed at replacing traditional systems or existing designs for spatial structures, this reinforcement will be embedded together with the contraction mesh and its wire diameter will not be greater than 2 mm., with a passage between wires arranged in a frame of 25 to 50 mm., since larger diameters are harmful to the sheets thin for not being left with the coating required to provide all its contribution in the tensile effort.

- Blades of greater thickness to 15 mm: reinforcements in any case may be greater than 6 mm. 14. Storage: All the elements that keep slenderness should be stored by their shortest section while the short elements can be stacked without risk of breakage by this activity.

Description of the drawings

The present invention can be described graphically with the purpose of demonstrating by way of examples the construction processes of panel and determination of the area of maximum density using the triangle of FÉRET:

Drawing 1: This is a descriptive section of the elements that make up a panel with micro vibro concrete pressed, reinforcement meshes and poly styrene.

Drawing 2: Cross section of the elements that make up a panel with vibro pressed micro concrete, reinforcement meshes and poly styrene.

Drawing 3: Description of the groove system in a 150 x 150 mm grid. where the electro-welded mesh will be housed in the case of a reinforced panel or micro concrete in the case of a panel without reinforcement or interiors.

Drawing 4: FÉRET triangle in which the density curves are located in order to obtain the area of greatest density.

• 13

Claims

 Reinvindications 1. A procedure for the preparation of a mixture for obtaining the vibro micro concrete pressed in synthetic formwork, characterized in that the amount of cement to be added to the mixture will be equivalent to the multiplication of the volume of voids determined according to FAURY, by specific gravity of the cement 3,100 Kg./m ³ ; The result of this operation (cement weight) must replace the same proportion of fine aggregates (through sieve # 40) of the percentage obtained according to the density triangle of FÉRET. 2. A process for the preparation of micro vibro concrete pressed in synthetic formwork, according to claim one, characterized in that the design moisture content of the mixture will be determined by the water-cement ratio, equivalent to the multiplication of the factor 0, 40 to 0.45, for the amount of cement; This implies that the percentage of water will reach approximately 11.25% of the total materials that make up the mixture. The addition of additives such as plasticizers, accelerators, waterproofing or others, will be added replacing the water in the same proportion specified by the manufacturer of said additives or of the requirement of the element to be manufactured. 3. A process for the preparation of micro concrete vibro pressed in synthetic formwork, according to the previous claims, characterized by the high application of vibro compactor energy, the proportion of which depends on the thickness of the product to be constructed. 4. A process for the preparation of micro vibro concrete pressed in synthetic formwork, according to the preceding claims, characterized in that the mixture is poured into molds, forms or formwork, whose walls will be covered with a synthetic membrane (which may be latex) not less than 3 mm. thick, whose texture can be smooth, rough or any other shape, which will determine the appearance of the formwork surface, being sufficiently resistant to the stress of the pressed vibro and the weight of the material lodged. 5. A procedure for the construction of panels, lintels, columns, sheets and any other form (construction elements), using vibro micro concrete 14 Pressed in synthetic formwork, according to the preceding claims, characterized in that these construction elements require materials such as: • Through aggregates sieves 3/8 "or # 4, conditioned to the thickness of the construction element to be manufactured. • cement of any kind, depending on the environmental conditions of the place where the construction elements must be installed. • Polystyrene that provides relief, with thermo-acoustic characteristics to the panels according to drawings 1 and 2, and relief to most forms; although it may not be indispensable in very thin forms (such as moldings), in those designed to withstand efforts (such as lintels and columns) and in sheets. • Latex that gives texture and shape to the construction elements and also serves to disassemble them from their molds or formaletas. • Synthetic fiber, preferably nylon, added to the mixture, according to the dosage recommended by the manufacturer, which will avoid unwanted contractions in the setting. Its use is not essential in the manufacture of large body shapes (lintels, columns and others). • Metal wire mesh (preferably galvanized steel) with a diameter of no more than two millimeters and a pitch of no less than 10 mm used to absorb contraction forces. • Metal mesh (preferably iron), electro welded, with diameters between 4 mm. and 6 mm. and passage in both directions of 150 mm., as lateral reinforcement, placed on one or both sides of the panel. • Reinforcement steel located in the forms, depending on the effort to be supported (solicitation), which will be determined by analytical calculation. 6. The process for the preparation of micro vibro concrete sheets pressed in synthetic formwork, according to the preceding claims, characterized by the installation of metal parts, preferably iron, in the form of ^W L ", prior to the start of the setting process, by means of focused (point) vibrators; these metal parts have the function of fixing, mainly through welding, the sheet to any structure. fifteen . A procedure for fixing panels, lintels, columns, sheets and any other form (construction elements), made with vibro micro concrete pressed in synthetic formwork, according to the preceding claims, characterized in that once the cut (with disk or another type of cutter) of the required size and shape, can be held between them or between it and another element through any type of adhesive. 8. A procedure for fixing panels, lintels, columns, sheets and any other form (construction elements), made with vibro micro concrete pressed in synthetic formwork, according to the preceding claims, characterized in that it is carried out by means of screws, bolts, binchas, staples or any other form of fastening. 9. A panel made according to the preceding claims, characterized in that it is formed by an expanded polystyrene plate of 15 Kg./m3 of varying thickness between 25 mm. at 50mm., which provides the thermo acoustic property. The polystyrene plate is provided with transverse and longitudinal grooves on its two faces, 15 mm. wide by 8 mm. deep and at a step of 150 mm., according to drawing 3. 10. A panel according to the preceding claim, characterized in that the polystyrene layer includes ducts and boxes not larger than 50 mm. thick, for electrical, sanitary and any type of installations. 11. A panel made according to the preceding claims, characterized in that the vibro micro concrete pressed in synthetic formwork, wraps the two main faces as sheets of 10 mm. to 15 mm. thick each, reinforced by a metal mesh with a diameter of less than 2 mm. and step not less than 10 mm. as contraction steel, and on its perimeter the same micro concrete in the form of a tongue and groove to facilitate the assembly between the panels, until forming an entire wall according to Drawings 1 and 2. 12. A panel made according to the preceding claims characterized in that only micro concrete or micro concrete will be housed in the slots supplied embedding the electro welded mesh on each of its sides, and that 16 generate greater rigidity to the paiiel under normal conditions according to Drawings 1, 2 and 3. 13. A panel characterized in that the tongue and groove forms of the perimeter of the panel are located in the opposite direction that guarantee a correct assembly according to drawing 1. 14. A sheet or membrane, optimal for spatial facades, porches, firewalls, counters, characterized by thicknesses between 10 mm. and 15 mm., with an embedded metal mesh to avoid the effects of contraction, which, depending on the thickness, will be additionally accompanied by a 25 mm square mesh. at 50 mm with wire no larger than 2 mm. 15. A sheet or membrane according to the preceding claims, characterized by being flat, concave (dome), domed whose dimensions are preferably (not exclusively) between 1000 x 1000 mm. at 1000 x 1500 mm. 16. A sheet or membrane according to the preceding claims characterized by having metal pieces at strategic distances, preferably iron, in the form of ^W L "greater than 4 mm., To weld the sheet to a support structure. 17. A product of any form according to the preceding claims, characterized in that it contains a contracting metal mesh and in that it avoids excess weight, in its most robust part it contains an expanded polystyrene sheet. 18. A method according to the preceding claims, characterized by the manufacture of varied forms of micro concrete vibro pressed in synthetic formwork, using molds or formwork of synthetic origin with sufficient strength to withstand vibro-pressing effects, without presenting final deformations. 19. The use of panels according to the preceding claims, characterized by its various uses such as: enclosures, reinforced walls in hangars, interiors and exteriors of buildings maintaining a smooth pre-finish. 17 20. The use of different presentations of sheets, such as straight, vaulted and concave according to the preceding claims, characterized by their use in construction especially, but not exclusively in fake facades of buildings and interior decorations. 21. The use of forms of various kinds, according to the preceding claims, which is characterized by its use in decorations of buildings of any type, both interior and exterior, as well as forms of small and medium-sized solicitations such as: lintels, columns, inns, braces. 18